Abstract:
An insert-molded fiber optic transmission component has at least one insert and a main body portion. The main body portion has at least one adjoining surface, a portion of the at least one adjoining surface lying in a first plane. The insert has an engaging face disposed against the outer edge surface and a reference surface adjacent the engaging face, where the reference surface lies in a second plane, and the adjoining surface is adjacent the engaging face of the at least one insert and the first and second planes being parallel to and offset from one another.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Reference to Related Case 
         [0002]    This application claims priority under 35 U.S.C. §119(e) to provisional application No. 61/315,385, filed on Mar. 18, 2010, which is hereby incorporated by reference in its entirety. 
         [0003]    2. Field of the Invention 
         [0004]    A new design for an insert-molded transceiver body having metal heat sinks molded therein has fewer surfaces to seal, thereby preventing flash on the molded part. In particular, the transceiver body and its mold has a shut-off portion against the heat sinks to prevent flash during the molding process. 
         [0005]    During the process of injection molding, a cavity is created for the plastic to fill. The cavity of the mold is closed and the filled with a polymer. If the cavity area is not adequately sealed, a thin web of polymer material will leak past the desired cavity area, resulting in flash. Flash is undesirable on parts as it can break off and cause debris problems or cause the injection molded part to be larger than the dimensions allowed. Some small gaps in the closed mold are permissible, but the size of those gaps that do not cause flash are dependent on the viscosity of the polymer. 
         [0006]    Sometimes it is necessary to mold a polymer with an insert or component encapsulating (or being incapsulated by) the polymer. This is usually called insert-molding. The inserts are often made of metal, ceramics, or another polymer. To insert-mold a component, the mold cavity closes around the insert and the cavity is sealed around the insert. However, depending on the location of the insert within the molded piece (and therefore within the cavity), the tolerances of the insert may create gaps in the mold that are large enough to create flash. This may be even more prevalent when the insert is along one edge of the mold cavity. Thus, it may be difficult to insert-mold those inserts that are along an edge, and even more difficult when the insert forms one boundary of the insert-molded piece. When the insert forms one side of the insert-molded piece, the mold needs to seal against at least four sides (or surfaces) of the insert, and maybe more depending on the complexity of the piece. Thus, the mold needs to be designed to seal against those multiple surfaces of the insert. Typically, however, the insert used in the mold is not always perfect and has tolerances in its dimensions. This means that the insert may not exactly fit the mold and allow for gaps in the molding process, which leads to undesirable flash. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is directed to an insert-molded fiber optic transmission component having at least one insert that includes a main body portion having at least one outer edge surface and at least one adjoining surface, a portion of the at least one adjoining surface lying in a first plane, and the at least one insert having an engaging face disposed against the at least one outer edge surface and at least one reference surface adjacent the engaging face, the at least one reference surface lying in a second plane, wherein the at least one adjoining surface is adjacent the engaging face of the at least one insert and the first and second planes being parallel to and offset from one another. 
         [0008]    In some embodiments, the at least one insert comprises two inserts, the at least one outer surface comprises two outer surfaces, the two outer surfaces disposed on opposite sides of the main body portion, and the at least one adjoining surface comprises two adjoining surfaces, wherein the two inserts are disposed on opposite sides of the main body portion. 
         [0009]    In some embodiments, the at least one insert has an opening extending at least partially therethrough and a portion of the main body extends into the opening in the at least one insert to retain the at least one insert against the at least one outer edge surface. 
         [0010]    In some embodiments, the main body has a central surface, the central surface being disposed adjacent to the at least one adjoining surface and on an opposite side of the at least one adjoining surface from the at least one outer edge surface, the central surface lying in a third plane, the third plane parallel to the first and second planes and offset from the first plane. 
         [0011]    In another aspect, the invention is directed to an insert-molded fiber optic transmission component having at least one insert that includes a main body portion having at least one outer edge surface and at least two adjoining surfaces, a portion of a first of the at least two adjoining surfaces lying in a first plane and a portion of a second of the at least two adjoining surfaces lying in a second plane, and the at least one insert having an engaging face disposed against the at least one outer edge surface and at least two reference surfaces adjacent the engaging face, a first of the at least two reference surfaces lying in a third plane and a second of the at least two reference surfaces lying in a fourth plane, wherein the at least one adjoining surface is disposed adjacent the engaging face of the at least one insert and the first and third planes are parallel to and offset from one another and the second and fourth planes are parallel to and offset from one another, exposing a portion of the engaging face. 
         [0012]    In yet another aspect, the invention is directed to an insert-molded fiber optic transmission component having at least one insert that includes a main body portion having at least one outer edge surface and a central body surface, the at least one outer edge surface having a top edge, and the at least one insert having an engaging face at least partially disposed against the at least one outer edge surface and at least one reference surface adjacent the engaging face and generally perpendicular thereto, wherein the top edge of the at least one outer edge surface is disposed below the at least one reference surface exposing at least a portion of the engaging face of the at least one insert. 
         [0013]    Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings. 
         [0014]    It is to be understood that both the foregoing general description and the following detailed description of the present embodiments of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operations of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a top perspective view of a transceiver body with two heat sinks according to the prior art; 
           [0016]      FIG. 2  is a bottom perspective view of the transceiver body of  FIG. 1 ; 
           [0017]      FIG. 3  is a perspective view of a portion of a mold for the transceiver body of  FIG. 1  with the heat sinks positioned on the mold; 
           [0018]      FIG. 4  is another portion of the mold of  FIG. 3  illustrated relative to the heat sinks and transceiver body cavity; 
           [0019]      FIG. 5  is a top perspective view of one embodiment of a transceiver body with two heat sinks according to the present invention; 
           [0020]      FIG. 6  is an front view of the transceiver body of  FIG. 5 ; 
           [0021]      FIG. 7  is a top view of the transceiver body of  FIG. 5 ; 
           [0022]      FIG. 8  is a bottom view of the transceiver body of  FIG. 5 ; 
           [0023]      FIG. 9  is a cross section view of the assembly along the line  9 - 9  in  FIG. 8 ; 
           [0024]      FIG. 10  is a cross section view of the assembly along the line  10 - 10  in  FIG. 8   
           [0025]      FIG. 11  is a bottom perspective view of the transceiver body of  FIG. 5 ; 
           [0026]      FIG. 12  is a perspective view of a portion of a mold to form the transceiver body of  FIG. 5  with two heat sinks in place; 
           [0027]      FIG. 13  is a perspective view of another portion of the mold of  FIG. 12  illustrated relative to the heat sinks and transceiver body cavity; 
           [0028]      FIG. 14  is a is a cross section view of another embodiment of a transceiver body according to the present invention through a central part thereof; 
           [0029]      FIG. 15  is a detail view of a portion of the transceiver body of  FIGS. 14 ; and 
           [0030]      FIG. 16  is a perspective view of a portion of a mold for the transceiver body of  FIG. 14 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0031]    Reference will now be made in detail to the present preferred embodiment(s) of the invention, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. 
         [0032]    One embodiment of the present invention is directed is a transceiver body that has two heat sinks injection-molded together. In the prior art, as illustrated in  FIGS. 1 and 2 , The transceiver body  10  is in the middle and has two heat sinks  12  on opposite sides. The bottom of the transceiver body  10  is illustrated in  FIG. 2 . Careful examination of the  FIGS. 1-2 , will reveal that there are four surfaces of the heat sinks  12  that have to match identically on each side of the transceiver body  10  or there will be problems with flash. Since the heat sinks  12  function as one side of the molded transceiver body  10 , the mold must fit almost perfectly with each of the heat sinks  12  to prevent flash.  FIGS. 3 and 4  illustrate the heat sinks  12  in a portion of a mold  14  used to make the transceiver body  10  of  FIGS. 1 and 2 . However, the heat sinks  12  have a relatively large tolerance (±0.01 mm) in their length and height. These tolerances are sufficiently large enough to cause flash problems as the mold  14  may not be able to seal correctly around the heat sinks  12  given the that the molds  14  are designed to align along each of the vertical and horizontal surfaces of the heat sink. 
         [0033]    Referring to  FIGS. 5-11 , an insert-molded fiber optic transmission component  100 , or a transceiver body, is illustrated as having a main body portion  102  and at least one insert  104 . As illustrated, the transceiver body  100  has two inserts  104 , which are illustrated as heat sinks in this embodiment, but the invention may apply to any insert-molded component. The main body portion  102  has a top surface  106 , a bottom surface  108 , a front surface  110 , a back surface  112 , and two outer edge surfaces  114 . The main body portion  102  has other features that are relevant to the operation of the transceiver body (such as an opening  116 , latches  118 , pads  120 ) but are not relevant to the present invention and will not be discussed further. 
         [0034]    The inserts  104 , which are usually made of metal, ceramic, or another polymer or any other appropriate material, have a top surface  130 , a bottom surface  132 , a front surface  134 , a back surface  136 , an outside surface  138 , and an inside surface  140  that engages the outer edge surface  114  of the main body portion  102 . See  FIG. 10 . Each of the inserts  104  also preferably have an opening  142  that extends at least partially through the insert  104  between the outside surface  138  and the inside surface  140 . In the embodiment illustrated in  FIGS. 5-11 , the opening  142  extends all the way through the insert  104  (see  FIG. 9 ) and can even be used as a port for injecting the material (typically a polymer) into the mold to form the main body portion  102 . The combination of the opening  142  and a portion of the main body  102  (or material used to make the main body  102 ) extending into the opening  142  functions to hold the inserts  104  on the main body  102  in a fixed relationship. 
         [0035]    The insert-molded fiber optic transmission component  100  solves the problems noted above with respect to the flash as a result of the molding process because the area of the outer edge surface  114  of main body portion  102  making contact with the inside surface  140  of the insert  104  is smaller than the area of the inside surface  140 , thereby exposing a portion of the inside surface  140  of the insert  104 . In particular, see  FIGS. 5 ,  9 , and  10 . 
         [0036]    As further illustrated in  FIG. 9 , the top surface  130  of insert  104  is generally a flat surface and lies in a plane A. In this regard, the top surface  130  functions as a reference plane for the main body portion  102  and, in particular, for the main body portion  102  immediately adjacent the outer edge surface  114  and the inside surface  140  of the insert  104 . The top surface  106  of the main body portion  102  immediately adjacent the outer edge surface  114  also lies in a plane B that is preferably parallel to, but offset by a distance from, the plane A. The same is also true with bottom surface  108  of main body portion  102  and a bottom surface  132  of insert  104 . Referring now to  FIG. 7 , the back surface  136  of insert  104  lies in a plane C and the back surface  112  of the main body  102  adjacent the insert  104  lies in a plane D. Planes C and D are preferably parallel to but offset from one another, again exposing a portion of the inside surface  140  of the insert  104 . The same spatial relationships are present at the front of the transceiver body  100  as can be seen in  FIGS. 5 ,  7 ,  8 , and  10 . 
         [0037]    A portion of a mold  300  to mold the fiber optic transmission component  100  is illustrated in  FIGS. 12 and 13 . The inserts  104  are disposed on portions  302 , which surround a center portion  304  that molds the main body portion  102 . The details of the fiber optic transmission component  100  are not illustrated in the mold figures for clarity. Additionally, not all parts of the mold are illustrated for clarity. It should be noted that the top of the center portion  304  is higher than the bottom of the inserts  104 , which as noted above, allows for a portion of the inside surface  140  of the insert  104  to be visible and prevents flash around the long edges of the inserts  104 . At the upper end of the mold portion  300  is a structure  306  that provides for the exposed portion of the inserts  104  at the front surface  134  and back surface  136 . The size of the structure  306  and the difference in portions  302  and  304  are larger than the variations in the dimensions of the inserts  104 , which ensures that the edges of the inserts  104  will be behind the mold portions and prevent flash formation.  FIG. 13  illustrates a top portion  308  that, like portion  304 , is disposed between the two inserts  104 . 
         [0038]    Another embodiment of a insert-molded fiber optic transmission component  200 , or a transceiver body, is illustrated in  FIGS. 14 and 15  as having a main body portion  202  and at least one insert  204 . As illustrated, the transceiver body  200  has two inserts  204 , which are illustrated as heat sinks in this embodiment, but the invention may apply to any insert-molded component. The main body portion  202  has a top surface  206 , a bottom surface  208 , and two outer edge surfaces  214 . The main body portion  202  has other features that are relevant to the operation of the transceiver body (such as an opening  216  and pads  220 ) but are not relevant to the present invention and will not be discussed further. 
         [0039]    The inserts  204 , which are usually made of metal, ceramic, or another polymer or any other appropriate material, have a top surface  230 , a bottom surface  232 , an outside surface  238  and an inside surface  240  that engages the outer edge surface  214  of the main body portion  202 . See  FIG. 15 . Each of the inserts  204  also preferably has an opening  242  that extends at least partially through the insert  204  between the outside surface  238  and the inside surface  240 . Preferably, the opening  242  extends all the way through the insert  204  and can even be used as a port for injecting the material (typically a polymer) into the mold to form the main body portion  202 . The combination of the opening  242  and a portion of the main body  202  (or material used to make the main body  202 ) extending into the opening  242  functions to hold the inserts  204  on the main body portion  202  in a fixed relationship. 
         [0040]    In this embodiment, the portion of the main body portion  202  adjacent the inserts  204  is smaller than in the previous embodiment and provides for a larger exposed portion of the inside surface  240  of the insert  204 , as is more visible in  FIG. 15 . As can be in  FIGS. 14 and 15 , the top surface  230  of insert  204  is generally a flat surface and lies in a plane X. Thus, the top surface  230  functions as a reference plane for the transceiver body  200 . The top surface  206  of the main body portion  202  lies in a second plane, plane Y, which is parallel to and offset from plane X. In this embodiment of transceiver body  200 , the portion  250  of the main body  202  immediately adjacent the outer edge surface  214  is on a different plane, plane X, that is preferably parallel to, but offset by a distance from, the planes X and Y. It should be noted that planes X and Y may lie on the same plane, but X and Z should not be on the same plane. As is obvious to one of ordinary skill in the art, when planes Y and Z are the same, the embodiment will be substantially similar to the fiber optic transmission component  100 . 
         [0041]    Fig. illustrates a portion of a mold  400  to mold the fiber optic transmission component  200  is illustrated in  FIG. 16 . The inserts  204  are disposed on portions  402 , which surround a center portion  404  that molds the main body portion  202 . The details of the fiber optic transmission component  200  are not illustrated in the figures for mold  400  for clarity. Additionally, not all parts of the mold are illustrated for clarity. It should be noted that the top of the center portion  404  is higher than the bottom of the inserts  204 , which as noted above, allows for a portion of the inside surface  240  of the insert  204  to be visible and prevents flash around the long edges of the inserts  204 . In this mold, there is an extra portion  408  that extends upward along the inserts  204  and forms the portion  250  of the main body  202  immediately adjacent the outer edge surface  214 . See  FIG. 15 . At the upper end of the mold portion  400  is a structure  406  that provides for the exposed portion of the inserts  204  at the front surface  234  and back surface  236 . The size of the structure  406  and the difference in portions  402  and  404  are larger than the variations in the dimensions of the inserts  204 , which ensures that the edges of the inserts  204  will be behind the mold portions and prevent flash formation. 
         [0042]    It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.