Molded communications module having integrated plastic circuit structures

An embodiment disclosed herein relates to a communications module. The communications module includes a body composed of a plastic resin and a plurality of conductive traces and contact pads defined on a portion of a surface of the body. The module also includes at least one substantially vertical ridge defined on the body surface, and at least one pocket defined on the body suitable for receiving an electronic component. The communications module may also include a body composed of a plastic resin and conductive features defined on a surface of the body configured to render the communications module operable without implementing a printed circuit board as part of the body. Additional embodiments relate to systems and methods for attaching one or more optical transmit assemblies to the communications module and for electrically connecting conductive traces in a temporary fashion on the surface of the body of the communications module.

BACKGROUND

1. The Field of the Invention

The present invention generally relates to communications modules. In particular, the present invention relates to a communications module, such as an optical transceiver module, that is integrally fabricated so as to reduce part count and simplify construction and design.

2. The Relevant Technology

Traditionally designed optical transceiver modules typically include several components, including one or more optical subassemblies, a printed circuit board with associated electronic circuitry, and a shell supporting the printed circuit board. Though proven, this design nevertheless compels various compromises to be tolerated, due to limitations inherent in the above-mentioned components and their respective interconnections. In light of this, a need exists in the art for a communications module, such as an optical transceiver module, that includes improvements that provide simplification of design and part count reduction while improving device reliability.

BRIEF SUMMARY

An embodiment disclosed herein relates to a communications module. The communications module includes a body composed of a plastic resin and a plurality of conductive traces and contact pads defined on a portion of a surface of the body. The module also includes at least one substantially vertical ridge defined on the body surface, and at least one pocket defined on the body suitable for receiving an electronic component.

An additional embodiment disclosed herein relates to a communications module. The communications module includes a body composed of a plastic resin and one or more conductive features defined on a surface of the body. The one or more conductive features are configured to render the communications module operable without implementing a printed circuit board as part of the body.

A further embodiment disclosed herein relates to a system for electrically connecting at least one optical subassembly to an optical transceiver module. The optical transceiver module has a molded body and conductive features defined on portions of the molded body. The system comprises an interconnect portion integrally formed with the molded body including: a plurality of holes defined on a front wall of the molded body, the holes being configured to each receive a corresponding one of a plurality of leads extending from an optical subassembly, and a plurality of lead seats each in communication with a corresponding one of the plurality of holes, each lead seat configured such that the lead received by the corresponding hole is in electrical communication with the lead seat. The system also includes a plurality of traces defined on the molded body that each electrically connect with a corresponding one of the lead seats.

Another embodiment disclosed herein relates to a method for electrically connecting conductive traces in a temporary fashion. The traces are included on a surface of a molded body of an optical transceiver module. The method includes defining a plurality of trace interconnection features as extended portions on a surface of the molded body such that the trace interconnection features are interposed between the traces. The method also includes applying a conductive material to each of the trace interconnection features such that the trace interconnection features electrically interconnect the traces to one another. The method further includes, when electrical interconnection of the traces is no longer needed, altering a structure of each of the trace interconnection features such that the traces are no longer electrically interconnected by the trace interconnection features.

Additional features and advantages will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the teaching herein. The features and advantages of the teaching herein may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

DETAILED DESCRIPTION

Reference will now be made to figures wherein like structures will be provided with like reference designations. It is understood that the drawings are diagrammatic and schematic representations of exemplary embodiments of the invention, and are not limiting of the present invention nor are they necessarily drawn to scale. It is also understood that reference to a “first”, or a “second” etc. element (such as a first and second interconnect portions) in this description and in the claims is meant to distinguish one element from another and is not meant to imply sequential ordering unless explicitly stated.

FIGS. 1A-12Cdepict various features of embodiments of the present invention, which are generally directed to a communications module for use in transmitting and receiving data signals in a communications network. In particular, a communications module implemented as an optical transceiver module is disclosed. The optical transceiver module includes a molded integral body and electronic component surface designed to substantially simplify transceiver design and reduce part count. Because of its simplified design, the molded transceiver is highly stable and efficiently produced, thereby increasing part yield during manufacture.

1. Example Molded Communications Module

Reference is first made toFIGS. 1A,1B, and2, which depict various details regarding features of the present invention, according to one embodiment. These figures show one type of communications module that can benefit from the teachings of the present invention. In particular, an optical transceiver module (“transceiver”), generally designated at100, is shown as an exemplary communications module including aspects of one embodiment of the present invention.

As shown, the transceiver100is implemented as having a form factor and configuration conforming to a Small Form Factor Pluggable (“SFP”) standard, as defined by applicable Multi-Source Agreements (“MSAs”) standard in the industry. However, it should be noted that transceivers and other communications modules that differ in form factor, operational configuration, or other aspects can also benefit from the principles discussed herein. Indeed, modules such as 10 Gigabit Small Form Factor Pluggable (“XFP”) transceivers having varying form factors and data rates can also employ features of the embodiments to be described herein. The following discussion is therefore not meant to limit the scope of the present invention in any way.

As shown, the transceiver100includes a body110that is formed by standard injection molding or other suitable molding process. As such, the transceiver body is also referred to herein as a “molded module.” As will be described, the body110serves multiple purposes within the transceiver100that were formerly performed by multiple components, and as such simplifies transceiver design by serving as an integrated component.

The transceiver body110is composed of a suitable material to enable the formation of conductive features on the body in the manner described below. In one embodiment, the body110is composed of a plastic resin, such as a liquid crystal polymer, having a catalyst intermixed therewith. In one embodiment, the catalyst is composed substantially of palladium, but other suitable materials offering the same functionality could alternatively be used. As mentioned, this material composition for the transceiver body enables conductive features to be defined on the body, as will be described further below.

The transceiver body110further includes a top body surface110A and bottom body surface110B, and defines a front end112and back end114. The back portion of the body110proximate the back end114defines an edge connector116that enables the transceiver100to operably connect with a host device (not shown). The edge connector116itself defines a top surface116A and bottom surface116B. Note that the edge connector116has a height that is relatively less than that of other portions of the body110, in conformance with industry-defined standards for such an interface.

As seen inFIG. 2, the transceiver100includes a pair of optical subassemblies that each operably connect with connectorized optical fibers. In detail, a transmitter optical subassembly (“TOSA”)118and receiver optical subassembly (“ROSA”)120are included in the transceiver100and are shown in operable communication with the transceiver body110inFIG. 2. The TOSA118operably connects with the transceiver body110via a TOSA interconnect portion122that extends beyond and between both the body top and bottom surfaces110A and110B, while the ROSA120operably connects with the transceiver body via a ROSA interconnect portion124, which extends beyond and between the body top and bottom surfaces. Further details regarding the particular modes of connection between the TOSA, ROSA, and the transceiver body are described in more detail to follow.

Inspection ofFIGS. 1A-2reveals that the present transceiver design differs from previously known designs in that a printed circuit board, traditionally included within a transceiver shell, is not present. Instead, the molded transceiver body integrally serves the functionality previously performed by the printed circuit board and shell. In particular, the conductive contact pads, traces, and electronic components traditionally found on a transceiver printed circuit board are now included on the top and bottom surfaces110A and110B of the transceiver body110. Further, the structure of the transceiver body110is configured such that it also performs the functionality traditionally performed by a discrete shell in housing the printed circuit board and other transceiver components. Thus, significant consolidation and integration of formerly discrete transceiver components is realized via the present transceiver configuration. Further, use of the present transceiver body enables the inclusion of various surface features and three-dimensional structures to be included thereon, as will be described.

Together withFIGS. 1A-2, reference is now made toFIG. 3, showing various further details of the transceiver100. A plurality of contact pads130are included on both the top and bottom surfaces116A and B of the edge connector116for interfacing with corresponding pads or conductive features of the host device (not shown). Among these pads are disposed a first data signal pad pair130A and a second data signal pad pair130B that each facilitate the transfer of high speed data signals between the host device and the transceiver100. Additionally, a plurality of conductive traces134are also included on the transceiver body110and operably connect with corresponding contact pads130on both the top and bottom surfaces116A and B of the edge connector116to enable the transfer of various signals in the transceiver100. Among these traces are disposed a first data signal trace pair134A and a second data signal trace pair134B that each operably connect with the corresponding first or second data signal pad pairs130A or130B of the edge connector116. Also included are ground traces134C that operably connect with corresponding ground contact pads130C on the edge connector116.

The conductive contact pads130and traces134are defined on the surface of the transceiver body110by a process known as laser direct structuring, wherein a guided laser is employed during transceiver body manufacture in etching the surfaces of the body110where conductive features such as the contact pads and traces are to be located. Laser etching in this manner removes several microns of the plastic resin body material at the surface thereof, which exposes and activates the palladium catalyst imbedded in the plastic resin. So prepared, placement of the body110in an electroless plating bath causes copper or other suitable component of the bath to adhere to the laser etched portions of the body, thereby forming the contact pads130, traces134and other conductive features described below on the body.

Formation of conductive features on a catalyst-containing plastic resin using the laser direct structuring process as described above yields a product also known as and referred to herein as a “plastic circuit.” This process and technology is owned and licensed by LPKF Laser and Electronics AG, Germany, http://www.lpkf.com/. Products formed by this process are generally known as molded interconnect devices (“MID”s).

Should the particular path, shape, or other configuration of the contact pads130, traces134, or other conductive features need to be altered for a transceiver body yet to be manufactured, the laser need simply be reprogrammed to etch the body surface in accordance with the desired change. In this way, reconfiguration of the conductive features of the transceiver body is readily achieved without significant expense or time.

In accordance with embodiments of the present invention, the transceiver body110can be configured to include various surface features serving various purposes for the transceiver100. These surface features give the transceiver body110a three dimensional (“3-D”) aspect that is not possible with known transceivers and other communication modules employing standard printed circuit boards (“PCBs”). The transceiver body configured to include the 3-D features to be described below is also referred to herein as a “3-D MID.”

A first 3-D feature is shown on the transceiver body110as a plurality of various body extensions140that are formed as a result of the injection molded design of the body. The body extensions140serve various purposes in connection with the structure and functionality of the transceiver100, such as providing structural bracing or spacing, and surfaces for engagement with a cover to provide a housing (not shown) for the transceiver, for instance. In one embodiment, the body extension140(seen inFIG. 2) proximate the TOSA118and ROSA120can be plated with conductive material via the laser direct structuring or other suitable process in order to reduce or prevent the emission of EMI from the transceiver100. In other embodiments, other surfaces of the transceiver100can also be conductively plated to reduce EMI emission.

Another 3-D feature of the transceiver body110is shown at144, wherein a hole, or via, is defined through the body so as to extend from the top body surface110A to the bottom surface110B. The via144enables signals transmitted on selected traces134to be transferred from one body surface to another, as best shown inFIGS. 1A and 1B. Note that the interior surface of the via144is slanted with respect to the top and bottom body surfaces110A, B. This is to enable sufficient laser etching to be performed on the via144so that a conductive material may be applied thereto. Generally, the slant of such surfaces should be no greater than about 75 degrees from a plane define by the top or bottom body surface110A or110B. More generally, the slant is determined by the requirements of the particular laser etching equipment used. Note that many such vias can be defined in the transceiver body110.

A component pocket146is defined on the top body surface110A, as best shown inFIG. 1A, as yet another possible 3-D feature made possible by the transceiver body110configured in accordance with one embodiment. The component pocket146is sized and configured to receive therein an integrated circuit chip or other electronic or optoelectronic component. In the illustrated embodiment, an integrated laser driver/post amplifier/controller (“LDPA controller”)150is shown inFIGS. 2 and 3as residing within the component pocket146.

The floor of the component pocket146includes a conductive pad154(FIG. 1) that is configured to electrically connect with the LDPA controller150, either through wirebonds (not shown), an electrically conductive pad on the underside of the LDPA controller150, or other electrical connective scheme when it is disposed in the component pocket146. The conductive pad154in turn is electrically connected to one or more of the traces134that extend to the component pocket146, such as the ground traces134C in the present embodiment. The LDPA controller150is secured within the component pocket146with a conductive adhesive in one embodiment, or by solder paste or other suitable securing substance.

Note that, because the component pocket146is sunken with respect to the top body surface110A, a top surface of the LDPA controller150when placed in the pocket is positioned substantially level with the top body surface110A. This enables electrical connections of minimum length to be established between selected traces134that terminate at the component pocket146and conductive pads positioned on the LDPA controller150. These electrical connections in the present embodiment are achieved by the use of wire bonds (not shown). As improved signal transmission is achieved with wire bonds when the wire bond length is minimized, the minimization of length between the terminations of the traces134proximate the component pocket146and the pads of the LDPA controller150advantageously operates to improve signal transmission—especially high frequency signals—between the two structures. Once placement, securing, and wire bonding of the LDPA controller150within the component cavity146is complete, the controller can be covered with epoxy to prevent damage to the controller or wire bonds.

Note that one or more component pockets146having varying sizes, depths, and particular configurations can be disposed at various locations on the top and bottom body surfaces110A/B to receive multiple components as may be needed for a particular application. Also, though shown here with an LDPA controller, any one of various different components may be placed in this or other component pockets defined on the molded transceiver body. Further, more than one component may be received in each component pocket.

As best seen inFIG. 2, the molded transceiver body110includes a plurality of additional component pads158that, like the component pad154of the component pocket146, enable the electrical connection of various electronic components to the body. Such electronic components can include capacitors, resistors, etc.

As yet another example of 3-D featuring of the molded transceiver body110, a plurality of vertical ridges160are defined on the body so as to enable conductive traces to be defined thereon. In particular, a first ridge160A having the data signal trace pair134A disposed thereon, and a second ridge160B having the data signal trace pair134B disposed thereon are shown. The traces of each pair134A and134B are disposed on opposing sides of the respective ridges160A and160B. This configuration enables the traces of each pair to effectively couple with one another, thereby controlling their respective impedance, i.e., creating a differential impedance known as “broadside coupling,” and preserving the quality of the data signals transmitted therethrough. Such a configuration compensates for the fact that no ground exists in the transceiver body110as would typically exist for coupling purposes in a standard printed circuit board.

Two troughs162as additional 3-D features are included on the transceiver body, defined on the top surface116A of the edge connector116such that a back portion of each ridge160A and160B is positioned in the respective trough. So configured, the troughs162enable the ridges160A and160B to extend into the edge connector116in such a way as to not exceed the industry-defined 1 mm height restriction for this style of edge connector. Note that the rear termination of the troughs162corresponds with the point at which the data signal traces pairs134A and134B electrically connect with the corresponding data signal pads130A and130B, respectively.

Yet another 3-D feature of the molded transceiver body110is a plurality of trace interconnection features164located at various points on the transceiver body. These trace interconnection features164are employed to temporarily interconnect the various traces134one with another during the transceiver manufacturing process. Once interconnection between the traces134is no longer needed, the trace interconnection features164can be modified such that trace interconnection is terminated. Further details regarding the trace interconnection features164, their structure and operation is described in more detail to follow.

Further note that the traces134disposed on the transceiver body110can pass between the bottom and top body surfaces110A and110B around the edges of the transceiver body, such as at locations166. This is another feature not possible with standard printed circuit board technology.

Note that the transceiver body110is not limited to a single thickness, as is common with known printed circuit boards, but rather can be configured to have various 3-D surface features and thicknesses as may be needed or desired for a particular application. Thus, instead of a 1 mm thick printed circuit board in accordance with the thickness required for the edge connector, the transceiver body can have a plurality of thicknesses and configurations along its length on either the top, bottom, or other surface thereof.

A transceiver made in accordance with the principles presented herein includes relatively fewer parts than similar known transceiver designs, which yields a simpler, more stable and lower cost system. This in turn increases the potential for high volume production of such a transceiver. Further, the present transceiver does not suffer from the limitations described herein that are typically associated with known printed circuit boards. Transceiver design freedom is also greatly enhanced as a result of practice of the above embodiments.

2. Structural and Operational Aspects of Optical Subassembly Attachment with a Molded Communications Module

With continuing reference toFIG. 2, reference is now made toFIGS. 4 and 5in describing various features regarding embodiments of the present invention.

As briefly described above, suitable electrical connections between optical subassemblies and other portions of the transceiver, such as a printed circuit board, are often difficult to achieve without the use of an intermediary interface, i.e., a flexible circuit or lead frame connector. However, these components add to the complexity of the device and often introduce difficulties in matching impedance along the signal transmission path through the transceiver.

In accordance with embodiments of the present invention, operable connection of the TOSA118and ROSA120is achieved in a simple manner without the use of interposed structures, such as flexible circuits, lead frame connectors, and the like. In particular, and as has been mentioned, the TOSA interconnect portion (“TIP”)122and ROSA interconnect portion (“RIP”)124of the transceiver100are configured as part of a system to enable operable interconnection between the transceiver body110and the TOSA118and ROSA120, respectively. As mentioned, the system described herein is configured for use with a four Gigabit SFP optical transceiver module; however, transceivers and other molded communications modules made in accordance with the principles taught herein can also benefit from the present disclosure.

In greater detail, TIP122and RIP124each include a plurality of wall holes122A and124A, respectively, which are defined through a front end wall112A, best seen inFIG. 5. The inner cylindrical surfaces of the wall holes122A and124A are conductively plated and are in physical and electrical communication with corresponding lead seats112B and124B, respectively, defined on the top body surface110A adjacent an interior portion of the front end wall112A, best seen inFIGS. 1A and 1B. Note that the wall holes122A and124A of the TIP122and RIP124are arranged such that some of the lead seats122B and124B are disposed on the top body surface110A and some on the bottom body surface110B, as best seen inFIG. 1A and 1B.

Each of the lead seats122B,124B is electrically connected with a corresponding one of front end top traces134E or front end bottom traces134F. The traces134E,134F are produced as a result of the laser direct structuring process described above, and are configured to electrically connect with other components or features of the transceiver100, host device, or other structure. Note that in the present embodiment, pairs of the front end top traces134E are positioned on opposite vertical sides of third and fourth ridges160C or160D, which in turn are defined on the top transceiver body surface110A. The structure and operation, including broadside coupling, of the ridges160C/160D and traces134E are similar to that described in connection with the first and second ridges160A/160B and the data signal trace pairs134A/134B.

In addition, the lead seats122B,124B are configured to receive a corresponding one of the leads126,128of the TOSA118or ROSA120, respectively, so as to establish electrical communication between traces and components of the transceiver body110and the TOSA/ROSA. In particular, and as best seen inFIGS. 1A and 1B, each lead seat122B/124B defines a half cylindrical concavity extending parallel to the horizontal surfaces of the transceiver body110. Also, the lead seats122B/124B are positioned with respect to one another so as to enable each seat to receive a corresponding one of the four leads126(TOSA) or five leads128(ROSA). This is achieved by configuring the thickness of transceiver body110to allow the wall holes122A/124A and lead seats122B/124B to be positioned proximate the top and bottom transceiver body surfaces110A/110B.FIG. 6shows that the middle lead128of the ROSA120is raised further above the other two leads shown so as to accommodate this lead. Note that the positioning of the leads of the TOSA118and ROSA120as they extend from the respective TOSA or ROSA bodies are typically fixed in accordance with industry standards. In this configuration, ready interconnection between the lead seats122B/124B and the corresponding traces134E/134F is achieved.

FIGS. 2,6, and7show the transceiver body110operably connected with the TOSA118and ROSA120such that electrical signals can pass there between. In particular, the TOSA leads126are received into the wall holes122A of the TIP122such that the leads are received into the corresponding lead seats122B. Similarly, the ROSA leads128are received into the wall holes124A of the RIP124such that the leads are received into the corresponding lead seats124B. Once received into the corresponding wall hole122A/124A and lead seat122B/124B, each lead of the TOSA118and ROSA120is secured by soldering or other suitable adhesive such that electrical signals can pass to and from the leads and lead seats.

One advantage realized by the lead interconnection scheme described above is the obviation of the need to bend or otherwise orient the leads of the TOSA118or ROSA120. This is so by virtue of the ability of the TOSA and ROSA interconnection portions122and124to provide structure for directly receiving the TOSA/ROSA leads126and128in their original orientations, as shown inFIG. 4. As has already been mentioned, prior known devices have been largely unable to electrically connect with an optical subassembly without either bending the leads or through the use of an intervening structure, such as a flexible circuit or lead frame connector. Lead bending is undesired for its propensity to cause hidden damage to glass seals disposed around the base of each TOSA/ROSA lead when bent to connect with a standard printed circuit board. And, as previously mentioned, the use of intervening structures presents issues with both device complexity and signal path impedance matching. The present invention overcomes the limitations of each of these scenarios by eliminating the need both for intervening structures and bending of the TOSA/ROSA leads, as already described.

Note that the illustrated interconnection scheme is but one possible configuration for operably connecting an optical subassembly to a molded communications module having plastic circuits. Indeed, it is appreciated that the particular shape and positioning of the elements of the TIP122, the RIP124, and the TOSA118/ROSA120can be altered while still benefiting from the functionality of the present invention. For instance, the shape of the TOSA/ROSA leads could be other than cylindrical or could be arranged to extend from the respective OSA base differently from that shown in the accompanying figures. In such cases, the wall holes and lead seats of the TOSA and ROSA interconnect portions could be altered in shape and position to enable operable communication between the OSA and the transceiver or other communications module to be achieved. OSAs having more or fewer leads could also be included, and the number of OSAs connected to the transceiver can vary from what is shown.

It is also possible to enable the OSA leads to operably connect with the respective wall holes without the use of lead seats. In such a configuration, traces would be defined to operably connect with the wall holes, which holes would be conductively plated. In particular, the OSA leads would be soldered or adhesively attached directly to the wall hole surfaces. This serves as one example of expansion of the principles of the present invention beyond that explicitly illustrated and described herein.

3. Structural and Operational Aspects of Trace Interconnection Features

With continuing reference toFIG. 3, reference is now made toFIGS. 8 and 10. As briefly described above, various trace interconnection features (“TIF”s)164are included as extended portions defined on the transceiver body110to enable the temporary interconnection of selected conductive features of the transceiver body. Briefly, the electroless plating process spoken of above deposits a thin layer of conductive material, such as copper or gold, on all surfaces of the transceiver body110that have been previously laser etched. However, the thickness of the conductive layer deposited by this process is insufficient to meet the mechanical requirements for certain conductive surfaces of the transceiver body110. For instance, the contact pads130of the edge connector116must include a conductive layer thicker than what can be normally provided via the electroless plating solution. This is necessary partially because of the physical engagement these surfaces undergo when the transceiver100is slid into/out of a host device, for example.

In light of the above limitation with the electroless plating solution, it is necessary to augment the conductive layer thickness of the contact pads130to ensure that these surfaces are sufficiently robust for mechanical engagement with the conductive features of the host device. Electroplating is one preferred way by which the contact pad conductive layer thicknesses can be increased. However, in order for electroplating to occur, the surfaces to be plated must be electrically connected one to another.

The present invention provides a means by which the conductive surfaces to be electroplated can be temporarily and electrically interconnected. Indeed, in one embodiment the TIFs164are used to interconnect selected traces134of the transceiver body110, which traces in turn electrically interconnect the contact pads130to be electroplated.

As best seen inFIG. 3, a first set of four TIFs164A are included on the transceiver top body surface110A proximate the ridges160A and160B, while a second set of eight TIFs164B are included near the outer edges of the transceiver body top surface proximate the trace passaround locations166. The TIFs164A and164B are shaped in the illustrated embodiment as triangular surface features extending from the top body surface110A and are conductively coated with a conductive material produced as a result of the laser etching and electroless plating process described further above. In addition, the TIFs164are each positioned so as to interconnect adjacent traces to one another. When such TIFs164A and B are placed in series adjacent one another, a complete interconnection of all the desired trace134occurs. As shown, the TIFs164A electrically interconnect the traces or portions of the traces134A, B, and C, while the TIFs164B electrically connect the traces134D that extend to the top body surface110A from the bottom body surface110B via the trace passaround locations166. The two TIFs164B nearest the back end114of the transceiver body110each interconnect with one of the traces134D of the top body surface110A, thereby completing interconnection of the traces134A, B, and C with the traces134D. So configured a complete trace interconnection for the desired trace portions is achieved.

With the desired portions of the traces134physically and therefore electrically interconnected as described above, an electroplating process can then be performed as standard in the art to deposit additional conductive material on desired portions of the transceiver body110such as, in the present case, the contact pads130. Note that additional or alternative conductive features can also be electroplated, thereby illustrating one expansion of the principles of the present embodiment.

Once the electroplating process is complete, the temporary electrical interconnection of the various traces134must be terminated so as to allow for proper discrete operation of each trace once transceiver manufacture is complete. This is achieved by altering each of the TIFs164so as to interrupt the electrical interconnection it produces. In one embodiment, this interruption occurs by removing a portion of each TIF164by a grinding, milling, cutting, other suitable process. The result of such removal is best seen inFIG. 5, wherein a top portion of each triangular TIF164has been removed, thereby removing the conductive material on the TIF surface that formerly electrically interconnected the adjacent traces.

It is not necessary to remove the entire TIF structure, but rather only enough of the TIF structure that is necessary to eliminate any electrical connection between adjacent traces164. When removing portions of the TIFs, especially those that will have a portion that remains connected to the high speed data signal traces134A and134B after removal, care should be taken to remove as much of the TIF as is needed to prevent the unwanted creation of a radiation point by the remaining portion of the TIF.

Note thatFIG. 8shows various details regarding the traces134D included on the bottom body surface110B.FIG. 8further shows the manner in which the traces134D pass from the bottom body surface110B to the top body surface110A via the trace passaround locations166to interconnect with the TIFs164B. Use of the trace passaround locations166as configured inFIGS. 3,8and10enables a convenient transfer of traces from one transceiver body surface to another.

Note that, though they are disposed in the present embodiment in three general locations on the top body surface110A, the TIFs164A and B can alternatively be placed and grouped in any number of possible configurations on the transceiver body110. For instance, the TIFs could be located in one, two, or more general locations on the transceiver body, both on bottom and top, depending on particular design and structural constraints of the transceiver.

FIGS. 9A-9Cshow cross sectional views of various possible TIF shapes.FIG. 9Ashows a TIF364A having a triangular cross section, similar to the TIFs164shown inFIGS. 3,8and10.FIG. 9Bshows a TIF364B having a semi-circular cross section, while TIF364C inFIG. 9Chas a trapezoidal, mesa-like structure. In addition to these possible shapes, other geometric and non-uniform shapes and configurations are also possible while still preserving the functionality of the TIF.

Reference is now made toFIGS. 11A and 11B, which depict details regarding TIFs configured in accordance with another embodiment. In particular, portions of various traces134disposed on the top body surface110A of the transceiver body110are shown in a region proximate the trace passaround location166. Between the various traces134is a plurality of TIFs264, implemented as conductive features defined on the top body surface110A by the laser etching and electroless plating described earlier. Indeed, in one embodiment the TIFs264are produced integrally with the traces134on the top body surface110. In the configuration shown inFIG. 11A, electrical interconnection between the various traces134is established via the TIFs264.

FIG. 11Bshows the traces134in an electrically disconnected state, wherein the TIFs264are no longer interconnecting the traces. In particular, holes280are drilled or otherwise defined into the top body surface110A to split each TIF264and disconnect the traces from one another. A punch, drill, drill press, or other suitable implement can be used to define the holes280. The holes280need only be defined deep enough into the top body surface110A to break the electrical continuity between adjacent traces134. However, any suitable hole depth can also be defined, if desired. Also, the shape of the holes can be other than round, if needed.FIG. 11Cshows a cutaway view of the holes280, illustrating the nature of the electrical disconnection of the traces134made possible by the holes.

Though illustrated inFIGS. 11A and 11Bas located proximate the trace passaround locations166, the trace hole configuration shown can alternatively be placed in other locations, such as on the edge connector116. These and other possible locations are therefore considered part of the present disclosure. Thus, placement of the TIFs can be chosen so as to minimize interference with other transceiver components.

Reference is now made toFIGS. 12A-12C, which depict trace interconnection features employed in a configuration according to yet another embodiment of the present invention. As seen in these figures, a plurality of “punch-out” cavities480are interposed between both sets of traces134shown. Trace interconnection features (“TIFs”)464are also defined between the traces134are aligned with the punch-out cavities480so as to extend down into and past each punch-out cavity. This arrangement is best seen inFIG. 12Bwhere a floor of each punch-out cavity is positioned between either open end of the cavity. This configuration enables the TIFs464to electrically connect the traces134to one another in preparation for electroplating, as described above. Note that trace interconnection features can be defined on the top, bottom, or both surfaces of the floor of each punch-out cavity.

After electroplating is complete and interconnection of the traces is no longer needed, the floor of each punch-out cavity480is punched out by a suitable punching device. This electrically disconnects the traces134from one another, as desired. The design illustrated in these figures has the advantage of maintaining a planar surface in the region of the TIFs without the need for structures rising above the top or bottom surfaces of the transceiver body.