Improved encapsulated, overmolded and/or underfilled electrical components
having a complete encapsulation, overmolding and/or underfilling with a
coefficient of thermal expansion that is uniform and substantially free
of gradients includes a polymeric matrix and an inorganic filler having a
platelet geometric structure. The platelet structure of the filler allows
a desirable coefficient of thermal expansion to be achieved using a very
low level of filler material. This low level of filler material
facilitates lower viscosity during forming of the encapsulation and/or
overmolding, thereby facilitating complete filling of a mold cavity and
underfilling of space between a circuit board and a semi-conductor chip
electrically connected to the circuit board. In addition, the low
viscosity has processing advantages that reduce the potential for damage
to electrical components during encapsulation, overmolding and/or
underfilling.