Pluggable Optical Connector Interfaces for Electro-Optical Circuit Boards

A study is hereby presented on system embedded photonic interconnect technologies, which would address the communications bottleneck in modern exascale data centre systems driven by exponentially rising consumption of digital information and the associated complexity of intra-data centre network management along with dwindling data storage capacities. It is proposed that this bottleneck be addressed by adopting within the system electro-optical printed circuit boards (OPCBs), on which conventional electrical layers provide power distribution and static or low speed signaling, but high speed signals are conveyed by optical channels on separate embedded optical layers. One crucial prerequisite towards adopting OPCBs in modern data storage and switch systems is a reliable method of optically connecting peripheral cards and devices within the system to an OPCB backplane or motherboard in a pluggable manner. However the large mechanical misalignment tolerances between connecting cards and devices inherent to such systems are contrasted by the small sizes of optical waveguides required to support optical communication at the speeds defined by prevailing communication protocols. An innovative approach is therefore required to decouple the contrasting mechanical tolerances in the electrical and optical domains in the system in order to enable reliable pluggable optical connectivity. This thesis presents the design, development and characterisation of a suite of new optical waveguide connector interface solutions for electro-optical printed circuit boards (OPCBs) based on embedded planar polymer waveguides and planar glass waveguides. The technologies described include waveguide receptacles allowing parallel fibre connectors to be connected directly to OPCB embedded planar waveguides and board-to-board connectors with embedded parallel optical transceivers allowing daughtercards to be orthogonally connected to an OPCB backplane. For OPCBs based on embedded planar polymer waveguides and embedded planar glass waveguides, a complete demonstration platform was designed and developed to evaluate the connector interfaces and the associated embedded optical interconnect. Furthermore a large portfolio of intellectual property comprising 19 patents and patent applications was generated during the course of this study, spanning the field of OPCBs, optical waveguides, optical connectors, optical assembly and system embedded optical interconnects

Silicon circuits for chip-to-chip communications in multi-socket server board interconnects

Multi-socket server boards (MSBs) exploit the interconnection of multiple processor chips towards forming powerful cache coherent systems, with the interconnect technology comprising a key element in boosting processing performance. Here, we present an overview of the current electrical interconnects for MSBs, outlining the main challenges currently faced. We propose the use of silicon photonics (SiPho) towards advancing interconnect throughput, socket connectivity and energy efficiency in MSB layouts, enabling a flat-topology wavelength division multiplexing (WDM)-based point-to-point (p2p) optical MSB interconnect scheme. We demonstrate WDM SiPho transceivers (TxRxs) co-assembled with their electronic circuits for up to 50 Gb/s line rate and 400 Gb/s aggregate data transmission and SiPho arrayed waveguide grating routers that can offer collision-less time of flight connectivity for up to 16 nodes. The capacity can scale to 2.8 Gb/s for an eight-socket MSB, when line rate scales to 50 Gb/s, yielding up to 69% energy reduction compared with the QuickPath Interconnect and highlighting the feasibility of single-hop p2p interconnects in MSB systems with >4 sockets

Co-Package Technology Platform for Low-Power and Low-Cost Data Centers

We report recent advances in photonic–electronic integration developed in the European research project L3MATRIX. The aim of the project was to demonstrate the basic building blocks of a co-packaged optical system. Two-dimensional silicon photonics arrays with 64 modulators were fabricated. Novel modulation schemes based on slow light modulation were developed to assist in achieving an efficient performance of the module. Integration of DFB laser sources within each cell in the matrix was demonstrated as well using wafer bonding between the InP and SOI wafers. Improved semiconductor quantum dot MBE growth, characterization and gain stack designs were developed. Packaging of these 2D photonic arrays in a chiplet configuration was demonstrated using a vertical integration approach in which the optical interconnect matrix was flip-chip assembled on top of a CMOS mimic chip with 2D vertical fiber coupling. The optical chiplet was further assembled on a substrate to facilitate integration with the multi-chip module of the co-packaged system with a switch surrounded by several such optical chiplets. We summarize the features of the L3MATRIX co-package technology platform and its holistic toolbox of technologies to address the next generation of computing challenges

Optoelectronic devices and packaging for information photonics

This thesis studies optoelectronic devices and the integration of these components onto optoelectronic multi chip modules (OE-MCMs) using a combination of packaging techniques. For this project, (1×12) array photodetectors were developed using PIN diodes with a GaAs/AlGaAs strained layer structure. The devices had a pitch of 250μm, operated at a wavelength of 850nm. Optical characterisation experiments of two types of detector arrays (shoe and ring) were successfully performed. Overall, the shoe devices achieved more consistent results in comparison with ring diodes, i.e. lower dark current and series resistance values. A decision was made to choose the shoe design for implementation into the high speed systems demonstrator. The (1x12) VCSEL array devices were the optical sources used in my research. This was an identical array at 250μm pitch configuration used in order to match the photodetector array. These devices had a wavelength of 850nm. Optoelectronic testing of the VCSEL was successfully conducted, which provided good beam profile analysis and I-V-P measurements of the VCSEL array. This was then implemented into a simple demonstrator system, where eye diagrams examined the systems performance and characteristics of the full system and showed positive results. An explanation was given of the following optoelectronic bonding techniques: Wire bonding and flip chip bonding with its associated technologies, i.e. Solder, gold stud bump and ACF. Also, technologies, such as ultrasonic flip chip bonding and gold micro-post technology were looked into and discussed. Experimental work implementing these methods on packaging the optoelectronic devices was successfully conducted and described in detail. Packaging of the optoelectronic devices onto the OEMCM was successfully performed. Electrical tests were successfully carried out on the flip chip bonded VCSEL and Photodetector arrays. These results verified that the devices attached on the MCM achieved good electrical performance and reliable bonding. Finally, preliminary testing was conducted on the fully assembled OE-MCMs. The aim was to initially power up the mixed signal chip (VCSEL driver), and then observe the VCSEL output

Laser ablation of polymer waveguide and embedded mirror for optically-enabled printed circuit boards (OEPCB)

Due to their inherent BW capacity, optical interconnect (OI) offers a means of replacement to BW limited copper as bottlenecks begin to appear within the various interconnect levels of electronics systems. Low-cost optically enabled printed circuit boards are a key milestone on many electronics roadmaps, e.g. iNEMI. Current OI solutions found in industry are based upon optical fibres and are capable of providing a suitable platform for inter-board applications especially on the backplane. However, to allow component assembly onto high BW interconnects, an integral requirement for intra-board applications, optically enabled printed circuit boards containing waveguides are essential. Major barriers to the deployment of optical printed circuit boards include the compatibility of the technique, the cost of acquiring OI and the optical power budget. The purpose of this PhD research programme is to explore suitable techniques to address these barriers, primarily by means of laser material processing using UV and IR source lasers namely 248 nm KrF Excimer, 355 nm UV Nd:YAG and 10.6 µm IR CO2. The use of these three main lasers, the trio of which dominates most PCB production assembly, provides underpinning drive for the deployment of this technology into the industry at a very low cost without the need for any additional system or system modification. It further provides trade-offs among the suitable candidates in terms of processing speed, cost and quality of waveguides that could be achieved. This thesis presents the context of the research and the underlying governing science, i.e. theoretical analysis, involving laser-matter interactions. Experimental investigation of thermal (or pyrolitic) and bond-breaking (or photolytic) nature of laser ablation was studied in relation to each of the chosen lasers with regression analysis used to explain the experimental results. Optimal parameters necessary for achieving minimum Heat Affected Zone (HAZ) and surface/wall roughness were explored, both of which are key to achieving low loss waveguides. While photochemical dominance – a function of wavelength and pulse duration – is desired in laser ablation of photopolymers, the author has been able to find out that photothermallyprocessed materials, for example at 10.6 µm, can also provide desirable waveguides. Although there are literature information detailing the effect of certain parameters such as fluence, pulse repetition rate, pulse duration and wavelength among others, in relation to the etch rate of different materials, the machining of new materials requires new data to be obtained. In fact various models are available to try to explain the laser-matter interaction in a mathematical way, but these cannot be taken universally as they are deficient to general applications. For this reason, experimental optimisation appears to be the logical way forward at this stage of the research and thus requiring material-system characterisation to be conducted for each case thereby forming an integral achievement of this research. In this work, laser ablation of a single-layer optical polymer (Truemode™) multimode waveguides were successfully demonstrated using the aforementioned chosen lasers, thus providing opportunities for rapid deployment of OI to the PCB manufacturing industry. Truemode™ was chosen as it provides a very low absorption loss value < 0.04 dB/cm at 850 nm datacom wavelength used for VSR interconnections – a key to optical power budget – and its compatibility with current PCB fabrication processes. A wet-Truemode™ formulation was used which required that optical polymer layer on an FR4 substrate be formed using spin coating and then UV-cured in a nitrogen oxygen-free chamber. Layer thickness, chiefly influenced by spinning speed and duration, was studied in order to meet the optical layer thickness requirement for multimode (typically > 9 µm) waveguides. Two alternative polymers, namely polysiloxane-based photopolymer (OE4140 and OE 4141) from Dow Corning and PMMA, were sparingly utilized at some point in the research, mainly during laser machining using UV Nd:YAG and CO2 lasers. While Excimer laser was widely considered for polymer waveguide due to its high quality potential, the successful fabrication at 10.6 µm IR and 355 nm UV wavelengths and at relatively low propagation loss at datacom wavelength of 850 nm (estimated to be < 1.5 dB/cm) were unprecedented. The author considered further reduction in the optical loss by looking at the effect of fluence, power, pulse repetition rate, speed and optical density on the achievable propagation but found no direct relationship between these parameters; it is therefore concluded that process optimisation is the best practice. In addition, a novel in-plane 45-degree coupling mirror fabrication using Excimer laser ablation was demonstrated for the first time, which was considered to be vital for communication between chips (or other suitable components) at board-level

Integrated silicon photonic packaging

Silicon photonics has garnered plenty of interests from both the academia and industry due to its high-speed transmission potential as well as sensing capability to complement silicon electronics. This has led to significant growth on the former, valuing at US$626.8M in 2017 and is expected to grow 3-fold to US$ 1,988.2M by 2023, based on data from MarketsandMarkets™. Silicon photonics’ huge potential has led to worldwide attention on fundamental research, photonic circuit designs and device fabrication technologies. However, as with silicon electronics in its early years, the silicon photonics industry today is extremely fragmented with various chip designs and layouts. Most silicon photonic devices fabricated are not able to reach the hand of consumers, due to a lack of information related to packaging design rules, components and processes. The importance of packaging technologies, which play a crucial role in turning photonic circuits and devices into the final product that end users can used in their daily lives, has been overlooked and understudied. This thesis aims to – 1. fill the missing gap by adapting existing electronics packaging techniques, 2. assess its scalability, 3. assess supply chain integration and finally 4. develop unique packaging approaches specifically for silicon photonics. The first section focused on high density packaging components and processes using University of California, Berkeley’s state-of-the-art silicon photonic MEMS optical switches as test devices. Three test vehicles were developed using (1) via-less ceramic and (2) spring-contacted electrical interposers for 2D integration and (3) through-glass-via electrical interposers for 2.5D heterogeneous integration. A high density (1) lidless fibre array and (2) a 2D optical interposer, which allows pitch-reduction of optical waveguides were also developed in this thesis. Together, these components demonstrated the world’s first silicon 2 photonic MEMS optical switch package and subsequently the highest density silicon photonic packaging components with 512 electrical I/Os and 272 optical I/Os. The second section then moved away from active optical coupling that was used in the former, investigating instead passive optical packaging concepts for the future. Two approaches were investigated - (1) grating-to-grating and (2) evanescent couplings. The former allows the development of pluggable packages, separating fibre coupling away from the device while the latter allows simultaneous optical and electrical packaging on a glass wafer in a single process. Lastly, the knowhow and concepts developed in this thesis were compiled into packaging design rules and subsequently introduced into H2020-MORPHIC, PIXAPP packaging training courses (as a trainer) and other packaging projects within the group

Thin-film VCSEL and optical interconnection layer fabrications for fully embedded board level optical interconnects

textSemiconductor technology has been splendid evolved. As a consequence of, massive data traffic is required in system level. However copper based interconnection reached the upper limit of data transfer rate and can not provide enough bandwidth for high performance system. Copper based interconnection in long haul application was replaced to optical fiber. Optical interconnection in system level is generally considered as an alternative to provide high bandwidth. However, unlike long haul application, optical interconnection in system level encountered many problems such as compatibility, robustness and packaging difficulty. The compatibility to current electrical board system and packaging difficulty must be solved. This dissertation describes a fully embedded board level optical interconnection, which can solve many problems, components fabrication and hybrid integration with electrical layers. Thin-film VCSEL array and flexible optical waveguide are demonstrated. The optical interconnection layer integrated with thin-film VCSEL and photo-detector arrays is demonstrated.Electrical and Computer Engineerin

Integration of optical interconnections and optoelectronic components in flexible substrates

Licht als informatiedrager voor datacommunicatie kende een ongezien succes in de laatste decennia. Wegens de lage verliezen en hoge datasnelheden hebben ze voor het overbruggen van lange afstanden hun elektrische tegenhangers reeds geruime tijd verdrongen. Deze trend zet zich ook voort voor korte afstand communicatie op printplaten. Naast zijn functie als informatiedrager, wordt licht ook gebruikt om een waaier aan fysische grootheden te meten. Ook hier heeft licht enkele significante voordelen t.o.v elektrische informatiedragers, waardoor optische sensoren wijdverspreid zijn. Een tweede duidelijke trend binnen de elektronica is het gebruik van flexibele printkaarten. Deze zijn veel dunner, lichter en betrouwbaarder dan de klassieke harde printkaarten, waardoor ze uiterst geschikt zijn voor draagbare toepassingen waar compactheid en een laag gewicht hoge vereisten zijn. De flexibiliteit van de printplaten laat ook toe hen te gebruiken op onvlakke oppervlakken en op bewegende onderdelen. Het doel van het gepresenteerde doctoraatswerk is de ontwikkeling van een nieuw technologieplatform dat bovengenoemde trends combineert. Alle bouwblokken van optische communicatie, gaande van actieve opto-elektronische componenten, aanstuurelektronica, golfgeleiderbaantjes en galvanische verbindingen tot optische koppelstructuren tussen de verschillende bouwblokken, worden zodanig gerealiseerd dat elke component flexibel is en geïntegreerd wordt in een dunne folie met een dikte van slechts 150µm. Op die manier bekomen we een flexibele folie met alle passieve en actieve onderdelen voor optische communicatie geïntegreerd met enkel een elektrische interface naar de buitenwereld, wat de aanvaarding en toepassing van deze technologie in de huidige elektronica aanzienlijk kan versnellen. Binnen het doctoraatswerk werden alle voorgestelde technologieën en processen gerealiseerd en geoptimaliseerd. Bovendien werden de optische verliezen, warmteaspecten, hoogfrequent gedrag, mechanisch gedrag en betrouwbaarheid van de technologie gekarakteriseerd en vergeleken met de huidige state-of-the-art

Design and Development of an Optical Chip Interferometer For High Precision On-Line Surface Measurement

Advances in manufacturing and with the demand of achieving faster throughput at a lower cost in any industrial setting have put forward the need for embedded metrology. Embedded metrology is the provision of metrology on the manufacturing platform, enabling measurement without the removal of the workpiece. Providing closer integration of metrology upon the manufacturing platform will improve material processing and reliability of manufacture for high added value products in ultra-high-precision engineering. Currently, almost all available metrology instrumentation is either too bulky, slow, destructive in terms of damaging the surfaces with a contacting stylus or is carried out off-line. One technology that holds promise for improving the current state-of-the-art in the online measurement of surfaces is hybrid photonic integration. This technique provides for the integration of individual optoelectronic components onto silicon daughter boards which are then incorporated on a silica motherboard containing waveguides to produce a complete photonic circuit. This thesis presents first of its kind a novel chip interferometer sensor based on hybrid integration technology for online surface and dimensional metrology applications. The complete metrology sensor system is structured into two parts; hybrid photonic chip and optical probe. The hybrid photonic chip interferometer is based on a silica-on-silicon etched integrated-optic motherboard containing waveguide structures and evanescent couplers. Upon the motherboard, electro-optic components such as photodiodes and a semiconductor gain block are mounted and bonded to provide the required functionality. Optical probe is a separate entity attached to the integrated optic module which serves as optical stylus for surface scanning in two measurement modes a) A single-point for measuring distance and thus form/surface topography through movement of the device or workpiece, b) Profiling (lateral scanning where assessment of 2D surface parameters may be determined in a single shot. Wavelength scanning and phase shifting inteferometry implemented for the retrival of phase information eventually providing the surface height measurement. The signal analysis methodology for the two measurement modes is described as well as a theoretical and experimental appraisal of the metrology capabilities in terms of range and resolution. The incremetal development of various hybrid photonic modules such as wavelength encoder unit, signal detection unit etc. of the chip interferometer are presented. Initial measurement results from various componets of metrology sensor and the surface measurement results in two measurement modes validate the applicability of the described sensor system as a potential metrology tool for online surface measurement applications

Index to NASA Tech Briefs, 1975

This index contains abstracts and four indexes--subject, personal author, originating Center, and Tech Brief number--for 1975 Tech Briefs