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High density vertical optical interconnects for passive assembly.

Drew Weninger, Samuel Serna, Achint Jain

    Optics Express
    |February 14, 2023
    PubMed
    Summary

    Novel optical couplers enable higher bandwidth in co-packaged optics. This technology is crucial for scaling beyond 50 Tbps top-of-rack switches by facilitating dense, vertical stacking of optical transceivers (TxRx).

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    Area of Science:

    • Photonics and Optical Engineering
    • Integrated Optics
    • Semiconductor Device Technology

    Background:

    • Co-packaging of optics and electronics is key for next-generation data center switches exceeding 50 Tbps.
    • Scaling bandwidth, cost, and energy efficiency in co-packaged designs depends on optical transceiver (TxRx) density, not just transistor scaling.
    • Vertical stacking of optical TxRx chips is necessary due to the larger footprint of optical components.

    Purpose of the Study:

    • To propose and simulate a novel chip-to-chip optical coupler for dense, vertical integration in co-packaged optics.
    • To enable efficient, high-bandwidth optical connections between silicon nitride and silicon on insulator waveguides.

    Main Methods:

    • Proposed a novel coupler scheme using overlapping, inverse double tapers for vertical coupling.

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    Last Updated: Aug 10, 2025

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  • Utilized Lumerical's 3D Finite Difference Time Domain (FDTD) solver for detailed optical simulations.
  • Investigated performance metrics including insertion loss, alignment tolerances, bandwidth, and angular tolerances.
  • Main Results:

    • Achieved insertion losses below -0.13 dB with a 1 µm inter-chip spacing.
    • Demonstrated significant alignment tolerances: ~2.6 µm vertically and ±2.8 µm laterally.
    • Obtained a 1 dB bandwidth exceeding 300 nm and angular tolerances of ±2.3 degrees (twist) and 0.4 degrees (tilt).

    Conclusions:

    • The proposed coupler is a viable enabling technology for high-performance, high-density co-packaged optical designs.
    • Demonstrated CMOS-compatible, out-of-plane optical connections suitable for scaling optical transceivers (TxRx).
    • The coupler's wide tolerances and low loss support practical implementation in future switch architectures.