The present invention relates to the field of opto-electrical assemblies, and associated apparatus and methods.
Opto-electrical assemblies typically comprise a plurality of components, which may be purely optical, purely electrical, a combination of optical and electrical, or merely structural/thermal. Generally, these components are in thermal and mechanical communication with one another, but can also be in optical and/or electrical communication too. Consequently, the manner in which one component operates may affect the characteristics of further components.
Unwanted influence between components can have an adverse effect on the operation of the assembly. For example, consider the transfer of heat from one component to a further component. In such instances, the properties of the latter component may change adversely. Also, the thermal deposition in that latter component may result in mechanical changes in size, which may affect characteristics such as optical alignment, or may induce stresses that affect mechanical reliability etc.
Therefore, it can be considered valuable to isolate each component as much as possible. However, this is in contrast with the desire to tightly integrate components within assemblies, which has the effect of exacerbating problems associated with unwanted influence. Consideration is needed as to how to provide opto-electrical assemblies, which are easy to manufacture, satisfy the space requirements, and mitigate unwanted optical, electrical, mechanical and thermal influence. There is value providing components as close together as possible when communicating at high speeds (e.g. in excess of 10 GHz).
a shows an embodiment of an opto-electrical assembly as known in the art.
a shows an opto-electrical assembly 100, comprising a lens 110, optical element 120, printed circuit board 140, heat sink 150 and electrical element, which in this case is an integrated circuit 130.
The optical element 120 and integrated circuit 130 are attached mechanically and electrically to the printed circuit board 140, which allows for electrical signals to be passed between both the optical element 120 and integrated circuit 130. In this example, the optical element 120 and integrated circuit 130 are electrically connected using wire bonds 160. This is shown diagrammatically in
The printed circuit board 140 is also in mechanical communication with the heat sink 150. In use, heat generated by the optical element 120 and integrated circuit 130 is communicated through the printed circuit board 140 to the heat sink 150. This is shown in
As is shown in
When the assembly 100 of
Unwanted movement and stress in the assembly 100 also occurs, due at least in part to mismatch between properties of the different component (e.g. differences in the coefficient of thermal expansion, etc.). As a result, the alignment of the optical element 120 can be affected. Similarly, because of unwanted movement/stresses, the alignment of the lens 120 can be affected. For example, referring to
Broadly, disclosed is a opto-electrical assembly that balances optical, electrical, thermal and mechanical connections for non-hermetic, low cost equipment practice for high speed optical engines for easy integration into optical modules.
According to a first aspect of the invention there is provided an opto-electrical assembly, the assembly comprising an optical carrier; one or more optical elements attached to the optical carrier, and configured for electrical communication with the optical carrier; a flexible connector attached to the optical carrier, and configured to provide electrical communication between the one or more optical elements and further circuitry, the flexible connector configured to allow for relative movement of the optical carrier and further circuitry during use of the assembly.
Such an assembly may allow for movement, such as movement due to thermal expansion, during use to be accommodated or tolerated. Such an assembly may allow for regions or portions of the assembly to be fixed to a module of device (e.g. a heat dissipater to a casing, or the like), without unwanted stresses being induced in the assembly.
The flexible connector may comprise a foil or sheet. The flexible connector may comprise a first portion and a second portion, wherein the first portion is movable with respect to the second portion. The first portion may be rotatable with respect to the second portion. The first portion may be translatable with respect to the second portion. The first portion may be attached to the carrier, while the second portion may be configured for attachment to, or communication with, further circuitry.
The assembly may further comprise an optical guide. The optical guide may be attached to the optical carrier. The optical guide may be fixedly or moveably attached to the carrier. The optical guide may comprise a fibre guiding portion. The optical guide may comprise a lens portion. The optical guide may comprise an optical fibre so as to provide for optical communication to/from the one or more optical elements. The optical fibre may be a flexible fibre. The flexible fibre may allow for movement, such as movement due to thermal expansion, of the assembly during use to be accommodated.
The optical carrier may be a fully or partially transparent carrier. The optical carrier may be a glass carrier. The optical carrier may be a silicon carrier. The one or more optical elements may be attached to the optical carrier such that they receive and/or transmit optical signals through the optical carrier. The assembly may be configured such that the optical guide guides an optical signal to/from the one or more optical elements through the optical carrier. The optical carrier may be provided with one or more electrical communication paths for communicating electrical signals to/from the one or more optical elements and the flexible connector. The communication paths may be provided by a metalized pattern.
The assembly may be configured such that the coefficient of thermal expansion of the optical carrier and the one or more optical elements is roughly the same, or similar.
The assembly may comprise a heat dissipater. The heat dissipater may be in thermal communication with the one or more optical elements and/or one or more electrical elements (such as an IC). The heat dissipater may be in thermal connection with the one or more optical elements and the one or more electrical elements (such as an IC) via an adhesive. The one or more optical elements and electrical elements (such as an IC) may be fully or partially covered by a sealant, or the like. The heat dissipater may be in thermal communication with the one or more optical elements and electrical elements (such as an IC) via the sealant. The heat dissipater may be in thermal communication with the optical carrier.
The heat dissipater may be configured for attachment to a heat sink, such as casing of a device or module, or the like. The assembly may be configured such that the heat dissipater is provided on an opposite side of the optical carrier to the optical guide.
The one or more optical elements may be optical receivers, such as 4-channel optical receivers. The one or more optical elements may be optical transmitters, such as 4-channel optical transmitters. The assembly may be configured as a multi-channel array. The one or more optical elements may be optical die.
The assembly may comprise one or more electrical elements, such as integrated circuits (e.g. application specific integrated circuits, field programmable gate arrays, microcontrollers, programmable intelligent computers, or the like). The one or more electrical elements may be for use with the one or more optical elements. The one or more electrical elements may be attached to the optical carrier. The one or more electrical elements may be in electrical communication with the one or more optical elements via the optical carrier (e.g. using the metalized pattern). The one or more electrical elements may be attached to the same side of the carrier as the one or more optical elements.
The one or more optical/electrical elements may be attached to the optical carrier using solder, such as solder bumps. The one or more optical/electrical elements may be flip chip elements.
The flexible connector may comprise an aperture. The assembly may be configured such that the optical carrier is received at least partially within the aperture. The optical carrier may be attached to a periphery region of the aperture. The flexible connector may be attached to a periphery region of the optical carrier.
The optical carrier may be soldered, glued, or the like, to the flexible connector. The aperture may be configured to allow for the one or more optical/electrical elements to be in thermal communication with the heat dissipater.
The assembly may comprise a substrate. The substrate may be in communication with the one or more optical elements via the flexible connector. The substrate may be provided by a printed circuit board, or the like. The substrate may comprise surface mounted technology. The substrate may be configured to allow for communication with the further circuitry, and further apparatus, modules, devices, etc. For example, the substrate may comprise a module connector, slot connector, or the like.
According to a second aspect of the invention there is provided an opto-electrical assembly, the assembly comprising one or more optical elements and one or more electrical elements attached to an optical carrier; a heat dissipater, in thermal communication with the one or more optical elements and one or more electrical elements, and configured for thermal communication with casing of an optical module or device; an optical guide, the optical guide comprising a flexible fibre in optical communication with the one or more optical elements through the carrier; and a flexible connector, the flexible connector attached to the optical carrier to provide electrical communication between the optical carrier and further circuitry; and wherein the optical guide and flexible connector are configured to allow for movement of the assembly in use.
According to a third aspect of the invention there is provided an opto-electrical assembly, the assembly comprising one or more optical elements and one or more electrical elements attached to an optical carrier; a heat dissipater, in thermal communication with the one or more optical elements and one or more electrical elements, and configured for thermal communication with casing of an optical module or device; an optical guide, the optical guide comprising a flexible fibre in optical communication with the one or more optical elements through the carrier; and a flexible connector, the flexible connector attached to the optical carrier to provide electrical communication between the optical carrier and further circuitry; and wherein the optical guide and flexible connector are configured to allow for movement of the carrier and further circuitry during use of the assembly.
According to a fourth aspect of the invention there is provided an opto-electrical assembly, the assembly comprising one or more optical elements attached to an optical carrier; a flexible connector attached to the optical carrier, and configured to provide electrical communication between the one or more optical elements and further circuitry, the flexible foil connector configured to allow for movement the assembly during use, such as relative movement of the assembly and further circuitry.
According to a fifth aspect of the invention there is provided an optical module or device, the optical module or device comprising an assembly according to any of the features of the first, second, third or fourth aspects.
The optical module or device may comprise a casing. The module or device may be configured such that a heat dissipater is in thermal communication with the casing. The heat dissipater may be in fixed or movable communication with the casing.
According to a sixth aspect of the invention there is provided a means for an opto-electrical circuit assembly, the means for an opto-electrical circuit assembly comprising one or more means for optical signalling attached to a means for carrying; a flexible means for connection, the flexible means attached to the means for carrying, and configured to provide electrical communication between the one or more means for optical signalling and further circuitry, the flexible means for connection configured to allow for relative movement of the means for carrying and further circuitry during use of the means for an opto-electrical circuit assembly.
According to a seventh aspect of the invention there is provided apparatus comprising one or more optical and electrical flip chip die soldered to a metalized pattern of a glass support; a heat stud, in thermal communication with the one or more optical and electrical die, and configured for thermal connection with casing of an optical module or device; an optical guide, the optical guide configured to receive an optical fibre to allow communication of optical signals with the one or more optical die through the glass support; a flexible circuit, the flexible circuit attached to the glass support to provide electrical communication between the one or more optical die and further circuitry; and wherein the flexible circuit has a glass carrier attachment portion and a module attachment portion, the glass carrier attachment portion being movable with respect to the module attachment portion to allow for movement of the apparatus in use.
According to an eighth aspect of the invention there is a method of providing an opto-electrical assembly. The method may include providing any of the features of any of the above aspects. The method may include providing one, some or all of the features in a non-hermetic environment.
Other aspects and advantages of embodiments of the invention will be readily apparent to those ordinarily skilled in the art upon a review of the following description.
Embodiments of the invention will now be described in conjunction with the accompanying drawings, wherein:
a shows an embodiment of an opto-electrical assembly as known in the art;
b illustrates the connection between the optical element and integrated circuit of the opto-electrical assembly of
c illustrates the heat dissipation of the opto-electrical assembly of
d; shows an alternative design of an opto-electrical assembly containing a passively aligned lens (including light path) and a heat sink.
a shows an embodiment of an opto-electrical assembly in accordance with the teachings of this invention;
b is a side view of the opto-electrical assembly of
c shows a flexible connector that can be used with the opto-electrical assembly of
d illustrates another embodiment of the opto-electrical assembly of
a, 3b, and 3c show the opto-electrical assembly of
a shows an embodiment of an opto-electrical assembly comprising a mechanical interface for an optical single fiber connector in accordance with the teachings of this invention;
b illustrates the opto-electrical assembly of
c illustrates the opto-electrical assembly of
a, 6b, and 6c show further examples of assemblies comprising optical guides in accordance with the teachings of this invention; and
a, 7b 8, 9a, 9b and 9c illustrate practical applications of opto-electrical assemblies in accordance with the teachings of this invention.
This invention will now be described in detail with respect to certain specific representative embodiments thereof, the materials, apparatus and process steps being understood as examples that are intended to be illustrative only. In particular, the invention is not intended to be limited to the methods, materials, conditions, process parameters, apparatus and the like specifically recited herein.
a shows a plan view of an embodiment of an optical carrier 200. In this example, the optical carrier 200 has two attached optical elements 220a, 220b and two attached electrical elements, which in this case are integrated circuits 230a, 230b for use with the optical elements 220a, 220b. The optical carrier 200 comprises glass, such as Pyrex™, or the like. The carrier 200 is transparent. However, the carrier has a metalized pattern 280 to provide electrical communication between the optical element 220a, 220b and the integrated circuit 230a, 230b, as well as to a perimeter region 285 of the carrier 200, which allows for electrical connection with a flexible connector 300, as will be described. Because the carrier 200 is glass, the co-efficient of thermal expansion of the carrier 200 and the optical element 220a, 220b should preferably be matched.
Here, the optical elements 220a, 220b are provided by optical die. One optical element is a 4-channel receiver, while the other optical element is a 4-channel transmitter. In this example, they are configured as a multichannel array. It will be appreciated that this configuration is exemplary only. The carrier may have any number of optical elements. The carrier may have any number of electrical elements.
b shows a side view of the carrier 200 at section A-A of
c shows a flexible connector 300 for use with the carrier 200. The connector is provided by a flexible foil, or sheet. The connector 300 comprises a first portion 310 and a second portion 320. The first portion 310 is moveably connected to the second portion 320 at a joined region 330. Here, the first portion 310 can rotate with respect to the second portion 320. The first portion 310 can also translate with respect to the second portion 320.
The first portion 310 has an aperture region 340. The carrier 200 and connector 300 are configured such that they make electrical and mechanical connection at a perimeter region 345 of the aperture region 340. The second portion 320 comprises a terminal 350 for connecting the connector 300 to a substrate, such as a printed circuit board, or the like. The terminal 350 may be considered to be a connector for connecting to a substrate, but equally the 350 terminal may be configured for connecting to a device or module, etc.
The connector 300 comprises electrical communication paths arranged in a known manner, which pass from the aperture region 340 to the terminal 350 and allow for electrical signals to be communicated from further circuitry to and from the optical carrier 200, and thus the optical element 220a, 220b/integrated circuit 230a, 230b.
An assembly 400, comprising the carrier 200 and connector 300 is shown in
It will be appreciated that in some embodiments, the flexible connector may comprise the module connector 520.
Adhesive 420 has been used to attach the heat dissipater 410 with the assembly 400. The adhesive 420 also serves to protect the optical elements 220a, 220b and integrated circuit 230a, 230b. This means that the optical element 220a, 220b/integrated circuit 230a, 230b can be sealed against contaminants.
a shows a cross section of an assembly 460 similar to that described above, but comprising a single optical element 620, and in this example, a single integrated circuit 630 for use with the optical element 620.
Here, the assembly 460 comprises an opto-mechanical interface 600 for guiding an optical connector for use with an optical element 620. In this example, the opto-mechanical interface 600 is attached to the carrier 200, and comprises a lens portion 610 and a fibre guiding portion 615. The fibre guiding portion 615 is configured to receive an optical fibre and align the received optical fibre with the lens portion 610 to allow for communication to/from the optical element 620. While in this example, the fibre guiding portion 615 and the lens portion 610 are integral with the opto-mechanical interface 600, that need not always be the case: each may be provided individually.
b shows an embodiment of the assembly 460 shown in
c shows a similar configuration to that described in
As can be seen from
In addition, because the electrical and optical connections are flexible, the heat dissipater 650, 410 can be fixable attached to the casing 750, or heat sink 450, or the like, without causing any additional stresses in the assembly 400, 460.
Of course, while in the above examples an opto-mechanical interface 600 having a fibre guide portion 615, ferrule portion 815, or a lens portion 610 have been described, it will be appreciated that any other number of opto-mechanical interface 600 may be used.
a, 7b and 8 show a further example of an assembly similar to that described in relation to
a, 9b and 9c show a further example of the assembly described in relation to
Although in some of the above examples, two optical elements and two integrated circuits have been described, it will be appreciated that such embodiments are exemplary only. The assembly may comprise one, or more that two optical elements, or one, or more than two integrated circuits. In some example, the assembly comprises only optical elements. For example, the assembly may be provided for a single channel receiver and/or transmitter.
Numerous modifications may be made without departing from the spirit and scope of the invention as defined in the appended claims.