Teemu Alajoki

Parallel optical interconnect between ceramic BGA packages on FR4 board using embedded waveguides and passive optical alignments

We have studied technologies to design and fabricate high-bit-rate chip-to-chip optical interconnects on printed circuit boards (PCBs) using board-embedded polymer waveguides and surface-mounted component packages or modules. In order to demonstrate the developed technologies, a 4times10 Gb/s optical interconnect was completely integrated on a standard FR4 PCB. The optical link demonstrator consists of 4-channel BGA-mounted transmitter and receiver modules as well as of four parallel multimode optical waveguides fabricated on top of the solder mask of the PCB using lithographic patterning. The transmitters and receivers built on low-temperature co-fired ceramic (LTCC) substrates include 4times10 Gb/s flip-chip mounted VCSEL or photodiode array, wire-bonded driver and receiver ICs, and optical coupling structures. Two microlens arrays and a micro-mirror enable optical coupling between the optoelectronic devices and the waveguide array. The passive optical alignment was based on the marks and structures fabricated both in the LTCC process and in the patterning of the optical layers. The characterized optical alignment tolerances are in the limits of accuracy of the surface-mount technology. The demonstrated technology is suitable for interconnecting CBGA-packaged ICs or multi-chip-modules

Embedded optical interconnect on printed wiring board

Integration of high-speed parallel optical interconnects into printed wiring boards (PWB) is studied. The aim is a hybrid optical-electrical board including both electrical wiring and embedded polymer waveguides. Robust optical coupling between the waveguide and the emitter/detector should be achieved by the use of automated pick-and-place assembly. Different coupling schemes were analyzed by combining non-sequential ray tracing with Monte-Carlo tolerance simulation of misalignments. A modular demonstrator was designed based on three different kind of optical coupling schemes: butt-coupling and couplings based on microlens arrays and on micro ball lenses. The optical front-ends were implemented with PIN and flip-chip-VCSEL arrays as well as 10-Gb/s/channel electronics onto LTCC-based (low-temperature co-fired ceramic) transmitter and receiver modules, which were surface mounted on high-speed PWBs. An electrical simulation model was developed for the design of a VCSEL-based transmitter circuit. Polymer waveguides were fabricated on separate FR-4 boards to allow characterization of alignment tolerances with different waveguides. Optical and adhesion properties of several potential waveguide materials were characterized. The simulations and experiments suggest that, with optimized optomechanical structures and with low loss waveguides, it is possible to achieve acceptable total path loss and yield with the accuracy of automated assembly.

Fiber-Optic Transceiver Module for High-Speed Intrasatellite Networks

High-speed intrasatellite networks are needed to interconnect units such as synthetic aperture radars, high-resolution cameras, and fast image-compression processors that produce data beyond gigabits per second. We have developed a fiber-optic link, named SpaceFibre, which operates up to 3.125 Gb/s and is compatible with the existing SpaceWire network. The link provides symmetrical, bidirectional, full-duplex, and point-to-point communication. It employs 850-nm vertical-cavity surface emitting lasers, radiation-hardened laser-optimized 50/125 mum graded-index fibers, and GaAs p-i-n photo diodes. The transceiver electronics is realized using a multilayer-ceramic-substrate technology that enables the passive alignment of optical fibers to active devices. The SpaceFibre link demonstrator was tested to transfer data at 2.5 Gb/s over 100 m with a bit error rate of less than 1.3middot10-14. Fiber-pigtailed modules were stressed with temperature variations from -40degC to +85degC, vibrations up to 30 g, and mechanical shocks up to 3900 g. The test results of 20 modules show that the SpaceFibre link is a promising candidate for the upcoming high-speed intrasatellite networks

Multi channel in-plane and out-of-plane couplers for optical printed circuit boards and optical backplanes

We present multi channel optical interconnects, based on integrated glass fibers, with passively aligned in-plane and 90° out-of-plane couplers for printed circuit boards. The out-of-plane coupler features micro optics, mechanical alignment structures, and a snap-fit system to assemble the complex coupler out of several simple, self aligning parts. Further we present an optical printed circuit board for on-board transmitter and receiver electronics for four channels using 4×10 Gbit/s transmitter and receiver chips.

Single-mode tuning of a 1540-nm diode laser using a Fabry-Pe/spl acute/rot interferometer

We realized a wavelength-tunable laser using a 1540-nm Fabry-Pe/spl acute/rot diode laser and a silicon surface micromachined Fabry-Pe/spl acute/rot interferometer device in the short external cavity configuration. This hybrid-integrated system enables the use of standard laser chips and potentially has a low cost. We obtained single-mode tuning of 13 nm, a sidemode suppression ratio of better than 25 dB, and an average single-mode fiber-coupled power of 100 /spl mu/W. The emitter can be employed in optical communication and fiber-optic sensor applications.

Extremely short external cavity lasers: the use of wavelength tuning effects in near field sensing

An adjustable extremely short external cavity (ESEC; cavity length 0...50 microns) can be used to tune the wavelength of an edge emitting Fabry-Perot semiconductor laser up to two percents. This means about 30 nm tuning range for the 1550-nm lasers and about 15 nm tuning range for the 800-nm lasers. In addition to the use in WDM and other tunable laser applications, this phenomenon can be directly used in realizing wavelength tuning sensitive near field sensors. In this paper, we discuss the ESEC laser tuning mechanism by using various numerical models and experimentation. We show simulations and experimental results for two different wavelength tuning schemes: a single mirror tuning, and tuning by using a micromachined Fabry Perot interferometer. In addition, we discuss and show results on wavelength tuning enhanced readout in near field optical data storage, and on near field surface profilometry via laser wavelength tuning.

Parallel optical interconnect between surface-mounted devices on FR4 printed wiring board using embedded waveguides and passive optical alignments

Technologies to design and fabricate high-bit-rate chip-to-chip optical interconnects on printed wiring boards (PWB) are studied. The aim is to interconnect surface-mounted component packages or modules using board-embedded optical waveguides. In order to demonstrate the developed technologies, a parallel optical interconnect was integrated on a standard FR4-based PWB. It consists of 4-channel BGA-mounted transmitter and receiver modules as well as of four polymer multimode waveguides fabricated on top of the PWB using lithographic patterning. The transmitters and receivers built on low-temperature co-fired ceramic (LTCC) substrates include flip-chip mounted VCSEL or photodiode array and 4x10 Gb/s driver or receiver IC. Two microlens arrays and a surface-mounted micro-mirror enable optical coupling between the optoelectronic device and the waveguide array. The optical alignment is based on the marks and structures fabricated in both the LTCC and optical waveguide processes. The structures were optimized and studied by the use of optical tolerance analyses based on ray tracing. The characterized optical alignment tolerances are in the limits of the accuracy of the surface-mount technology.

Wavelength-tunable laser module using low-temperature cofired ceramic substrates

We realized a prototype series of the 1550-nm band wavelength-tunable laser module. The edge-emitting Fabry-Perot diode laser operates in the short external cavity configuration and is tuned by a silicon surface micromachined Fabry-Peacuterot interferometer device. Low-temperature cofired ceramic (LTCC) substrate technology was used in the module packaging to enable the passive alignment of the photonic components. Low conductor resistance and dielectric loss, multilayer structures with fine-line capability, compatibility with hermetic sealing, and the ability to integrate passive electrical components (resistors, capacitors, and inductors) into the substrate make LTCC a useful technology for telecommunication applications. In addition, the fair match of the thermal expansion coefficient to optoelectronic chips reduces packaging-induced thermomechanical stresses. The precision three-dimensional (3-D) structures, such as cavities, holes, and channels manufactured in the ceramic parts, ease the packaging process via the passive assembly. The wavelength tuning range of the realized modules ranged from 8 to 19 nm and single-mode fiber-coupled output power was between 100 and 570 muW. The hybrid arrangement uses standard laser chips and, therefore, potentially provides a cost-effective and easily configurable solution for last-mile fiber optic communications

Optical interconnect on printed wiring board

Integration of high-speed parallel optical interconnects into printed wiring boards (PWB) is studied. The aim is a hybrid optical-electrical board including both electrical wiring and embedded polymer waveguides. Robust optical coupling between the waveguide and the emitter/detector should be achieved by the use of automated pick-and-place assembly. Different coupling schemes were analyzed by combining non-sequential ray tracing with Monte-Carlo tolerance simulation of misalignments. The simulations demonstrate that, with optimized optomechanical structures and with very low loss waveguides, it is possible to achieve acceptable total path loss and yield with the accuracy of automated assembly. A technical demonstrator was designed and realized to allow testing of embedded interconnects based on three different kind of optical coupling schemes: butt-coupling, and couplings based on micro-lens arrays and on micro-ball lenses. They were implemented with PIN and flip-chip-VCSEL arrays as well as 10-Gb/s/channel electronics onto LTCC-based (low-temperature co-fired ceramic) transmitter and receiver modules, which were surface mounted on high-speed PWBs. The polymer waveguides were on separate FR-4 boards to allow testing and characterization of alignment tolerances with different waveguides. With micro-lens array transmitter, the measured tolerances (±10 μm) were dominated by the thickness of the waveguides.

Printed hybrid systems

This paper presents research activities carried out at VTT Technical Research Centre of Finland in the field of hybrid integration of optics, electronics and mechanics. Main focus area in our research is the manufacturing of electronic modules and product structures with printed electronics, film-over-molding and polymer sheet lamination technologies and the goal is in the next generation of smart systems utilizing monolithic polymer packages. The combination of manufacturing technologies such as roll-to-roll -printing, injection molding and traditional component assembly is called Printed Hybrid Systems (PHS). Several demonstrator structures have been made, which show the potential of polymer packaging technology. One demonstrator example is a laminated structure with embedded LED chips. Element thickness is only 0.3mm and the flexible stack of foils can be bent in two directions after assembly process and was shaped curved using heat and pressure. The combination of printed flexible circuit boards and injection molding has also been demonstrated with several functional modules. The demonstrators illustrate the potential of origami electronics, which can be cut and folded to 3D shapes. It shows that several manufacturing process steps can be eliminated by Printed Hybrid Systems technology. The main benefits of this combination are small size, ruggedness and conformality. The devices are ideally suited for medical applications as the sensitive electronic components are well protected inside the plastic and the structures can be cleaned easily due to the fact that they have no joints or seams that can accumulate dirt or bacteria.