Report on OSU Opto-Pack Prototypes K.K. Gan The Ohio State University June 11, 2001 K.K. Gan ATLAS Opto-Pack Review 1
Outline Introduction Result on VCSEL opto-pack prototypes Result on PIN opto-pack prototypes Result on temperature cycling Result on test with opto-boards Production Plan Conclusions K.K. Gan ATLAS Opto-Pack Review 2
OSU Design connector concept design use precisely fabricated cap and base for alignment simple two-piece design for mass production cap holes for fibers base deposit gold traces for wire bonding, VCSEL and PIN placements K.K. Gan ATLAS Opto-Pack Review 3
VCSEL Opto-Pack K.K. Gan ATLAS Opto-Pack Review 4
PIN Opto-Pack K.K. Gan ATLAS Opto-Pack Review 5
produced caps and bases with rounded corners using machinable ceramic material tested: aluminum silicate and macor difficult to obtain consistent precision! redesign base with square corners for ease of fabrication by Hybrid-Tek alumina sheet ground to proper thickness and cut into strips strips cut into bases by American Dicing can produce bases with precision within specification 3D traces have good connectivity (~ 94%)! fabricate cap with Ultem (polyetherimide) for radiation tolerance (10 Grad) Cap and Base Prototypes use manual micro mold injection to save development time can fabricate ~ 10 caps per hour K.K. Gan ATLAS Opto-Pack Review 6
VCSEL Base Width 40 σ = 5.6 µ m 30 Count 20 20 µm 10 0 1.25 1.30 1.35 1.40 Width (mm) accept ~ 90% of bases K.K. Gan ATLAS Opto-Pack Review 7
VCSEL Placement VCSEL needs to be placed with a precision of 10 µm! use precisely fabricate jig precision base slot slightly larger than base precisely located pocket for VCSEL pocket slightly larger than VCSEL! 3 contributions to placement uncertainty! 12 out 18 bases fabricated satisfy power coupling spec.! new VCSEL placement scheme K.K. Gan ATLAS Opto-Pack Review 8
New VCSEL Placement Scheme measure location of pin in cap mold using comparator! place VCSEL at expected fiber location put base on comparator move cross-hair to expected fiber location based on measured width move VCSEL to cross-hair with micro-manipulator operation time: ~ 5 minutes expect more precise pin location with CMM measurement! should further improve coupled power K.K. Gan ATLAS Opto-Pack Review 9
Cap Fabrication Mold K.K. Gan ATLAS Opto-Pack Review 10
Fiber Placement Jig K.K. Gan ATLAS Opto-Pack Review 11
Cap with Precisely Fabricated Cavity K.K. Gan ATLAS Opto-Pack Review 12
Base with VCSEL K.K. Gan ATLAS Opto-Pack Review 13
Completed VCSEL Opto-Pack 1 mm K.K. Gan ATLAS Opto-Pack Review 14
Coupled VCSEL Power @ 10 ma 1500 1000 Power (uw) 500 specification 0 0 5 10 15 20 25 30 35 Base all VCSEL opto-packs have coupled power well above spec. K.K. Gan ATLAS Opto-Pack Review 15
Coupled VCSEL Power vs Usage 1500 power (uw) 1000 500 specification cap1 cap2 0 0 2 4 6 8 10 12 Trial caps can be used multiple times K.K. Gan ATLAS Opto-Pack Review 16
Coupled VCSEL Power vs Usage 1500 power (uw) 1000 500 specification 0 0 5 10 15 20 25 30 35 Base same cap gives good power on 31 bases! cap is reusable and inter-changeable K.K. Gan ATLAS Opto-Pack Review 17
VCSEL Waveform VCSEL opto-pack has fast rise and fall times K.K. Gan ATLAS Opto-Pack Review 18
Temperature Cycling 10 VCSEL opto-packs were temperature cycling: ~ 300 cycles between -10 0 C and 60 0 C! no degradation observed K.K. Gan ATLAS Opto-Pack Review 19
PIN Opto-pack Responsivity 1 0.8 Responsivity 0.6 0.4 specification 0.2 0 0 1 2 3 4 5 6 7 Trial PIN opto-pack responsivity is above spec. K.K. Gan ATLAS Opto-Pack Review 20
BER of Opto-packs on Opto-board opto-packs can run with low PIN current K.K. Gan ATLAS Opto-Pack Review 21
disadvantages advantages: Pro and Con of OSU Design need to fabricate more packages extra time: 2000 caps x 10 min = 2 months of manpower limited number of PIN/VCSEL per package to reduce loss select VCSEL opto-packs of similar coupled power for appropriate I set opto-board without 21 long fibers is much easier to handle cure epoxy on opto-board in oven without fibers for die replacement cap with fibers can be attached to package at end of module assembly K.K. Gan ATLAS Opto-Pack Review 22
Production Plan can transfer technology to any interested institution OSU will provide jigs manpower need assuming 30 minutes per VCSEL or PIN! need 1.5 manpower-year to fabricate 3000 packages K.K. Gan ATLAS Opto-Pack Review 23
Summary on OSU Opto-pack Prototype OSU prototype program successfully completed can fabricate VCSEL opto-packs with good coupled power can fabricate PIN opto-packs with good responsivity opto-packs can run at low PIN current remountable caps offer maximum flexibility in opto-board assembly and repair K.K. Gan ATLAS Opto-Pack Review 24