Overmould / insert mould onto Flexi-PCB

[marvincooper]

I have just started on a project where I will need to produce a flexible (probably silicone) housing around a flexi-rigid PCB, a lithium battery, LCD and a button.

The product is highly cosmetic and worn next to the skin. The housing needs to hermetically seal the electronics.

I am looking into manufacturing methods and could use some advice please!

Current thinking is this:

Encapsulate the electronics assembly, including the battery and display. This would be potentially be by low-pressure injection moulding with a flexible resin. I am not sure how compatible the flexi part of the PCBA will be to this process, what considerations I need to be aware of?

The encapsulation will also include 2 rigid plastic parts which will form part of the housing.

The encapsulated sub-assembly will then be over-molded with silicon (or similar flexible resin) to provide the cosmetic finish.

My questions are –
1. Can you encapsulate a flexible PCB and retain flexibility?
2. What pitfalls are there?
3. What alternative approaches should I consider?
4. What suppliers have experience of this kind of product and construction?

Any advice much appreciated.

 

[wongs9982]

I will use tpe -tpu instead of silicon. hardness shore D 50.
the flex pcb can be flexible afterward.
I am eager to help.