LED assembly having overmolded lens on treated leadframe and method therefor

1 . A method of manufacturing an LED assembly, comprising:

providing a base on a leadframe;

installing an LED within said base;

treating said leadframe with said base thereon to prepare for overmolding; and

overmolding a cover onto said leadframe with said base thereon to encapsulate said LED.

2 . The method of claim 1 wherein said step of providing a base on a leadframe includes:

overmolding said base onto said leadframe.

3 . The method of claim 1 wherein said step of providing a base on a leadframe includes:

overmolding said base onto said leadframe around a contact area of said leadframe.

4 . The method of claim 1 wherein said step of installing an LED within said base includes:

mounting said LED onto said base; and

bonding wires of said LED to said leadframe.

5 . The method of claim 1 wherein said step of installing an LED within said base includes:

using a ball grid array assembly to surface mount said LED onto said base and connect leads of said LED to said leadframe.

6 . The method of claim 1 wherein said step of installing an LED within said base includes:

using a die attach and wire bonder assembly to attach said LED to said base and electrically connect wires of said LED to said leadframe.

7 . The method of claim 1 wherein said step of treating said leadframe includes:

plasma treating said leadframe with said base thereon.

8 . The method of claim 7 wherein said step of plasma treating said leadframe includes:

blasting said leadframe with said base thereon with a stream of at least one of high energy ions, atoms, molecules and electrons to remove at least a thin layer of surface contaminants.

9 . The method of claim 1 wherein said step of treating said leadframe includes:

applying an interfacial bonding material to said leadframe with said base thereon to prepare said leadframe with said base thereon for said subsequent step of overmolding said cover.

10 . The method of claim 1 wherein said step of overmolding said lens includes:

hermetically sealing said LED between said base and said overmolded cover.

11 . The method of claim 1 wherein said step of overmolding said lens includes:

overmolding liquid silicone rubber onto said leadframe with said base thereon under low pressure to encapsulate said LED and form a lens thereover.

12 . The method of claim 1 wherein said step of overmolding said lens includes:

bonding said lens onto said leadframe and said base.

13 . The method of claim 7 wherein the surface energy of said base increases to about 72 dynes for a period of about 24 hours and said step of overmolding occurs within said period.

14 . A method of manufacturing an LED assembly, comprising:

overmolding a base onto a leadframe;

installing an LED onto said base;

surface treating at least one of said base and said leadframe; and

overmolding a lens onto said at least one of said base and said leadframe to encapsulate said LED.

15 . The method of claim 14 wherein said step of surface treating includes one of (i) cold plasma treating said at least one of said base and said leadframe and (ii) applying an interfacial bonding material to said at least one of said base and said leadframe.

16 . A method of manufacturing a plurality of LED assemblies, comprising:

providing a continuous leadframe having a plurality of contact areas;

forming an open package around each of said plurality of contact areas by overmolding a base around each of said contact areas and attaching an LED die to said leadframe;

cold plasma treating said open package; and

overmolding a lens onto said open package to form an LED assembly.

17 . A method of manufacturing LED assemblies, comprising:

providing an overmolded leadframe;

attaching an LED die to said overmolded leadframe; and

surface treating said overmolded leadframe with said LED die mounted thereto to prepare said overmolded leadframe for a subsequent step of encapsulating said LED die.

18 . The method of claim 17 further including:

overmolding a lens onto said overmolded leadframe to enclose said LED.

19 . A method of manufacturing LED assemblies, comprising:

providing a leadframe having a plurality of base members secured thereto;

mounting an LED to each of said bases;

wire bonding said LED to said leadframe;

surface treating said leadframe with said LED mounted and bonded thereto; and

overmolding a cover onto said leadframe over said LED.

20 . An LED assembly, comprising:

a base on a leadframe;

an LED supported by said base and electrically connected to said leadframe; and

a cover overmolded onto at least one of said base and said leadframe to encapsulate said LED, said at least one of said base and said leadframe cold plasma treated to allow said lens to be bonded thereto.