US20030152331A1 - Methods and apparatus for fiber-optic modules with shielded housing/covers having mixed finger types - Google Patents

Abstract

A fiber-optic module having a housing/shielding unit and a module chassis frame having optical, electrical and electro-optical components. The housing/shielding unit functions both as a protective outer housing and an electromagnetic shield. The housing/shielding unit includes forward fingers and backward fingers. The forward fingers provide an EMI seal around an opening in a bezel, face-plate, back-plate, wall, or panel of a host system and thereby can ground the housing/shielding unit to a chassis ground. The backward fingers can contact host tabs of the host system and can also thereby ground the housing/shielding unit to a chassis ground. The module chassis frame may be formed of a conductive material and can be grounded as well through a host system faceplate or otherwise to the chassis ground.

Description

CROSS REFERENCE TO RELATED APPLICATION
• This United States non-provisional patent application claims the benefit and is a continuation-in-part of U.S. patent application Ser. No. 09/782,875, filed on Feb. 12, 2001 by Dair et al. having Attorney Docket No. 003918.P014, both of which are to be assigned to E2O Communications, Inc.[0001]
FIELD OF THE INVENTION
• The invention relates to electromagnetic shielding, and more specifically, to electromagnetic shielding of fiber-optic modules.[0002]
BACKGROUND OF THE INVENTION
• As the need for greater data bandwidth over networks has exploded over the past few years, there has been a move towards using optical fibers as a transmission medium. Today, optical fiber made of dielectric materials are routinely used in communication channels from large public transmission media to Local Area Networks transmitting information from one node to another. The main difference between a fiber-optic communication system and other types of communication systems is that signals are transmitted as light or photons over optical fibers. Optical fiber or fiber-optic cables enable high speed communication of signals by guiding light or photons therein. At each end of a fiber-optic cable a transducer may be found that converts a light, photon or optical signal into an electrical signal; an electrical signal into a light, photon or optical signal; or a pair of transducers may do both. At a transmission end, an electrical-to-optical converter (EO) converts electrical signals into light or optical signals. At a receiving end, an optical-to-electrical converter (OE) converts a light, photon or optical signal into an electrical signal. In nodes of a communication system, it may be desirable to both transmit and receive light or optical signals at a node. In which case an optical-to-electrical converter (OE, i.e. receiver) and an electrical-to-optical converter (EO, i.e. transmitter) may be included to receive and transmit optical or light signals respectively. Therefore, the optical-to-electrical converter (OE, i.e. receiver) and the electrical-to-optical converter (EO, i.e. transmitter) are oftentimes physically located together as a single module referred to as an electro-optic, opto-electronic or fiber-optic transceiver. Fiber-optic transceivers, including fiber-optic transmitters and fiber-optic receivers, can also be referred to as fiber-optic modules.[0003]
• Because of the high frequency needed in some of the electronics and the electro-optic components, such as the optical-to-electrical converter (OE, i.e. receiver) and electrical-to-optical converter (EO, i.e. transmitter), electromagnetic radiation can be generated which can interfere with other communication systems. This electromagnetic radiation is oftentimes referred to as electromagnetic interference (EMI). Electromagnetic radiation radiating externally out from a fiber-optic module or a system that incorporates the fiber-optic module is of great concern. To reduce electromagnetic radiation from radiating out of fiber-optic modules and systems with fiber optic modules as EMI, external electromagnetic shielding of internal electronic and opto-electronic components is often utilized. The external electromagnetic shielding can additionally reduce effects of external electromagnetic radiation on the internal components of a fiber-optic module and the system.[0004]
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a rear isometric view of the fiber-optic module according to a first embodiment of the invention[0005]
• FIG. 2 is a front isometric view of the fiber-optic module according to the first embodiment of the invention[0006]
• FIG. 3 is a rear isometric view of a housing/shielding unit according to the first embodiment of the invention.[0007]
• FIG. 4A is a bottom rear isometric view of the housing/shielding unit according to the first embodiment of the invention.[0008]
• FIG. 4B is a bottom rear isometric view of an alternate housing/shielding unit according to an alternate embodiment of the invention.[0009]
• FIG. 5A is an isometric view of a module chassis frame and a housing/shielding unit according to the first embodiment of the invention.[0010]
• FIG. 5B is an isometric view of a module chassis frame and a housing/shielding unit according to an alternate embodiment of the invention.[0011]
• FIG. 6 is an exploded view of the fiber-optic module with the housing/shielding unit and the module chassis frame according to the first embodiment of the invention.[0012]
• FIG. 7 is an isometric view of a module chassis frame and a housing/shielding unit for an fiber-optic module according to a second embodiment of the invention.[0013]
• FIG. 8A is a front isometric view of a housing/shielding unit according to the second embodiment of the invention.[0014]
• FIG. 8B is a front isometric view of an alternate housing/shielding unit according to an alternate embodiment of the invention.[0015]
• FIG. 9A is a bottom isometric view of the housing/shielding unit according to the second embodiment of the invention.[0016]
• FIG. 9B is a bottom rear isometric view of an alternate housing/shielding unit according to an alternate embodiment of the invention.[0017]
• FIG. 10A is a top exploded view of the second embodiment of the fiber-optic module according to the invention.[0018]
• FIG. 10B is a bottom exploded view of the second embodiment of the fiber-optic module according to the invention.[0019]
• FIG. 11A is a side view of the second embodiment of the fiber-optic module of FIG. 10 mounted within a host system.[0020]
• FIG. 11B is a side view of the first embodiment of the fiber-optic module of FIG. 6 mounted within a host system.[0021]
• FIG. 12A is a front view of the second embodiment of the fiber-optic module of FIG. 10 mounted within a host system.[0022]
• FIG. 12B is a front view of the first embodiment of the fiber-optic module of FIG. 6 mounted within a host system.[0023]
• FIG. 13 is a perspective view of a host system incorporating embodiments of the fiber-optic modules of the invention.[0024]
• FIG. 14 illustrates a starting sheet of material for the embodiments of the housing/shielding unit.[0025]
• FIG. 15A illustrates an unfolded flat pattern layout for an embodiment of the housing/shielding unit.[0026]
• FIG. 15B illustrates fold and bend lines on the unfolded flat pattern layout of FIG. 15A.[0027]
• FIG. 15C illustrates an unfolded flat pattern layout for an embodiment of the housing/shielding unit.[0028]
• FIG. 15D illustrates fold and bend lines on the unfolded flat pattern layout of FIG. 15C.[0029]
• FIG. 16A illustrates an unfolded flat pattern layout for an embodiment of the housing/shielding unit.[0030]
• FIG. 16B illustrates fold and bend lines on the unfolded flat pattern layout of FIG. 16A.[0031]
• FIGS.[0032]17A-17C illustrate alternate methods of assembling a housing/shielding unit with a module chassis frame to form a fiber-optic module.
• FIG. 18A is a top plan view of a first embodiment of our new design for a one-piece shielded housing;[0033]
• FIG. 18B is a right side elevational view thereof, the left side elevational view being a mirror image;[0034]
• FIG. 18C is a front elevational view thereof;[0035]
• FIG. 18D is a rear elevational view thereof;[0036]
• FIG. 18E is a bottom plan view thereof;[0037]
• FIG. 18F is a top perspective view thereof;[0038]
• FIG. 18G is a bottom perspective view thereof;[0039]
• FIG. 19A is a top plan view of a second embodiment of our new design for a one-piece shielded housing;[0040]
• FIG. 19B is a right side elevational view thereof, the left side elevational view being a mirror image;[0041]
• FIG. 19C is a front elevational view thereof;[0042]
• FIG. 19D is a rear elevational view thereof;[0043]
• FIG. 19E is a bottom plan view thereof;[0044]
• FIG. 19F is a top perspective view thereof;[0045]
• FIG. 19G is a bottom perspective view thereof;[0046]
• FIG. 20A is a top plan view of a third embodiment of our new design for a one-piece shielded housing;[0047]
• FIG. 20B is a right side elevational view thereof, the left side elevational view being a mirror image;[0048]
• FIG. 20C is a front elevational view thereof;[0049]
• FIG. 20D is a rear elevational view thereof;[0050]
• FIG. 20E is a bottom plan view thereof;[0051]
• FIG. 20F is a top perspective view thereof; and[0052]
• FIG. 20G is a bottom perspective view thereof.[0053]
• FIG. 21A is a top plan view of a first embodiment of our new design of a patterned material layer for a one-piece shielded housing;[0054]
• FIG. 21B is a front elevational view thereof, the rear elevational view being a mirror image;[0055]
• FIG. 21C is a bottom plan view thereof;[0056]
• FIG. 21D is a right side elevational view thereof, the left side elevational view being a mirror image;[0057]
• FIG. 22A is a top plan view of a second embodiment of our new design of a patterned material layer for a one-piece shielded housing;[0058]
• FIG. 22B is a front elevational view thereof, the rear elevational view being a mirror image;[0059]
• FIG. 22C is a bottom plan view thereof;[0060]
• FIG. 22D is a right side elevational view thereof, the left side elevational view being a mirror image; and[0061]
• FIG. 23 is a top plan view of a third embodiment of our new design of a patterned material layer for a one-piece shielded housing, a bottom plan view being a mirror image and the patterned material layer being a thin and flat sheet so that only the top plan view need be shown.[0062]
• FIG. 24 is a top perspective view of a fiber optic module for another embodiment of the invention.[0063]
• FIG. 25 is a bottom perspective view of the fiber optic module of FIG. 24.[0064]
• FIG. 26A is a rear perspective view of the fiber optic module of FIG. 24.[0065]
• FIG. 26B is a top view of the fiber optic module of FIG. 24.[0066]
• FIG. 27 is a side view of the fiber optic module of FIG. 24.[0067]
• FIG. 28 is a front view of the fiber optic module of FIG. 24 mounted against a faceplate, backplate, or bezel in a system.[0068]
• FIG. 29 is a side view of the fiber optic module of FIG. 24 mounted in a system.[0069]
• FIG. 30 is a top view of the fiber optic module of FIG. 24 mounted in a system.[0070]
• FIG. 31 is a top view of a pattern for a front portion of a shielded housing/cover of the fiber optic module of FIG. 24.[0071]
• FIG. 32 is a top view of the pattern of FIG. 31 including bend/fold lines.[0072]
• FIG. 33 is a top perspective view of a fiber optic module for another embodiment of the invention.[0073]
• FIG. 34 is a side view of the fiber optic module of FIG. 33.[0074]
• FIG. 35 is a top view of the fiber optic module of FIG. 33.[0075]
• FIG. 36 is a front view of the fiber optic module of FIG. 33.[0076]
• FIG. 37 is a side view of the fiber optic module of FIG. 33 mounted in a system.[0077]
• FIG. 38 is a top view of the fiber optic module of FIG. 33 mounted in a system.[0078]
• FIG. 39 is a top view of a pattern for a front portion of a shielded housing/cover of the fiber optic module of FIG. 33.[0079]
• FIG. 40 is a top view of the pattern of FIG. 39 including bend/fold lines.[0080]
• Like reference numbers and designations in the drawings indicate like elements providing similar functionality.[0081]
DETAILED DESCRIPTION OF THE INVENTION
• In the following detailed description of the invention, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be obvious to one skilled in the art that the invention may be practiced without these specific details. In other instances well known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the invention.[0082]
• The invention includes embodiments of fiber-optic modules and their methods of manufacture and assembly of component parts. Fiber-optic module generally refers to fiber-optic transmitter modules, fiber-optic receiver modules, and fiber-optic transceiver modules. The various fiber-optic modules can also be referred to as opto-electronic transmitter, receiver or transceiver modules; and electro-optic transmitter, receiver or transceiver modules. The fiber-optic module of the invention is capable of reducing electromagnetic interference (EMI) from both the fiber-optic module and from the system that incorporates the fiber-optic module. In accordance with one embodiment of the invention, a fiber-optic module comprises a module chassis frame and a housing/shielding unit. The housing/shielding unit can be formed of one piece in which case it can also be referred to as a one-piece integrated housing/shielding unit, a one piece shielded housing, an EMI box or container, or a single-piece shielded housing integrating a protection function and a shielding function. The module chassis frame can also be referred to as a chassis, a frame, or a support fixture. The housing/shielding unit functions both as a protective outer housing for the fiber-optic module as well as an EMI suppression device and a chassis grounding feature. The housing/shielding unit can protect and shield the optical, electrical, and optical-electrical components within a fiber-optic module. The housing/shielding unit can be formed out of conductive materials such as a metal, a plated plastic, a conductive plastic or other electrically conductive material. The module chassis frame can be formed of a nonconductive material such as a non-conductive plastic. The module chassis frame can also be formed of a conductive material such as sheet metal, a plated plastic, or conductive plastic so as to provide, EMI shielding as well. The module chassis frame is the central structural support to which components of the fiber-optic module attach. These components can include an opto-electronic transmitter and/or an opto-electronic receiver. In the case of a fiber-optic transceiver module, the fiber-optic module includes a transmitter optical subassembly, a receiver optical subassembly and an electrical subassembly. Each of the opto-electronic transmitter and the opto-electronic receiver has a header which is shielded by a hollow cylindrical shielding collar. The hollow cylindrical shielding collar provides electromagnetic shielding as well. The opto-electronic transmitter may include a Vertical Cavity Surface Emitting Laser (VCSEL) or a conventional semiconductor laser mounted inside of the header.[0083]
• The housing/shielding is a multi-sided conductive enclosure than can be formed out of sheet metal, plated plastic, conductive plastic or other electrically conductive material. In one embodiment, sheet metal is etched or stamped to form the housing/shielding unit. The housing/shielding unit also includes a pair of flaps and a septum which allow it to be spot-welded, soldered, glued or otherwise fastened after it is attached to the module chassis frame. The housing/shielding unit forms an enclosure that surrounds the module chassis frame. Fingers or tabs extend from the housing/shielding unit to ground it to a bezel, a faceplate, backplate, or a wall of a housing of a host system. In one embodiment, the fingers press against the bezel, backplate, faceplate or wall of the housing of the host system to seal electromagnetic radiation therein. In another embodiment, the fingers press against an opening in the bezel, the faceplate, backplate, or the wall of the housing of the host system to seal electromagnetic radiation therein.[0084]
• The grounding scheme for the fiber-optic module includes signal grounding and chassis grounding. Two grounds are utilized for isolation to prevent currents induced in the chassis ground from affecting the integrity of signal ground. Signal ground is provided through one or more ground pins of a transceiver printed circuit board (PCB) next to the signal pins. The one or more ground pins couple to ground traces on a printed circuit board of the host system. Chassis ground is established by coupling to an outer housing of the host system which is electrically isolated from the signal ground.[0085]
• The invention employs a housing/shielding unit that functions both as protective outer housing as well as an EMI shield or suppression device. The housing/shielding unit is a multi-sided enclosure which can be made from one piece or a single piece of sheet metal, plated plastic or other electrically conductive material having an opening at one end for receiving a fiber-optic connector to couple to one or more fiberoptic cables.[0086]
• Referring now to FIG. 1, an fiber-[0087]optic module100 of the invention is illustrated. In one embodiment, the fiber-optic module100 is a 1×9 fiber-optic transceiver module. In which case the fiber-optic module is a duplex-SC transceiver designed for use in Gigabit Ethernet applications and is compliant with specifications for IEEE-802.3z Gigabit Ethernet (1000Base-SX) andClass 1 Laser Safety regulations, operates with 50/125 micrometer and 62.5/125 micrometer multimode optical fibers, has anIndustry Standard 1×9 Footprint with integral duplex SC connector and meets a mezzanine height standard of 9.8 mm.
• The fiber-[0088]optic module100 includes a one-piece or single-piece integrated housing/shielding unit115 and amodule chassis frame120. The fiber-optic module100 with the one-piece or single-piece integrated housing/shielding unit115 may also be referred to as a forward shield configuration. The housing/shielding unit115 functions both as a housing and as an EMI shield. The housing/shielding unit115 minimizes internal electromagnetic radiation from radiating outward and interfering with other electronic circuits and devices. It also minimizes external electromagnetic radiation from radiating inward and interfering with the operation of the fiber-optic module100. It also minimizes the system electromagnetic radiation from leaking out through an opening in a bezel, a faceplate, backplate,, of a host panel through which the fiber-optic module is installed. Themodule chassis frame120 may be formed of a conductive material, such as a conductive plastic, to provide EMI shielding and to support other components assembled thereto.
• The housing/[0089]shielding unit115 has atop side116, aleft side117, aright side118, and aback side119 illustrated in FIG. 1. A pair oftangs114A and114B are present in theback side119 in order to couple theback side119 together with theleft side117 and theright side118 respectively. Theleft side117 and theright side118 each have atang114A and114B bent into an opening of a respective flaps (not shown in FIG. 1).
• The housing/[0090]shielding unit115 has one ormore fingers112 located near anose113 of the fiber-optic module100 at the edges of afrontal opening313. The one or more fingers can also be referred to as tabs. The one or more fingers are similarly shaped having a body and a tip which is round in one embodiment. The body of thefingers112 are bent outward from the main surface in one embodiment. In an alternate embodiment the tips may be slightly bent from the body of the fingers. The fingers can be equally sized and equally spaced or have different sizing and difference spacing between each.Fingers112A are located along an edge oftop side116 of the housing/shielding unit115.Fingers112B are located along an edge ofside117 of the housing/shielding unit115.Fingers112C are located along an edge of side118 (not shown in FIG. 1) of the housing/shielding unit115.Fingers112D are located along an edge of side119 (not shown in FIG. 1) of the housing/shielding unit115.Fingers112A,112B,112C and112D are generally referred to asfingers112. Thefingers112 have a forward curvature and are bent outwardly and slightly backwards from a frontal opening in the housing/shielding unit115 as illustrated. Thefingers112 can be used to ground the housing/shielding unit115 by coupling to a bezel or face-plate which is grounded. Thefingers112 are illustrated as being a plurality of fingers but can be one or more fingers on any one or all sides.
• Referring now to FIG. 2, the fiber-[0091]optic module100 includes the housing/shielding unit115 and themodule chassis frame120. The housing/shielding unit further includes a septum (not shown in FIG. 2) and anose strap210. The septum and nose strap are folded back into the frontal opening of the housing/shielding unit around themodule chassis frame120. Prior to folding the septum and nose strap back into the frontal opening, the electrical, optical and electro-optical components are installed on themodule chassis frame120 which is then inserted into thehousing115 in one embodiment, or in another embodiment, the housing is folded around themodule chassis frame120. Thenose strap210 and the septum hold themodule chassis frame120 in place within thehousing115. Themodule chassis frame120 includes one or moreoptical connector receptacles211 withoptical connector openings212. In one embodiment, the one or moreoptical connector receptacles211 are SC optical connector receptacles with theoptical connector openings212 being SC optical connector openings.
• Referring now to FIG. 3, a rear view of the housing/[0092]shielding unit115 is shown. The FIGS. 112A, 112B,112C, and112D are located along the edge of thefrontal opening313 of the housing/shielding unit115 as shown. The housing/shielding unit115 is a rectangular box made of sheet metal, plated plastic or any other electrically conductive material. Except for a single side of the housing/shielding unit115 that is open so that the module chassis frame can be inserted into it, all other sides of the housing/shielding unit can be closed. Once themodule chassis frame120 is inserted into the housing/shielding unit115 through the open side, it is closed to minimize electromagnetic radiation from the fiber optic module.
• Referring now to FIG. 4A, a bottom view of the housing/[0093]shielding unit115 is shown. The housing/shielding unit115 has anopen region400 in its bottom side. One ormore fingers112C are located along theedge419 of the housing/shielding unit115. Thefingers112 curve outward and point more forward from surfaces of the housing/shielding unit. Thefingers112 have spring-like resilience (i.e. spring loaded or flexible) and provide a mechanical and electrical contact between the fiber-optic module and a bezel, a face-plate or a wall (not shown in FIG. 4). Thus, thefingers112 can also be referred to as spring fingers or forward fingers. There are also a pair offlaps402A and402B and aseptum411 on the bottom side of the housing/shielding unit115. Theseptum411 theflaps402A-402B and405A-405B of the housing/shielding unit can be spot welded, soldered, glued, or otherwise fastened together. The housing/shielding unit115 forms an enclosure that surrounds themodule chassis frame120.Fingers112A,112B,112C, and112D can ground the housing/shielding unit115 to seal in electromagnetic radiation to avoid it affecting a host system, and to avoid the electromagnetic radiation of host system from leaking out through openings in the bezel, faceplate, or backplate.
• Referring now to FIG. 4B, a bottom left side isometric view of an alternate housing/[0094]shielding unit115′ is shown. The housing/shielding unit115′ differs from housing/shielding unit115 in the strap, left side, right side, bottom side and the back side. The housing/shielding unit115′ is additionally longer so that thefingers112 are nearer the front of theoptical connector openings212. That is backside119 is replaced byback side119′ with a retainingflap429;left side flap117 is replaced byleft side flaps117A and117B separated by a left side slit1511L;right side flap118 is replaced by right side flaps118A and118B separated by a right side slit1511R; bottom side flaps402A,402B,405A and405B are replaced by bottom side flaps415A and415B;strap210 is replaced bystrap210′,septum411 is replaced byseptum411′, andopen region400 is replaced byopen region400′. Otherwise, the housing/shielding unit115′ and the housing/shielding unit115 have similar elements and features including the one ormore fingers112A,112D,112C, and112D.
• The housing/[0095]shielding unit115′ forms an enclosure that surrounds themodule chassis frame120 or120′.Fingers112A,112B,112C, and112D can ground the housing/shielding unit115′ to seal internal electromagnetic radiation therein to avoid it affecting a host system and keep out external electromagnetic radiation to increase noise immunity of the electronic and opto-electronic components inside. It also minimizes the electromagnetic radiation of the host system from leaking out of openings in the bezel, faceplate, or backplate.
• Referring now to FIG. 5A, the housing/[0096]shielding unit115 and an alternatemodule chassis frame120′ are illustrated. Themodule chassis frame120′ has asingle pin opening536 in itsbase604′ through which all pins612 may extend but otherwise is similar to themodule chassis frame120. Themodule chassis frame120′ includes theoptical connector receptacles211 at one end and aleft wall602L and aright wall602R coupled to the base604′ at an opposite end. Thewalls602l and602R each have aslot634L and634R respectively on their inside surfaces. Theoptical connector receptacles211 have a rectangular opening or slot626 along the width of themodule chassis frame120′.
• The housing/[0097]shielding unit115 includes thefront nose strap210 and theseptum411. Thefront nose strap210 may be a metal or a plastic band used for fastening or clamping themodule chassis frame120 to the housing/shielding unit115. Thefront nose strap210 can consists of three portions, afirst extension portion210A, awrap portion210B and asecond extension portion210C. Thewrap portion210B engages with theslot638 of themodule chassis frame120 or120′. Theseptum411 can also be welded or bonded to bottom flaps of the housing/shielding unit115 to hold the module chassis frame therein.
• Referring now to FIG. 5B, the alternate housing/[0098]shielding unit115′ and the alternatemodule chassis frame120′ are illustrated. The housing/shielding unit115′ includes thefront nose strap210′ and theseptum411′. Thefront nose strap210′ may be a metal or a plastic strap used to fasten or clamp themodule chassis frame120 or120′ to the housing/shielding unit115′. Thefront nose strap210′ is a single portion compared to thefirst extension portion210A, wrapportion210B andsecond extension portion210C of thefront nose strap210. Thenose strap210′ engages with theslot638 of themodule chassis frame120 or120′. Theseptum411′ can be welded or bonded to bottom flaps of the housing/shielding unit115′ to hold the module chassis frame therein.
• Referring now to FIG. 6, an exploded view of the fiber-[0099]optic module100 of the invention is illustrated. The fiber-optic module100 includes the integrated one-piece housing/shielding unit115, themodule chassis frame120, and other optical, electrical and opto-electronic components. Themodule chassis frame120 includes theoptical connector receptacles211 at one end and aleft wall602L and aright wall602R coupled to a base604 at an opposite end. Thewalls602l and602R each have aslot634L and634R respectively on their inside surfaces. Theoptical connector receptacles211 have a rectangular opening or slot626 along the width of themodule chassis frame120. Thebase604 has one ormore pin openings636.
• The optical, electrical and opto-electronic components of the fiber-[0100]optic module100 are assembled into themodule chassis frame120. The components include a printed circuit board (PCB)610, a packagedtransmitter620 for transmitting optical signals, a packagedreceiver621 for receiving optical signals, a pair of shieldingcollars622A and622B, a pair ofSC connectors650A and650B, and aU-Plate624. The shieldingcollars622A and622B can be formed from rolled sheet metal, a plated plastic, a conductive plastic, or other conductive material formed into a hollow cylinder.
• In one embodiment, the[0101]transmitter620 is an 850-nm VCSEL and thereceiver621 an integrated GaAs PIN-preamplifier or PIN-diode.
• The printed[0102]circuit board610 includes one or more PCB signal pins612, edge traces614 on each side for straddle mounting thetransmitter620 and thereceiver621, andintegrated circuits616 for processing signals between the signal pins612 and thetransmitter620 and thereceiver621. Theintegrated circuits616 may use a five volt (5v), a three volt (3v) or other common power supply voltage used in integrated circuits and host systems. The PCB signal pins612 can include a transmit ground pin for transmitter components and a receive ground pin for receiver components. In an alternate embodiment, a single ground pin for electronic components may be provided, isolated from any shielding ground features for the fiber-optic module. The printed circuit board (PCB)610 may have a ground plane on its top or bottom surfaces to couple to ground and further provide electromagnetic shielding.
• The[0103]module chassis frame120 includes a rectangular opening orslot626, a pair of mountingposts632 extending from itsbase604 near left and right sides,slots634L and634R on inner sides of thewalls602L and602R, one ormore pin openings636, and one or moreoptical connector receptacles211 with one or moreoptical connector openings212. In one embodiment, the one or moreoptical connector openings212 is two and the optical connector openings are SC optical connector openings for a duplex SC optical connection. The one or moreoptical connector openings212 is separated by aslot638. Therectangular opening626 receives theU-plate624. The one ormore pin openings636 receives the one or more PCB signal pins612. Theslots634L and634R are press-fit slots and receive the sides of the printedcircuit board610. The pair of mountingposts632 allow the transceiver to be mechanically coupled to a printed circuit board or the like. The mountingposts632 can also be connected to chassis ground but should not be connected to signal ground.
• The grounding scheme of the fiber-optic module can be divided into categories of signal grounding and chassis grounding. The separation of signal grounding from chassis grounding can keep currents induced in a chassis ground from affecting signal integrity. Signal ground is through one or more ground pins of the PCB pins[0104]612 coupled from thePCB610 to a ground trace in a host printed circuit board. The housing/shielding unit115 or115′ is part of the chassis ground and electrically isolated from the signal ground, The housing/shielding unit115 or115′ couples to chassis ground of a host system through one or more of the fingers. The one or more fingers couple to a host panel near a host panel opening through which the fiber-optic module may extend. The fingers surround the host panel opening and effectively reduce the size of the opening through which radiated electromagnetic energy may escape to seal the host panel opening through which the fiber-optic module may protrude. With the housing/shielding unit115 or115′ coupled to chassis ground, it acts as a plug to block EMI radiated emissions from escaping. Additionally, the smaller the host panel opening, the greater the shielding effectiveness as the host system begins to resemble a Faraday cage.
• The packaged[0105]transmitter620 may contain a VCSEL or a conventional semiconductor laser and is mounted inside thetransmitter port623A. The packagedreceiver621 may include a PIN diode that is mounted inside thereceiver port623B. In one embodiment, the transmitter and receiver are each packaged into a TO package and may be referred to as the Tx Header and Rx Header respectively. Each of the packagedtransmitter620 andreceiver621 have one or more pins orterminals619 which couple to the edge traces614 on each side of the printedcircuit board610 to straddle mount them.
• The[0106]SC connectors650A and650B include alens651A and651B mounted insideports623A and623B respectively. The ports can also be referred to as TO-can receptacles, TO-can holders, lens holders, etc. Semiconductor lasers and/or PINs can be mounted into metal TO-cans, which are then aligned into the ports or receptacles. The ports or receptacles have lenses between the fiber ferrules and the TO-cans. Note that lasers and photodiodes are not required to be packaged in TO-cans and can be packaged in other ways to mate with various shaped ports or receptacles. The ports and the packaging of the semiconductor lasers and/or PINs need only facilitate that light can be transmitted or received as the case may be. Each of theSC connectors650A and650B further includes a pair of snap lock clips652 each having a retainingprotrusion653, ferrule barrels654, support struts656 in a front portion. Each of theSC connectors650A and650B further includescircular recesses657 between each of theheaders623A and623B and theirrespective flanges655 in a rear portion. Each of thecircular recesses657 mates with theU-shaped openings627 of theU-plate624.
• The transmitter package is assembled to the SC connector to form the Transmitter Optical Subassembly (Tx OSA). This Transmitter Optical Subassembly is then soldered onto the[0107]PCB610. Prior to soldering theheader assemblies623A and623B, the pair of shieldingcollars622A and622B are attached with solder to the rear of theports623A and623B. ThePCB610 may be secured by two press-fit slots, one in each inner side of themodule chassis frame120. TheU-plate624 provides additional EMI sealing by minimizing leakage through the front of the module. The U-plate624 also includes aflap625 located at its top side. TheU-plate624 is electrically grounded to the housing/shielding unit115 by theflap625 making physical contact with the housing/shielding unit115.
• The optical, electro-optical, and the electronic components are assembled into the[0108]module chassis frame120 or120′ before the housing/shielding unit115 encloses it. Thetransmitter620 and thereceiver621 have theirpins619 coupled to thetraces614T and614B of the printedcircuit board610. In one embodiment thepins619 are straddle mounted to the printedcircuit board610 with somepins619 coupled to thetraces614T on a top side of thePCB610 andother pins619 coupled to thetraces614B on a bottom side of thePCB610. That is, one or more pins mount to one or more traces on one side of the printed circuit board and another one or more pins mount to one or more traces on an opposite side of the printed circuit board.
• The[0109]shielding collars622A and622B are inserted over theports623A and623B of theconnectors650A and650B respectively to provide EMI shielding. The TO packagedtransmitter620 andreceiver621 are coupled into theports623B and623A respectively. This forms the optical subassembly which is then attached to the electrical components that is in turn coupled into themodule chassis frame120. The front portion of theconnectors650A and650B are inserted intoopenings212 in the nose of themodule chassis frame120 so that the pairs of snap lock clips652 of each are nearly flush. Next theU-plate624 is inserted intoopening626 so that its U-openings627 fit into thecircular recesses657 of eachrespective connector650A and650B. The Up-late624 holds the subassembly of the optical and electrical components coupled into themodule chassis frame120. Additionally, the U-plate624 can couple to theshielding collars622A and622B and the housing/shielding unit115 or115′. Theflap625 of the U-plate624 couples to the housing/shielding unit115 or115′ when the fiber-optic module is fully assembled. This can electrically connect thecollars622A and622B, the U-plate624 and the housing/shielding unit115 or115′ together if all are formed of conductive materials. Assuming they are electrically connected, grounding the housing/shielding unit115 or115′ to chassis ground of a host system can also couple chassis ground into the U-plate624 and the shieldingcollars622A and622B for electromagnetic shielding externally as well as internally. The TO-can headers of the receiver and transmitter are coupled to signal ground or the respective receiver ground and transmitter ground.
• After the subassembly of optical and electrical components are coupled into the[0110]module chassis frame120 or120′, the housing/shielding unit115 or115′ can then be assembled around it. Assembly of the housing/shielding unit115 or115′ with themodule chassis frame120 or120′ can be performed in different ways.
• The housing/[0111]shielding unit115 or115′ can be formed out of a single sheet of material. It can then be folded around themodule chassis frame120 or120′ with the affixed subassembly of optical and electrical components. Alternatively, the housing/shielding unit115 or115′ can be pre-folded out of the single sheet of material but for one opening at a front or rear end. Themodule chassis frame120 or120′ with an affixed subassembly of optical and electrical components can then be inserted into the opening at the front or rear end of the housing/shielding unit115 or115′.
• In one embodiment, the housing/[0112]shielding unit115 has all sides pre-folded but for theback side119. Theback side119 is left unfolded so that themodule chassis frame120 can be inserted through a rear opening of the housing/shielding unit115. In this case, a nose end of themodule chassis frame120 and the subassembly of optical and electrical components affixed thereto is inserted through the rear opening in the back of the housing/shielding unit115 with its nose facing forward. After being completely inserted, theback side119 is then folded down to have thetangs114A and114B bent inward to mate with window openings of flaps coupled to eachside117 and118 to finish assembly of the housing/shielding unit115 around themodule chassis frame120.
• In another embodiment, the housing/[0113]shielding unit115 has all sides pre-folded but for theseptum411 andstrap210. Theseptum411 andstrap210 are left unfolded so that themodule chassis frame120 can be inserted through a frontal opening of the housing/shielding unit115. Theseptum411 andstrap210 are then folded around themodule chassis frame120 to form the housing/shielding unit115. In this case, a rear end of themodule chassis frame120 and the affixed subassembly of optical and electrical components is inserted through the frontal opening of the housing/shielding unit115 so that the rear faces rearward. After being completely inserted, theseptum411 andstrap210 are then folded down and around as illustrated in FIG. 5 to finish assembly of the housing/shielding unit115 around themodule chassis frame120.
• In yet another embodiment, all sides of the housing/[0114]shielding unit115 are folded around themodule chassis frame120 and its affixed components. These methods of assembly are further described below with reference to FIGS.14-17C.
• After assembling the housing/[0115]shielding unit115 around themodule chassis frame120 and its affixed components, then theseptum411 is welded, soldered, glued, or otherwise fastened to the pair offlaps402A and402B as shown in FIG. 4.
• Referring now to FIG. 7, an perspective view of a housing/[0116]shielding unit715 and themodule chassis frame120 for a fiber-optic module700 are illustrated. The housing/shielding unit715 is somewhat similar to the housing/shielding unit115 but has slightly different dimensions, a few different features and employed in different mounting configurations. The housing/shielding unit715 has one ormore fingers712 which are carved out of the surfaces near theperimeter735 of anopen end739. The one or more fingers can also be referred to as tabs. The one or more fingers are similarly shaped having a body and a tip which is round in one embodiment. The body of thefingers712 is bent from the main surface while the tips may be slightly bent from the body to horizontal with the surface. Thefingers712 have a backwards orientation, originating at the front or nose of the fiber-optic module700. Thus, the one ormore fingers712 may also be referred to as backward fingers and the fiber-optic module700 with the housing/shielding unit715 may also be referred to as a fiber-optic module with a backward shield configuration.
• The[0117]fingers712 can be grouped intofingers712A andfingers712C located on a top716 and a bottom730 respectively of the housing/shielding unit715.Fingers712B and712D are located along the edges of the opening of the housing/shielding unit715. Although FIG. 7 illustrates sixfingers712A on atop side716 and sixfingers712C on abottom side730, twofingers712B on aleft side717, and twofingers712D on aright side718, one or more fingers727 can provide a means of grounding the housing/shielding unit715.
• The housing/[0118]shielding unit715 differs further from the housing/shielding unit115 in that it has adifferent nose strap710. Thestrap710 and theseptum711 function similarly to thestrap210′ and theseptum411 of the housing/shielding unit115′. Because the dimensions of the housing/shielding unit715 are larger so that it can extend further forward through an opening, thestrap710 differs significantly from thestrap210 of the housing/shielding unit115.
• Referring now to FIG. 8A, a front view of the housing/[0119]shielding unit715 is shown. In this embodiment, the housing/shielding unit715 generally has the shape of an oblong box having six sides. Front side738 has afrontal opening739 where themodule chassis frame120 can be inserted. The front side738 of the housing/shielding unit715 includes theseptum710 that is welded or bonded to theflaps910A and910B. Thenose strap711 also located at theopening739 is used for strapping the housing/shielding unit to themodule chassis frame120.
• Referring now to FIG. 9A, a bottom isometric view of the housing/shielding unit is shown. Attached to the[0120]open end911 is afront strap710 shown in the folded down position. Also shown, are twobottom flaps910A and910B for welding or bonding toseptum711.
• Referring now to FIG. 8B, a front view an alternate embodiment of the housing/[0121]shielding unit715′ is shown. In this alternate embodiment, the housing/shielding unit715′ generally has a similar shape to the housing/shielding unit715. The housing/shielding unit715′ differs from housing/shielding unit715 in the left side, right side, bottom side and the back side. That is backside719 is replaced byback side719′ with a retainingflap429;left side flap717 is replaced byleft side flaps717A and717B separated by a left side slit1611L;right side flap718 is replaced by right side flaps718A and718B separated by a right side slit1611R; and bottom side flaps910A and910B are replaced by bottom side flaps910A′ and910B′. Otherwise the housing/shielding unit715′ and the housing/shielding unit715 have similar elements and features including the one ormore fingers712A,712B,712C, and712D.
• The housing/[0122]shielding unit715′ forms an enclosure that surrounds amodule chassis frame120 or120′.Fingers712A,712B,712C, and712D can ground the housing/shielding unit715′ to seal in electromagnetic radiation (EMI) to minimize affecting a host system.
• Referring now to FIG. 9B, a bottom isometric view of the alternate housing/[0123]shielding unit715′ is shown. Attached to theopen end911 is afront strap711 shown in the folded down position. Also shown, are twobottom flaps910A′ and910B′ for welding or bonding toseptum710.
• Referring now to FIGS. 10A and 10B, a top and bottom exploded view of the fiber-[0124]optic module700 of the invention is shown. In one embodiment, the fiber-optic module700 is a 1×9 fiber-optic transceiver module. In which case, the fiber-optic module transceiver complies with the industry standard 1×9 footprint and meets the mezzanine height requirement of 9.8 mm.
• The grounding scheme of the fiber-optic module can be divided into categories of signal grounding and chassis grounding. The separation of signal ground from chassis ground can keep currents induced in a chassis ground from affecting signal integrity. Signal ground is through one or more ground pins of the PCB pins[0125]612 coupled from thePCB610 to a ground trace in a host printed circuit board. The housing/shielding unit715 or715′ is part of the chassis ground and electrically isolated from the signal ground. The housing/shielding unit715 or715′ couples to chassis ground of a host system through one or more of thefingers712. The one ormore fingers712 couple to a host panel near a host panel opening through which the fiber-optic module may extend. Thefingers712 contact the host panel opening and effectively reduce the size of the opening through which radiated electromagnetic energy may escape to seal the host panel opening through which the fiber-optic module may protrude. With the housing/shielding unit715 or715′ coupled to chassis ground, it acts as a plug to block EMI radiated emissions from escaping. Additionally, the smaller the host panel opening, the greater the shielding effectiveness as the host system begins to resemble a Faraday cage.
• The fiber-[0126]optic module700 of the invention includes a housing/shielding unit715 or715′, and amodule chassis frame120 or120′. The optic, electronic, and opto-electronic components of the fiber-optic module are placed into themodule chassis frame120. These components and their assembly were previously described with reference to FIG. 6 and the fiber-optic module100 and are not repeated again for brevity. When the housing/shielding unit715 or715 is assembled around the module chassis frame and the optic, electronic, and opto-electronic components affixed thereto, it can couple to theflap625 of the U-plate624 so that it an be electrically grounded to chassis ground. Additionally, the U-plate624 can couple to theshielding collars622A and622B. This can electrically connect thecollars622A and622B, the U-plate624 and the housing/shielding unit715 or715′ together if all are formed of conductive materials. Assuming they are electrically connected, grounding the housing/shielding unit715 or715′ to chassis ground of a host system can also couple chassis ground into the U-plate624 and the shieldingcollars622A and622B for electromagnetic shielding externally as well as internally.
• After all the components have been attached to the[0127]module chassis frame120 or120′, the housing/shielding unit715 or715′ can then be assembled around it. Assembly of the housing/shielding unit715 or715′ around themodule chassis frame120 can be performed in the same ways previously described for the housing/shielding unit115 or115′.
• Referring now to FIGS. 11A and 11B, a magnified side view and a magnified frontal view of the fiber-[0128]optic module700 within a host system is illustrated. The fiber-optic module700 includes a backward shield which is provided by the one-piece or single-piece integrated housing/shielding unit715 or715′. The fiber-optic module700 with the one-piece or single-piece integrated housing/shielding unit715 or715′ provides an extended mount as illustrated by its nose extending beyond a bezel, faceplate, or backplate. The host system may be a hub, switch, bridge, server, personal computer, or other network or electronic equipment desiring to connect to a communication system using an fiber-optic module. The fiber-optic module700 is coupled to a printedcircuit board1130 within the host system. A bezel, faceplate, orbackplate1110 of the host system has a transceiver opening1112 through which the nose of the fiber-optic module extends when its coupled to the host system. Thetransceiver opening1120 of thebezel1110 is sized to appropriately mate with thefingers712 of the fiber-optic module700. Theopening1120 has an inner surface1114 which mates with thefingers712 to make an electrical coupling. By making contact to the inner surface1114, a backside surface of thebezel1110 can be insulated to avoid shorting an electrical component that might make contact thereto. When the nose of the fiber-optic module is inserted into the opening1112 or the opening1112 is threaded over the nose of the fiber-optic module700, thefingers712 compress towards the fiber-optic module when mating with the inner surface1114 and expand outward to form a tight mechanical fit and a reliable electrical connection. The expansion of thefingers712 outward effectively make theopening1120 smaller through which radiated electromagnetic energy might otherwise escape. Thefingers712 also deter the nose of the fiber-optic module700 from extending excessively out through theopening1120 of thebezel1110. With thebezel1110 grounded by the chassis of the host system, the housing/shielding unit715 of the fiber-optic module can be grounded by one ormore fingers712 coupling to the inner surface1114 of theopening1120. Alternatively, the housing/shielding unit715 of thetransceiver700 can be grounded through a pin or other connection coupled to thePCB1130 of the host system.
• Referring now to FIGS. 12A and 12B, a magnified side view and a magnified frontal view of the fiber-[0129]optic module100 within a host system is illustrated. The host system may be a switch, bridge, a server, personal computer, or other network or electronic equipment desiring to connect to a communication system using an fiber-optic module. The fiber-optic module100 is coupled to a printedcircuit board1130 within the host system. A bezel, faceplate, orbackplate1210 of the host system has atransceiver opening1220 through which the nose of the fiber-optic module partially extends when coupled to the host system. The fiber-optic module100, a forward shield configuration with the one-piece or single-piece integrated housing/shielding unit115 or115′, provides a flush mount as illustrated by FIG. 12A. Thetransceiver opening1220 of thebezel1210 is sized appropriately to allow insertion of a fiber-optic connector into the fiber-optic module100. The bezel, faceplate, orbackplate1210 of the host system has abackside surface1214 to which thefingers112 can make an electrical and a mechanical coupling. Furthermore, thefingers112 deter the EMI of both the fiber-optic module100 and thehost system board1130 from extending excessively out through the transceiver opening1212 of thebezel1210. When the nose of the fiber-optic module is inserted into the opening1112 or the opening1112 is threaded over the nose of the fiber-optic module100, one or more of thefingers112 couple to theback side surface1214 around the opening1212 of thebezel1210. With thebezel1210 grounded by the chassis of the host system, the housing/shielding unit115 of the fiber-optic module100 can be grounded by one ormore fingers112 coupling to theback side surface1214 of thebezel1210. Alternatively if the bezel is coupled to a chassis ground trace, the housing/shielding unit115 or115′ of the fiber-optic module100 can be grounded through a pin or other grounding feature that is coupled to a chassis ground trace of thePCB1130 of the host system commonly coupled to the bezel.
• Referring now to FIG. 13, an[0130]exemplary host system1300 is illustrated having the fiber-optic module100 and the fiber-optic module700. Thehost system1300 has a bezel, a faceplate or ahost panel1310 withopening1120 andopening1220 for the fiber-optic module700 and the fiber-optic module100 respectively. The fiber-optic module700 is coupled to host printedcircuit board1130. The fiber-optic module100 is coupled to host printedcircuit board1130′. The host printedcircuit boards1130 and1130′ may include a ground plane on a top surface or bottom surface under the area of thefiber optic module100 and700 in order to provide additional electromagnetic shielding. Withopenings1120 and1220 being relatively small encompassed by the housing/shielding unit715 or715′ of the fiber-optic module700 and the housing/shielding unit115 or115′ of the fiber-optic module100 respectively, thehost system1300 begins to resemble a Faraday cage. The housing/shielding unit115,115′,715,715′ effectively sealsopenings1120 and1220 in thehost panel1310 to deter electromagnetic radiation from leaking into or out of the host system. The one ormore fingers112 of the housing/shielding unit115 or115′ can surround theopening1220. The one ormore fingers112 of the housing/shielding unit115 or115′ can expand into theopening1120. With the housing/shielding unit115 or115′ coupled to chassis ground, it acts as a plug to block EMI radiated emissions from escaping.
• Most equipment such as the[0131]host system1300 utilizing high-speed fiber-optic modules are required to meet the requirements of: 1) the FCC in the United States; 2) the CENELEC EN55022 (CISPR 22) specification in Europe; and 3) the VCCI in Japan. The fiber-optic modules100 and700 are designed to perform to these specified limits of EMI including complying with FCC Class B limits. The fiber-optic modules100 and700 are also designed to provide good noise immunity from externally generated radio-frequency electromagnetic fields. Key components in the fiber-optic modules100 and700 to achieve good electromagnetic compliance (EMC) for EMI and external noise immunity are theinternal shields622A and622B, a metal or conductive plasticmodule chassis frame120 or120′, and the housing/shielding unit115,115′,715 or715′ withfingers112 or712 respectively of the fiber-optic modules100 and700.
• The fiber-[0132]optic modules100 and700 are further designed to meetClass 1 eye safety and comply with FDA 21CFR1040.10 and 1040.11 and the IEC 825-1.
• Referring now to FIGS.[0133]14-17C, methods of forming the housing/shieldingunits115′ and715′ out of a sheet of a material layer and assembly with themodule chassis frame120 or120′ is illustrated.
• In FIG. 14, a starting sheet of a layer of[0134]material1400 for the housing/shieldingunits115,115′,715 and715′ is illustrated. The sheet ofmaterial1400 is a conductive material and can be a metal, a plated plastic, a conductive plastic or other known type of electrically conductive material. A first step in the process is to stamp, etch or cut the patterns for the housing/shielding unit115,115′,715 or715′ out of the sheet ofmaterial1400.
• Referring now to FIG. 15A, an unfolded[0135]flat pattern layout1500 for the housing/shielding unit115′ is illustrated. The unfoldedflat pattern layout1500 is a patterned material layer for the housing/shielding unit115′ formed out of the starting sheet of the layer ofmaterial1400. In the unfoldedflat pattern layout1500, theforward fingers112,tangs114A and114B,strap210 and theseptum411′ of the housing/shielding unit115′ are easily discernable. A pair of left andright window openings1522L and1522R are also visible in the unfoldedflat pattern layout1500.
• Referring now to FIG. 15B, fold/bend lines are illustrated on the unfolded[0136]flat pattern layout1500 to form the housing/shielding unit115′. A slightly alternate pattern and alternate fold/bend lines can be utilized to form the housing/shielding unit115. The fold/bend lines illustrated on the unfoldedflat pattern layout1500 make other features and components of the housing/shielding unit115′ discernable. The fold/bend lines illustrated in FIG. 15B include left flap and rightflap fold lines1502L and1502R, a backflap fold line1504, left and righttang fold lines1505L and1505R, a retainingflap fold line1506, left wing and rightwing fold lines1508L and1508R, fingerbase bend line1512, left bottom flap and right bottomflap fold lines1514L and1514R, astrap fold line1516, and aseptum fold line1517.
• A[0137]left wing1520L and aright wing1520R includetang window openings1522L and1522R respectively. Thetangs114A and114B mate with thetang window openings1522L and1522R respectively to hold the left wing and right wing coupled to theback side119′ after folding. Theseptum411′ is coupled to theright bottom flap415A and theleft bottom flap415B with an adhesive or a weld to hold the housing/shielding unit and the module chassis frame assembled together.
• The left[0138]wing fold line1508L defines theleft wing1520L from theleft side flap117B. The rightwing fold line1508R defines theright wing1520R from theright side flap118B. The rightside fold line1502R and the right side slit1511R definesright flaps118A and118B from thetop side116. The leftside fold line1502L and the left side slit1511L defines leftflaps117A and117B from thetop side116. The right bottomflap fold line1514R defines theright bottom flap415A. The left bottomflap fold line1514L defines theleft bottom flap415B. The retainingflap fold line1506 defines a retainingflap429 coupled to theback side flap119′.
• The fold/bend lines illustrated on the unfolded[0139]flat pattern layout1500 are folded and/or bent to form the housing/shielding unit115′ as illustrated in FIG. 4B. Generally, the folds along fold lines are made at nearly a ninety degree angle but for the fold lines of thetangs114A and114B and fingers. Thefingers112 may be first bent or lastly bent to curve outward along the bend lines1512. The left flaps117A and117B and theright flaps118A and118B may be the next to be folded or they may be the first to be folded alongfold lines1502L and1502R. Theright bottom flap415A and theleft bottom flap415B are next folded along the right bottomflap fold line1514R and the left bottomflap fold line1514L respectively. The next sequence of fold/bend steps can depend upon the method of assembly of the fiber-optic module utilized.
• In a first case, the front of the housing/[0140]shielding unit115′ is assembled first. In this case, theseptum411′ is folded alongfold line1517 and then thestrap210′ is folded alongfold line1516. This is followed by theleft wing1520L and theright wing1520R being folded along the leftwing fold line1508L and the rightwing fold line1508R respectively; theback side flap119′ being folded along thefold line1504; thetangs114A and114B being folded alongfold lines1505L and1505R respectively; and the retainingflap429 being folded along the retainingflap fold line1506.
• In a second case, the rear of the housing/[0141]shielding unit115′ is assembled first. In this case, theleft wing1520L and theright wing1520R are folded along the leftwing fold line1508L and the rightwing fold line1508R respectively; theback side flap119′ is folded along thefold line1504; thetangs114A and114B are folded alongfold lines1505L and1505R respectively; and the retainingflap429 is folded along the retainingflap fold line1506. This is followed by theseptum411′ being folded alongfold line1517 and then thestrap210′ folded alongfold line1516.
• In yet another case for assembly of the fiber-optic module, either order of assembly in the first or second case can be utilized or mixed together. The one or[0142]more fingers112 may alternately be bent outward from a frontal opening the into their curved shape as a last step in the folding/bending process.
• A slightly alternate pattern of the[0143]layout1500 with alternate fold/bend lines is utilized to fold and bend into shape to form the housing/shielding unit115 as illustrated in FIGS.1-3,4A,5 and12A.
• Referring now to FIG. 15C, an unfolded[0144]flat pattern layout1500′ for the housing/shielding unit115 is illustrated. The unfoldedflat pattern layout1500 is a patterned material layer for the housing/shielding unit115 formed out of the starting sheet of the layer ofmaterial1400. In the unfoldedflat pattern layout1500′, theforward fingers112,tangs114A and114B,strap210 and aseptum411 of the housing/shielding unit115 are easily discernable. The pair of left andright window openings1522L and1522R are also visible in the unfoldedflat pattern layout1500′.
• Referring now to FIG. 15D, fold/bend lines are illustrated on the unfolded[0145]flat pattern layout1500′ to form the housing/shielding unit115. The fold/bend lines illustrated on the unfoldedflat pattern layout1500′ make other features and components of the housing/shielding unit115 discernable. The fold/bend lines illustrated in FIG. 15D include left flap and rightflap fold lines1502L′ and1502R′, a backflap fold line1504, left and righttang fold lines1505L and1505R, left wing and rightwing fold lines1508L and1508R, fingerbase bend line1512, left bottom flap and right bottomflap fold lines1514L′ and1514R′, a firststrap fold line1516′, and a secondstrap fold line1517′.
• The fold bend lines of the unfolded[0146]flat pattern layout1500′ are similar to the fold/bend lines of the unfoldedflat pattern layout1500 but for left flap and rightflap fold lines1502L′ and1502R′, left bottom flap and right bottomflap fold lines1514L′ and1514R′, a firststrap fold line1516′, and a secondstrap fold line1517′.
• The right[0147]side fold line1502R′ defines theright flap118 from thetop side116. The leftside fold line1502L′ defines leftflap117 from thetop side116. The right bottomflap fold line1514R′ defines the right bottom flaps402A and405A. The left bottomflap fold line1514L′ defines the left bottom flaps402B and405B. Theback fold line1504 defines theback side flap119 from thetop side116.
• The first[0148]strap fold line1516′ and the secondstrap fold line1517′ define thefirst extension portion210A, thewrap portion210B and thesecond extension portion210C of thestrap210. Thestrap210 is folded along the firststrap fold line1516′ and the secondstrap fold line1517′. Theseptum411 can couple to the right bottom flaps402A and405A and the left bottom flaps402B and405B with an adhesive or a weld to hold the housing/shielding unit and the module chassis frame assembled together.
• The fold/bend lines illustrated on the unfolded[0149]flat pattern layout1500′ are folded and/or bent to form the housing/shielding unit115 as illustrated in FIGS. 1, 2,3, and4A. Generally, the folds along fold lines are made at nearly a ninety degree angle but for the fold lines of thetangs114A and114B andfingers112. Thefingers112 may be first bent or lastly bent to curve outward along the bend lines1512. Theleft flap117 and theright flap118 may be the next to be folded or they may be the first to be folded alongfold lines1502L′ and1502R′. The right bottom flaps402A and405A and the left bottom flaps402B and405B are next folded along the right bottomflap fold line1514R′ and the left bottomflap fold line1514L′ respectively. The next sequence of fold/bend steps can depend upon the method of assembly of the fiber-optic module utilized. These were previously described with reference to the unfoldedflat pattern layout1500 of FIG. 15B.
• Referring now to FIG. 16A, the unfolded[0150]flat pattern layout1600 for the housing/shielding unit715′ is illustrated. The unfoldedflat pattern layout1600 is a patterned material layer for the housing/shielding unit715′ formed out of the starting sheet of the layer ofmaterial1400. In the unfoldedflat pattern layout1600, thebackward fingers712,tangs114A and114B,strap710 and theseptum711 of the housing/shielding unit715′ are easily discernable. A pair of left andright window openings1622L and1622R are also visible in the unfoldedflat pattern layout1600.
• Referring now to FIG. 16B, fold/bend lines are illustrated on the unfolded[0151]flat pattern layout1600 to form the housing/shielding unit715′. A slightly alternate pattern and alternate fold/bend lines can be utilized to form the housing/shielding unit715. The fold/bend lines illustrated on the unfoldedflat pattern layout1600 make other features of the housing/shielding unit715′ discernable.
• The fold/bend lines illustrated in FIG. 16B include left flap and right[0152]flap fold lines1602L and1602R, backflap fold line1604, left and righttang fold lines1605L and1605R, retainingflap fold line1606, left wing and rightwing fold lines1608L and1608R, fingerbase bend line1612B, fingertip bend line1612T, left bottom flap and right bottomflap fold lines1614L and1614R,strap fold line1616,septum fold line1617. Generally, the folds along fold lines are made at nearly a ninety degree angle but for the fold lines of thetangs114A and114B and fingers.
• A[0153]left wing1620L and aright wing1620R includewindow openings1622L and1622R respectively. Thetangs114A and114B mate with thewindow openings1622L and1622R respectively to hold the left wing and right wing coupled to theback side719′ after folding.
• The left[0154]wing fold line1608L defines theleft wing1620L from theleft side flap717B. The rightwing fold line1608R defines theright wing1620R from theright side flap718B. The rightside fold line1602R and the right side slit1611R definesright flaps718A and718B from thetop side716. The leftside fold line1602L and the left side slit1611L defines leftflaps717A and717B from thetop side716. The right bottomflap fold line1614R defines theright bottom flap910A′. The left bottom flap fold line1614L defines theleft bottom flap910B′. The retainingflap fold line1606 defines aretaining flap1626 coupled to theback side flap719′.
• The fold/bend lines illustrated on the unfolded[0155]flat pattern layout1600 are respectively folded and/or bent to form the housing/shielding unit715′ as illustrated in FIGS. 8B and 9B. The sequence of folding and bending of the fold lines in the unfoldedflat pattern layout1600 is similar to that of the unfoldedflat pattern layout1500 but for the fingers. Thefingers712 for the housing/shielding unit715′ or715 are generally easier to push or pull out of the surface of the unfoldedflat pattern layout1600 first. Then, the sequence of folding and bending can proceed similarly for any of the three methods of assembly previously described.
• Referring now to FIGS.[0156]17A-17C, methods of assembly of the housing/shieldingunits115 and715 with themodule chassis frame120 is illustrated.
• In FIG. 17A, the[0157]layout1500 or1600 are placed on top of themodule chassis frame120. Folding and bending is then performed around themodule chassis frame120 or120′ along the fold lines and bend lines described in FIGS.15A-15B or16A-16B respectively to form the housing/shielding unit115,115′,715 or715′. The housing/shielding unit115,115′,715 or715′ then surrounds themodule chassis frame120 or120′. Thetangs114A and114B are then folded into thewindow openings1522L and1522R or1622L and1622R. This results in a substantially complete fiber-optic module such as fiber-optic module100 illustrated in FIG. 1 for example.
• In FIG. 17B, the[0158]layout1500 or1600 is first folded and bent along the fold lines and bend lines described in FIGS.15A-15B or16A-16B respectively but forfold lines1516 and1517 or1616 and1617. This leaves the front of the housing/shielding unit115,115′,715 or715′ open without thestrap710 and theseptum711 being folded. Themodule chassis frame120 or120′ with the affixed components is inserted into the frontal opening with its rear entering first. Then thestrap210,210′ or710 and theseptum411 or711 are then foldedfold lines1516 and1517 or1616 and1617 as described in FIGS.15A-15B and FIGS.16A-16B to hold themodule chassis frame120 or120′ within the housing/shielding unit115,115′,715 or715′. After being folded, theseptum411 or711 is affixed in place by being welded by spot welding, soldered with a solder, glued with an adhesive or otherwise fastened to a pair of bottom flaps. This results in a substantially complete fiber-optic module such as fiber-optic module100 illustrated in FIG. 1 for example.
• In FIG. 17C, the[0159]layout1500 or1600 is first folded and bent along the fold lines and bend lines described in FIGS.15A-15B or16A-16B respectively but forfold lines1504,1505L,1505R,1506,1508L and1508R or1604,1605L,1605R,1606,1608L and1608R. After being folded, theseptum411 or711 is affixed in place by glue or welding. This leaves the rear of the housing/shielding unit115,115′,715 or715′ open without theback side flap119′ or719′ and the left andright wings1520L or1620L and1520L or1620R being folded. The front end of themodule chassis frame120 or120′ with the affixed components is inserted into the rear opening of the housing/shielding unit, nose first. The left andright wings1620L and1620R are then folded followed by backside flap119′ or719′ alongfold lines1504,1506,1508L and1508R or1604,1606,1608L and1608R as shown and described in FIGS.15A-15B or16A-16B respectively. Thetangs114A and114B are then folded alongfold lines1505L and1505R or1605L and1605R into theopenings1522L and1522R or1622L and1622R respectively. With theback side flap119′ or719′ held in place, the housing/shielding unit115,115′,715 or715′ is held around themodule chassis frame120 or120′. This results in a substantially complete fiber-optic module such as fiber-optic module100 illustrated in FIG. 1 for example.
• Fingers of a housing/shielding unit can deter electromagnetic radiation from leaking out of the opening by expanding and/or surrounding one or more portions of the opening or expanding into host tabs as will be illustrated below. In either case the fingers of the housing/shielding unit can make a connection to ground for the shielded housing/cover.[0160]
• Referring now to FIG. 24, a[0161]fiber optic module2400 is illustrated for another embodiment of the invention.Fiber optic module2400 includes a shielded housing/cover2415 as well as other elements previously described in reference tofiber optic modules100,100′,700 or700′. The shielded housing/cover2415 maybe an integrated one-piece housing/cover or a two-piece housing/cover. In the case of a two-piece housing/cover the shielded housing/cover includes a front-shielded housing/cover2415A and rear shielded housing/cover2415B. The rear shielded housing/cover2415B overlaps a portion of the front-shielded housing/cover2415A. Alternatively, the front shielded housing/cover2415A could overlap a portion of the rear housing/cover2415B. Thefiber optic module2400 provides forward fingers on the perimeter of the top and bottom of the nose and backward fingers in the sides near the nose and the perimeter of the shieldedhousing2415. Shielded housing/cover2415 includesforward fingers112A′ on the top side near the perimeter,forward fingers112C′ on the bottom side near the perimeter,backward fingers712B′ in the left side, andbackward fingers712D′ in the right side near the perimeter. The shieldedhousing2415 includes a fronttop side2416A, a reartop side2416B, a frontleft side2417A, a rearleft side2417B, abackside2419, a frontright side2418A, and a rearright side2418B. The shielded housing/cover2415 also includes astrap210′ and aseptum411′.
• Referring now to FIG. 25, a bottom perspective view of the[0162]fiber optic module2400 is illustrated.Fiber optic module2400 includes the chassis/base120 or120′. The chassis orbase120 or120′ includesvent openings633 on the bottom side thereof. Theleft side2417B of the shielded housing/cover2415 meets thebackside2419 of the shielded housing/cover2415 at a corner which may use a tongue andgroove coupling2430. Therear portion2415B of the shielded housing/cover2415 can include aback edge wrap2429B, aleft edge wrap2429L and a right edge wrap2429R. When assembled with chassis/base120 or120′, one or more of the edge wraps can wrap around chassis/base120 or120′ to couple them together. The front portion of the shielded housing/cover2415A includes a rightside bottom flap415A and a left sidebottom flap415B. When assembled with chassis/base120 or120′ the rightside bottom flap415A and the left sidebottom flap415B of the shielded housing/cover can be formed around chassis/base120 or120′ to couple them together. To hold thestrap210′ in place around the chassis/base120 or120′, theseptum411′ can be overlapped by the left and rightside bottom flap415A and415B.
• The[0163]forward fingers112A′ and112C′ and thebackward fingers712B′ and712D′ can be formed out of different shapes including round fingertips, rectangular fingertips, or triangular fingertips. The fingers maybe arched shaped or curved or bent in one or more places, in order to provide spring pressure and expand outward to seal around an opening in an enclosure, faceplate, or bezel for input/output connections. As previously mentioned the shielded housing/cover2415 can be an integrated one piece or a two-piece design. Similarly the shieldedhousing115,115′,715 and715′ can be either an integrated one-piece or a two-piece shielding housing/cover having a front portion and a rear portion. In this manner, the samerear portion2415B of the shielded housing/cover maybe used interchangeably with different front portions, such as thefront portion2415A of the shielded housing/cover2415. That is, by simply changing the front portion of the shielded housing/cover, backward fingers maybe supplied on top, bottom, left and right sides or forward fingers maybe provided on left, right, top and bottom sides or any combination thereof. This allows flexible assembly of fiber optic modules. The decision of the type of shielding for the fiber optic module can be postponed until the subassembly of the chassis is completed and the rear portion of the shielded housing is wrapped around it. The front portion of the shielded housing/cover being interchangeable, allows flexibility in manufacturing and meeting the demands of customers.
• Referring now to FIG. 26A, a rear perspective view of the[0164]fiber optic module2400 illustrates theforward fingers112A′ having rounded tips while thebackward fingers712B′ have more of a triangular shaped tip.
• Referring now to FIG. 26B, a top view of the[0165]fiber optic module2400 illustrate differences in the positions of theforward fingers112A′ and112C′ and thebackward fingers712B′ and712D′ in thefront portion2415A of the shielded housing/cover2415.
• Referring now to FIG. 27, a side view of the[0166]fiber optic module2400 better illustrates different possible shapes for the forward fingers. The forward fingers may be curved or bent in differing places. The front shielded housing/cover2415A includes theforward fingers112A′ on a top side and theforward fingers112C′ on a bottom side. Theforward fingers112A′ are illustrated as being curved or arched shaped in FIG. 27. Theforward fingers112C′ are illustrated as being bent in two places (i.e. bent shaped) in FIG. 27 but can take on a curved or arched shape or other bent configuration in order to make contact with a back side surface of a bezel, faceplate, or backplate. Theforward fingers112A′ can take on a bent shape or other bending configuration in order to make contact to a back side surface of a bezel, faceplate, or backplate.
• Referring now to FIG. 28, a front view of the[0167]fiber optic module2400 is illustrated mounted adjacent a bezel, faceplate, orbackplate2810. The bezel, faceplate, orbackplate2810 includes anopening2820 to allow a fiber optic plug to be inserted into thefiber optic module2400. Duplex SC receptacles for duplex SC plugs, provided in one embodiment, can be readily seen in the front view of thefiber optic module2400 separated by thestrap210′.
• To seal around the[0168]opening2820, theforward fingers112A′ and112C′ couple (i.e. press) against the backside surface of the bezel, faceplate, orbackplate2810 adjacent to theopening2820 without coupling into theopening2820. That is, theforward fingers112A′ and112C′ are not inserted into theopening2820. The left and right sidebackward fingers712B and712B′ also do not couple into theopening2820 nor do they couple against the backside surface of the bezel, faceplate, orbackplate2810. Rather, the backsidebackward fingers712B and712B′ couple to host tabs (not shown in FIG. 28). The host tabs can be integrated or coupled to the bezel, faceplate, orbackplate2810.
• Referring now to FIG. 29, a cutaway side view of the[0169]fiber optic module2400 inserted into ahost system2900 is illustrated. Thefiber optic module2400 couples to a host printedcircuit board1130 or1130′. The topforward fingers112A′ and the bottomforward fingers112C′ couple to abackside surface2902 of the bezel, faceplate, orbackplate2810 as illustrated in FIG. 29. The topforward fingers112A′ and the bottomforward fingers112C′ do not couple to aninside surface2902 of theopening2820. Neither do thebackward fingers712D′ couple into theopening2820. As can be seen, thebackward fingers712D′ (as well as thebackward fingers712B′) are offset from theopening2820 and thebackside surface2902 of the bezel, faceplate, orbackplate2810.
• Referring now to FIG. 30, a topside view of the[0170]fiber optic module2400 coupled into thehost system2900 is illustrated. As can be seen as viewed from the topside, thehost system2900 includes a leftside host tab3010B and a rightside host tab3010A. The right sidebackward fingers712D′ couple to aninside surface3014A of thehost tab3010A. The left sidebackward fingers712B′ couple to aninside surface3014B of thehost tab3010B. Thehost tabs3010A and3010B extend along the sides of the front shielded housing/cover2415A. The overlap may provide improved EMI performance in deterring electromagnetic radiation from leaking in and out of theopening2820. Thehost tabs3010A and3010B may additionally provide lateral support when optical plugs are pushed into and pulled out of for thefiber optic module2400, while the printedcircuit board1130 or1130′ provides horizontal support. Thehost tabs3010A and3010B may be coupled to thebackside2902 of the bezel, faceplate, orbackplate2810. Alternatively, thehost tabs3010A and3010B may be integrally formed with the bezel, faceplate, orbackplate2810 and extend backward from thebackside2902. The topforward fingers112A′ and the bottomforward fingers112C′ do not couple to thehost tabs3010A and3010B. Thus, thefiber optic module2400 can have its nose flush with thefaceplate2810.
• Referring now to FIG. 31, an unfolded flat pattern layout of the[0171]front portion2415A (i.e., the front shielded housing/cover) of the shieldedhousing2415 is illustrated. The rear shielded housing/cover2415B can be envisioned by slightly modifying FIG. 16B so that theslits1611L and1611R cut through the top716 to meet each other. The unfoldedflat pattern layout2415A is a patterned material layer formed out of the starting sheet of the layer ofmaterial1400. The front shielded housing/cover2415A and the rear shielded housing/cover2415B can be stamped, cut or etched out of a conductive material (i.e. a metal such as stainless steel for example). As mentioned previously, theforward fingers112A′ and112C′ and thebackward fingers712B′ and712D′ can be formed out of different shapes including round fingertips, rectangular fingertips or triangular fingertips.
• Referring now to FIG. 32, fold/bend lines are illustrated on the unfolded flat pattern layout of the front shielded housing/[0172]cover2415A. The fold/bend lines illustrated on the unfolded flat pattern layout make other features of the front shielded housing/cover2415A discernable.
• The fold/bend lines illustrated in FIG. 32 include left flap and right flap fold lines[0173]3202L and3202R, left bottom flap and right bottomflap fold lines3214L and3214R, the forward fingerbase bend line1512, the backward fingerbase bend line1612B, the fingertip bend line1612T, thestrap fold line1616, and theseptum fold line1617. Generally, the folds along fold lines are made at nearly a ninety degree angle but for the bend lines of thefingers112A′,112C′,712B′, and712D′.
• The right bottom[0174]flap fold line3214R defines theright bottom flap415A. The left bottomflap fold line3214L defines theleft bottom flap415B. The right side fold line3202R and the right bottomflap fold line3214R define the frontright side2418A. The left side fold line3202L and the left bottomflap fold line3214L define the frontleft side2417A. The left flap and right flap fold lines3202L and3202R define the fronttop side2416A.
• The fold/bend lines illustrated on the unfolded flat pattern layout of FIG. 32 are respectively folded and/or bent to form the front shielding/[0175]cover2415A as illustrated in FIGS.24-30. The sequence of folding and bending of the fold lines in the unfolded flat pattern layout of the front shielded housing/cover2415A is similar to that of the unfoldedflat pattern layouts1500 and1600 but for the fingers. Thebackward fingers712B′ and712D′ can be first pushed or pulled out of the surface of the unfolded flat pattern layout. Then, the sequence of folding and bending can proceed on the front shielded housing/cover2415A.
• As previously mentioned, the[0176]forward fingers112A′ and112C′ and thebackward fingers712B′ and712D′ may be arched shaped or curved or bent in one or more places, in order to provide spring pressure and expand outward to seal around theopening2820 and/or couple to thehost tabs3010A and3010B.
• Referring now to FIG. 33, a rear perspective view of a[0177]fiber optic module3300 is illustrated for another embodiment of the invention.Fiber optic module3300 includes a shielded housing/cover3315 as well as other elements previously described in reference tofiber optic modules100,100′,700,700′ and2400. The shielded housing/cover3315 maybe an integrated one-piece housing/cover or a two-piece housing/cover. In the case of a two-piece housing/cover the shielded housing/cover includes a front-shielded housing/cover3315A and rear shielded housing/cover3315B. The rear shielded housing/cover3315B overlaps a portion of the front-shielded housing/cover3315A in one embodiment. Alternatively, the front shielded housing/cover3315A could overlap a portion of the rear housing/cover3315B in another embodiment. Thefiber optic module3300 provides forward fingers on the perimeter of the left and right sides of the nose and backward fingers in the top and bottom near the nose and the perimeter of the shieldedhousing3315. In particular, shielded housing/cover3315 includesbackward fingers712A′ in the top side near the perimeter,backward fingers712C′ in the bottom side near the perimeter (not shown in FIG. 33),forward fingers112B′ in the left side, andforward fingers112D′ in the right side near the perimeter. The shieldedhousing3315 includes a fronttop side3316A, a reartop side3316B, a frontleft side3317A, a rear left side3317D, abackside3319, a frontright side3318A, and a rearright side3318B. The shieldedhousing3315 also includes astrap210′ and aseptum411′ as is shown in FIG. 25 of the shieldedhousing2415.
• [0178]Fiber optic module3300 includes the chassis/base120 or120′ and the optical, opto-electronic, and the electronic components assembled therein. The chassis orbase120 or120′ includesvent openings633 on the bottom side thereof. Theleft side3317B of the shielded housing/cover3315 meets thebackside3319 of the shielded housing/cover3315 at a corner which may use a tongue and groove coupling. Therear portion3315B of the shielded housing/cover3315 can include a back edge wrap, a left edge wrap and a right edge wrap. When assembled with chassis/base120 or120′ one or more of the edge wraps can wrap around chassis/base120 or120′ to hold them assembled together. The front portion of the shielded housing/cover3315A includes a rightside bottom flap415A and a left sidebottom flap415B. When assembled with chassis/base120 or120′ the rightside bottom flap415A and the left sidebottom flap415B of the shielded housing/cover can be found around chassis/base120 or120′ to hold them together. To hold thestrap210′ in place around the chassis/base120 or120′, theseptum411′ can be overlapped by the left and right side bottom flaps415A and415B.
• The[0179]forward fingers112B′ and112D′ and thebackward fingers712A′ and712C′ can be formed out of different shapes including round fingertips, rectangular fingertips or triangular fingertips. The fingers maybe arched shaped or curved or bent in one or more places, in order to provide spring pressure and expand outward to seal around an opening. The shielded housing/cover3315 can be an integrated one piece or a two-piece design. In this manner, the samerear portion3315B of the shielded housing/cover maybe used interchangeably with different front portions, such as thefront portion2415A of the shielded housing/cover2415. That is, by simply changing the front portion of the shielded housing/cover backward fingers maybe supplied on top, bottom, left and right sides or forward fingers maybe provided on left, right, top and bottom sides or any combination thereof. This allows flexible assembly of fiber optic modules. The decision of the type of shielding for the fiber optic module can be postponed until the subassembly of the chassis is completed and the rear portion of the shielded housing is wrapped around it. The front portion of the shielded housing/cover being interchangeable, allows flexibility in manufacturing and meeting the demands of customers.
• Referring now to FIG. 34, a side view of the[0180]fiber optic module3300 is illustrated. The front shielded housing/cover3315A includes theforward fingers112B′ extending from the left side, while theforward fingers112D′ extend from the right side. Theforward fingers112B′ can be curved or arched shaped, bent in two places, or otherwise bent in another manner (i.e. bent shaped) in order to make contact with a back side surface of a bezel, faceplate, or backplate.
• Referring now to FIG. 35, a top view of the[0181]fiber optic module3300 illustrates differences in the positions of theforward fingers112B′ and112D′ and thebackward fingers712A′ and712C′ in thefront portion3315A of the shielded housing/cover3415. Theforward fingers112B′ and112D′ extend from the perimeter of thefront portion3315A while thebackward fingers712A′ and712C′ are a distance away from the perimeter extending out of the surface of thefront portion3315A.
• Referring now to FIG. 36, a front view of the[0182]fiber optic module3300 and theforward fingers112B′ and112D′ and thebackward fingers712A′ and712C′ is illustrated. A bezel, faceplate, or backplate couples to the forward fingers while leaving an opening to allow one or more fiber optic plugs to be inserted into thefiber optic module3300. Duplex SC receptacles for duplex SC plugs, used in one embodiment, can be readily seen in the front view of thefiber optic module3300 separated by thestrap210′.
• Referring now to FIG. 37, a cutaway side view of the[0183]fiber optic module3300 inserted into ahost system3700 is illustrated. Thefiber optic module3300 couples to a host printedcircuit board1130 or1130′. Thehost system3700 includes a faceplate orbezel3710 which has anopening3720 to allow fiber optic plugs to connect to thefiber optic module3300. Thehost system3700 includeshost tabs3730A and3730A, separate and apart or integral with the faceplate orbezel3710 that can be grounded to chassis ground. Thebackward fingers712A′ and712C′ are offset from theopening3720 and abackside surface3712 of the bezel, faceplate, orbackplate3710. The topbackward fingers712A′ of the shieldedhousing3315 couple to an inside surface3374A of thehost tab3730A. The bottombackward fingers712C′ couple to an inside surface3774B of thehost tab3730B.
• The[0184]host tabs3730A and3730B extend along the top and bottom of the front shielded housing/cover3315A. The overlap between the host tabs and the front shielded housing/cover may provide improved EMI performance in deterring electromagnetic radiation from leaking in and out of theopening3720. Thehost tabs3730A and3730B may additionally provide horizontal support when optical plugs are pushed into and pulled out of thefiber optic module2400 along with the printedcircuit board1130 or1130′. Thehost tabs3730A and3730B may be coupled to abackside3712 of the bezel, faceplate, orbackplate3710. Alternatively, thehost tabs3730A and3730B may be integrally formed with the bezel, faceplate, orbackplate3710 and extend backward from thebackside3712. The left side forwardfingers112B′ and the right side forwardfingers112D′ do not couple to thehost tabs3730A and3730B but the backside3172 of thefaceplate3710.
• Referring now to FIG. 38, a cutaway topside view of the[0185]fiber optic module3300 coupled into thehost system3700 is illustrated. To seal around theopening3720, theforward fingers112B′ and112D′ couple (i.e. press) against thebackside surface3712 of the bezel, faceplate, orbackplate3710 adjacent to theopening3720 without coupling into theopening3720. That is, theforward fingers112B′ and112D′ are not inserted into theopening3720. The top and bottombackward fingers712A′ and712C′ also do not couple into theopening3720 nor do they couple against thebackside surface3712 of the bezel, faceplate, orbackplate3710. Rather, thebackward fingers712A′ and712C′ couple to thehost tabs3730A and3730B. Nor do thebackward fingers712A′ and712C′ and nor do theforward fingers112B′ and112D′, couple to aninside surface3724 of theopening3720. Thus, thefiber optic module3300 can have its nose flush with thefaceplate3710.
• Referring now to FIG. 39, an unfolded flat pattern layout of the[0186]front portion3315A (i.e., the front shielded housing/cover) of the shieldedhousing3315 is illustrated. The rear shielded housing/cover3315B can be envisioned by slightly modifying FIG. 16B so that theslits1611L and1611R cut through the top716 to meet each other.
• The unfolded[0187]flat pattern layout3315A is a patterned material layer formed out of the starting sheet of the layer ofmaterial1400. The front shielded housing/cover3315A and the rear shielded housing/cover3315B can be stamped, cut or etched out of a conductive material (i.e. a metal such as stainless steel for example). Theforward fingers112B′ and112D′ and thebackward fingers712A′ and712C′ can be formed out of different shapes including round fingertips, rectangular fingertips or triangular fingertips.
• Referring now to FIG. 40, fold/bend lines are illustrated on the unfolded flat pattern layout of the front shielded housing/[0188]cover3315A. The fold/bend lines illustrated on the unfolded flat pattern layout make other features of the front shielded housing/cover3315A discernable.
• The fold/bend lines illustrated in FIG. 40 include left flap and right[0189]flap fold lines4002L and4002R, left bottom flap and right bottomflap fold lines4014L and4014R, the forward fingerbase bend line1512, the backward fingerbase bend line1612B, the fingertip bend line1612T, thestrap fold line1616, and theseptum fold line1617. Generally, the folds along fold lines are made at nearly a ninety degree angle but for the bend lines of thefingers112B′,112D′,712A′, and712C′.
• The right bottom[0190]flap fold line4014R defines theright bottom flap415A. The left bottom flap fold line4014L defines theleft bottom flap415B. The rightside fold line4002R and the right bottomflap fold line4014R define the frontright side3318A. The leftside fold line4002L and the left bottom flap fold line4014L define the frontleft side3317A. The left flap and rightflap fold lines4002L and4002R define the fronttop side3316A.
• The fold/bend lines illustrated on the unfolded flat pattern layout of FIG. 40 are respectively folded and/or bent to form the front shielding/[0191]cover3315A as illustrated in FIGS.33-38. The sequence of folding and bending of the fold lines in the unfolded flat pattern layout of the front shielded housing/cover3315A is similar to that of the unfoldedflat pattern layouts1500 and1600 but for the fingers. Thefingers712A′ and712C′ can be first pushed or pulled out of the surface of the unfolded flat pattern layout. Then, the sequence of folding and bending can proceed on the front shielded housing/cover3315A.
• The[0192]forward fingers112B′ and112D′ and thebackward fingers712A′ and712C′ maybe arched shaped or curved or bent in one or more places, in order to provide spring pressure and expand outward to seal around theopening3720 and/or couple to thehost tabs3730A and3730B.
• The invention has a number of advantages over the prior art which will become clear after thoroughly reading this disclosure.[0193]
• The preferred embodiments of the invention are thus described. While the invention has been described in particular embodiments, the invention should not be construed as limited by such embodiments. For example, the fiber-optic modules have been described as having one or more pairs of a transmitter and a receiver for a fiber-optic transceiver module. However, the fiber-optic modules may also have one or more transmitters only or one or more receivers only for a fiber-optic transmitter module or a fiber-optic receiver module. Rather, the invention should be construed according to the claims that follow below.[0194]

Claims (79)

What is claimed is:

1. A fiber-optic module comprising:

a module chassis frame having optical, electrical, and opto-electronic components affixed therein, the optical, electrical, and opto-electronic components to process optical and electrical signals; and

a housing/shielding unit around the module chassis frame, the housing/shielding unit having a frontal opening to accept a fiber-optic cable connector, the housing/shielding unit is conductive and has one or more forward fingers and one or more backward fingers near an edge of the frontal opening to ground the housing/shielding unit and to provide an electromagnetic interference (EMI) seal around an opening in a bezel.

2. The fiber-optic module ofclaim 1 wherein,

the housing/shielding unit includes a front portion and a back portion.

3. The fiber-optic module ofclaim 1 wherein,

the housing/shielding unit protects the optical, electrical, and opto-electronic components and shields electromagnetic radiation.

4. The fiber-optic module ofclaim 1 wherein,

the one or more forward fingers couple to a backside surface of the faceplate near the opening, and

the one or more backward fingers couple to one or more host tabs of the bezel.

5. The fiber-optic module ofclaim 1 wherein,

the one or more forward fingers curve outward and forward from the edge of the frontal opening.

6. The fiber-optic module ofclaim 1 wherein,

the one or more backward fingers lift up from one or more surfaces of the housing/shielding unit and extend away from the edge of the frontal opening.

7. The fiber-optic module ofclaim 1 wherein,

the housing/shielding unit is metal, plated plastic, or conductive plastic.

8. The fiber-optic module ofclaim 1 wherein,

the module chassis frame is non-conductive and includes a pin to mount the fiber optic module to a host printed circuit board.

9. The fiber-optic module ofclaim 1 wherein,

the optical, electrical, and opto-electronic components include a transmitter subassembly and a receiver subassembly to transceive optical signals over a duplex optical fiber ribbon and the fiber optic module is a fiber-optic transceiver module.

10. The fiber-optic module ofclaim 8 wherein,

the fiber optic module includes a duplex SC optical connector and the fiber-optic module is a 1×9 fiber optic module.

11. The fiber-optic module ofclaim 1 wherein,

at least one forward finger of the one or more forward fingers extends from a right side and a left side of the housing/shielding unit, and

at least one backward finger of the one or more backward fingers extends from a top side of the housing/shielding unit.

12. The fiber-optic module ofclaim 1 wherein,

at least one forward finger of the one or more forward fingers extends from a right side and a left side of the housing/shielding unit, and

at least one backward finger of the one or more backward fingers extends from a bottom side of the housing/shielding unit.

13. The fiber-optic module ofclaim 1 wherein,

at least one forward finger of the one or more forward fingers extends from a right side and a left side of the housing/shielding unit, and

at least one backward finger of the one or more backward fingers extends from a top side and a bottom side of the housing/shielding unit.

14. The fiber-optic module ofclaim 1 wherein,

at least one backward finger of the one or more backward fingers extends from a right side and a left side of the housing/shielding unit, and

at least one forward finger of the one or more forward fingers extends from a top side of the housing/shielding unit.

15. The fiber-optic module ofclaim 1 wherein,

at least one backward finger of the one or more backward fingers extends from a right side and a left side of the housing/shielding unit, and

at least one forward finger of the one or more forward fingers extends from a top side and a bottom side of the housing/shielding unit.

16. The fiber-optic module ofclaim 1 wherein,

the one or more fingers are equally sized and equally spaced around each side around a perimeter of the housing/shielding unit.

17. The fiber-optic module ofclaim 1, wherein

the housing/shielding unit further has

a pair of bottom side flaps, and

a strap and a septum coupled to the strap,

the strap wrapping around a part of the frontal opening and the module chassis frame, the septum to couple to the pair of bottom side flaps, the strap and the septum to hold the module chassis frame and the housing/shielding unit together.

18. The fiber-optic module ofclaim 1 wherein,

the housing/shielding unit is an external electromagnetic shield and the fiber-optic module further has an internal electromagnetic shield coupled to the housing/shielding unit.

19. The fiber-optic module ofclaim 18 wherein,

the internal electromagnetic shield is a U-plate to provide an EMI seal around an optical connector and deter electromagnetic radiation from leaking out through the frontal opening of the fiber optic module.

20. The fiber-optic module ofclaim 19 wherein,

the U-plate includes a flap, the flap to couple to the housing/shielding unit to ground the U-plate when the housing/shielding unit is grounded.

21. The fiber-optic module ofclaim 17 wherein,

the internal electromagnetic shield is a shielding collar around an opto-electronic device to shield it from electromagnetic radiation.

22. The fiber-optic module ofclaim 17 wherein,

the one or more forward fingers of the housing/shielding unit are spring loaded to flex into position and couple to a bezel, faceplate, or panel, and

the one or more backward fingers are spring loaded to flex into position and couple to one or more host tabs.

23. A method of forming a shielded housing for a fiber-optic module, the method comprising:

forming a flat pattern of a front portion of the shielded housing from a sheet of conductive material, the flat pattern including one or more forward fingers and one or more backward fingers;

folding the flat pattern along fold lines to form flaps and sides of the shielded housing; and

bending the flat pattern along bend lines to form the one or more forward fingers and the one or more backward fingers of the shielded housing.

24. The method ofclaim 23 further comprising:

providing a back portion of the shielding housing to protect components and to shield electromagnetic radiation.

25. The method ofclaim 23 further comprising:

prior to the folding and the bending,

placing a flat pattern of a back portion of the shielded housing onto a chassis including an opto-electronic device to process optical and electrical signals, and

folding and bending the flat pattern of the back portion around the chassis to partially assemble the chassis and the shielded housing together.

26. The method ofclaim 23 wherein,

the flat pattern of the front portion of the shielded housing further includes

a strap and a septum.

27. The method ofclaim 23 wherein,

the folding and the bending of the flat pattern forms the front portion of the shielded housing including

a top side,

a left side flap including a left wing flap, and

a right side flap including a right wing flap.

28. The method ofclaim 27 wherein,

a strap extends from a front edge of the top side at one end,

and a septum extends at an opposite end of the strap.

29. The method ofclaim 27 wherein,

the one or more forward fingers extend from a front edge of the top side and the bottom left side flap, and the bottom right side flap.

30. The method ofclaim 27 wherein,

the one or more forward fingers extend from a front edge of the left side flap and the right side flap,

31. The method ofclaim 27 wherein,

the one or more backward fingers extend backward near a front edge from a surface of the top side.

32. The method ofclaim 27 wherein,

the one or more backward fingers extend from a surface of the left side flap and the right side flap.

33. The method ofclaim 23 wherein,

the forming of the flat pattern of the front portion of the shielded housing includes

etching the sheet of conductive material.

34. The method ofclaim 23 wherein,

the forming of the flat pattern of the front portion of the shielded housing includes

stamping the sheet of conductive material.

35. The method ofclaim 23 wherein,

the forming of the flat pattern of the front portion of the shielded housing includes

cutting the sheet of conductive material.

36. A front portion of a shielded housing formed by the method ofclaim 23.

37. A method for assembling a fiber optic module comprising:

assembling optical, electrical and optical-electrical components into a chassis to form a first subassembly;

forming a back portion of a shielded housing around the first subassembly to form a second subassembly;

storing the second subassembly in inventory waiting for customer orders; and

if a customer order is received, forming a front portion of the shielded housing around the second subassembly in response thereto.

38. The method ofclaim 37 wherein,

the front portion of the shielding housing includes one or more forward fingers.

39. The method ofclaim 37 wherein,

the front portion of the shielding housing includes one or more backward fingers.

40. The method ofclaim 37 wherein,

the front portion of the shielding housing includes one or more forward fingers and one or more backward fingers.

41. The method ofclaim 40 wherein,

the forming of the front portion around the second subassembly includes

folding a left side wing and a right side wing.

42. The method ofclaim 41 wherein,

the forming of the front portion around the second subassembly further includes

folding a strap and a septum, the strap folded across an open end to strap the shielded housing onto the second subassembly, the septum folded into the open end to couple to a bottom side of the shielded housing.

43. The method ofclaim 37 wherein,

the forming of the front portion of the shielded housing around the second subassembly further includes

forming a pattern of the front portion of the shielded housing into a sheet of conductive material, the pattern including the one or more fingers near an edge,

folding the sheet of conductive material along a plurality fold lines, and

bending the one or more fingers into shape.

44. A fiber optic module formed by the method ofclaim 37.

45. A fiber-optic module comprising:

a chassis having a pair of optical connector receptacles at one end and a pair of walls coupled to a base at an opposite end, the pair of walls having slots on inside surfaces, the pair of optical connector receptacles having a rectangular opening along the width of the chassis, the base having one or more pin openings;

a printed circuit board coupled into the slots in the pair of walls of the chassis, the printed circuit board having one or more pins in the one or more pin openings in the base of the chassis, the printed circuit board having electrical components to process electrical signals of the one or more pins;

a pair of opto-electronic components having pins coupled to traces of the printed circuit board at an edge, the traces coupled to the one or more pins or the electrical components of the printed circuit board, the pair of opto-electronic components to process electrical and optical signals;

a pair of optical connectors each having an optical port with a lens, a flange, a snap lock clip, a ferrule barrel, and a recess between the optical port and the flange, the pair of optical ports of the pair of optical connectors coupled to the pair of opto-electronic components respectively at one end and each of the snap lock clip and the ferrule barrel inserted into the respective pair of optical connector receptacles of the chassis at an opposite end;

a plate having a pair of u-shaped openings and a flap, the plate inserted into the rectangular opening of the chassis, the u-shaped openings of the plate engaging the recess between the optical port and the flange in each pair of the optical connectors to hold the pair of opto-electronic components and the pair of optical connectors to the chassis;

a first portion of a shielded housing around the chassis to protect the pair of opto-electronic components and the electrical components; and

a second portion of the shielded housing around the chassis coupled to the plate, the second portion of the shielded housing having one or more forward fingers and one or more backward fingers to couple to a panel.

46. The fiber-optic module ofclaim 45 wherein,

the shielded housing to conduct electromagnetic radiation to ground.

47. The fiber-optic module ofclaim 45 wherein, the first portion of the shielded housing to protect the printed circuit board, its electrical components and the pair of opto-electronic devices coupled to the printed circuit board,

the second portion of the shielded housing to shield external electrical components from electromagnetic radiation generated by the pair of opto-electronic devices and the electrical components, and

the second portion of the shielded housing to shield the pair of opto-electronic devices and the electrical components from electromagnetic radiation generated by external electrical components.

48. The fiber-optic module ofclaim 45 further comprising:

a pair of collars around the optical ports of the pair of optical connectors, the pair of collars coupled to the plate to couple to ground, the pair of collars to shield the pair of opto-electronic devices.

49. The fiber-optic module ofclaim 48 wherein,

the pair of collars to shield the pair of opto-electronic devices from electromagnetic radiation generated by the other to reduce cross-talk.

50. The fiber-optic module ofclaim 45 wherein,

the pair of opto-electronic devices couple to the printed circuit board by coupling pins to traces on a top side and a bottom side of the printed circuit board in a straddle mounted configuration.

51. The fiber-optic module ofclaim 45 wherein,

the chassis is formed of a conductive material to further shield the fiber optic module.

52. The fiber-optic module ofclaim 51 wherein,

the chassis further has a pair of mounting pins to mount the fiber optic module to a host printed circuit board.

53. The fiber-optic module ofclaim 45 wherein,

the chassis further has a pair of mounting pins coupled to a bottom surface to mount the fiber optic module.

54. The fiber-optic module ofclaim 45 wherein,

the chassis further has a slot between the pair of optical connector receptacles.

55. The fiber-optic module ofclaim 54 wherein,

the front portion of the shielded housing has a strap at one end and a septum at an opposite end to hold the shielded housing around the chassis coupled, the strap engaged in the slot of the chassis between the pair of optical connector receptacles.

56. The fiber-optic module ofclaim 45 wherein,

the front portion of the shielded housing is an external electromagnetic shield and the plate is an internal electromagnetic shield coupled to the external electromagnetic shield.

57. The fiber-optic module ofclaim 45 wherein,

the pair of optical connectors are SC optical connectors and the fiber-optic module is a 1×9 fiber-optic module.

58. The fiber-optic module ofclaim 45 wherein,

the one or more forward fingers curve outward and forward from the edge.

59. The fiber-optic module ofclaim 45 wherein,

the one or more backward fingers lift up from one or more surfaces of the shielded housing and extend backward from the edge.

60. The fiber-optic module ofclaim 46 wherein,

the front portion of the shielded housing is metal, plated plastic, or conductive plastic.

61. The fiber-optic module ofclaim 46 wherein,

the one or more forward fingers are equally sized and equally spaced around a portion of the perimeter of the shielded housing.

62. A system for providing electromagnetic interference (EMI) shielding, the system comprising:

a module chassis frame having a front end and a back end, the front end being hollow to allow for optical, electrical and optical-electrical components to be attached therein, the back end having a pair of separately enclosed compartments, each compartment to house a transmitter subassembly and a receiver subassembly, the transmitter subassembly having a first shielding collar around the transmitter subassembly and the receiver subassembly having a second collar around the receiver subassembly;

a U-plate having a top portion and a bottom portion having a pair of U-shaped openings, the top portion including a flap, the U-plate coupled into a slot of the module chassis frame to hold and shield the transmitter subassembly and the receiver subassembly;

a first portion of an electromagnetic interference (EMI) shielding box around the module chassis frame; and

a second portion of an electromagnetic interference (EMI) shielding box around the module chassis frame and coupled to the U-plate, the electromagnetic interference shielding box having one or more forward fingers around its perimeter and one or more backward fingers to contact to a host system.

63. The system ofclaim 62 wherein,

the EMI shielding box protects components and shield components from electromagnetic radiation.

64. The system ofclaim 62 wherein,

the module chassis frame is formed of a plastic, a conductive plated plastic, or a metal.

65. The system ofclaim 62 wherein,

the EMI shielding box is glued to the module chassis frame.

66. The system ofclaim 62 wherein,

the EMI shielding box is welded to the module chassis frame.

67. The system ofclaim 62 wherein,

the one or more forward fingers and the one or more backward fingers contact a host system faceplate of the host system to minimize electromagnetic radiation leaking out of the host system.

68. The system ofclaim 62 wherein,

the one or more forward fingers contact a backside of the host system faceplate around an opening.

69. The system ofclaim 62 wherein,

the one or more backward fingers contact a surface of one or more host tabs in the host system faceplate.

70. A fiber-optic module comprising:

a means for holding optical, electrical, and opto-electronic components, the optical, electrical, and opto-electronic components to process optical and electrical signals; and

a first portion of a means for shielding and housing the means for holding; and

a second portion of a means for shielding and housing the means for holding, the second portion having a frontal opening to accept a fiber-optic cable connector, the second portion of the means for shielding and housing being conductive and including

one or more first finger means near an edge of the frontal opening, the one or more first finger means to provide an EMI seal around an opening in a host system, and

one or more second finger means near an edge of the frontal opening, the one or more second finger means to provide an EMI seal around the opening in the host system.

71. The fiber-optic module ofclaim 70 wherein,

the one or more first finger means are forward fingers.

72. The fiber-optic module ofclaim 70 wherein,

the one or more second finger means are backward fingers and contact host tabs of the host system.

73. The fiber-optic module ofclaim 70 wherein,

the first and second portions of the means for shielding and housing to protect components and to shield electromagnetic radiation.

74. The fiber-optic module ofclaim 70 wherein,

the first and second portions of the means for shielding and housing protects the optical, electrical, and opto-electronic components and shields electromagnetic radiation.

75. The fiber-optic module ofclaim 70 wherein,

the first and second portions of the means for shielding and housing when coupled to ground through the one or more first finger means or the one or more second finger means, conducts electromagnetic radiation thereto.

76. The fiber-optic module ofclaim 70 wherein,

the one or more first finger means curve outward and forward from the edge of the frontal opening.

77. The fiber-optic module ofclaim 70 wherein,

the one or more second means lift up from one or more surfaces of the first portion of the shielding and housing means and extend backward from the edge of the frontal opening.

78. The fiber-optic module ofclaim 70 wherein,

the first and second portions of the means for shielding and housing is formed out of one of metal, plated plastic, and conductive plastic.

79. The fiber-optic module ofclaim 70 wherein,

the optical, electrical, and opto-electronic components include a transmitter subassembly and a receiver subassembly to transceive optical signals over an optical fiber and the fiber optic module is a fiber-optic transceiver module.

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