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Copyright 2009 Year IEEE. Reprinted from IEEE TRANSACTIONS ON COMPONENTS
AND PACKAGING TECHNOLOGIES. Such permission of the IEEE does not in any way imply
IEEE endorsement of any of Institute of Microelectronics products or services. Internal ofpersonal use of this material is permitted. However, permission to reprint/republish this
material for advertising or promotional purposes or for creating new collective works forresale or redistribution must be obtained from the IEEE by writing to pubs-
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IEEE TRANSACTIONS ON COMPONENTS AND PACKAGING TECHNOLOGIES, VOL. 32, NO. 3, SEPTEMBER 2009 593
Optical Coupling Methods for Cost-EffectivePolymer Optical Fiber Communication
Jayakrishnan Chandrappan, Member, IEEE, Zhang Jing, Ramkumar Veppathur Mohan, Philbert Oliver Gomez,Than Aye Aung, Xiao Yongfei, Pamidighantam V. Ramana, John H. Lau, Fellow, IEEE, and
Dim Lee Kwong, Fellow, IEEE
AbstractIn this paper, we report cost-effective light couplingmethods for polymer optical fiber (POF) communication. Here, wecompare the various optical coupling schemes in detail. By opticalsimulations, we analyze the conventional light coupling schemes,namely the direct coupling, lens coupling, and lensed fiber cou-pling. The simulation studies reveal that a lensed fiber tip partic-ularly at the receiver side improves the light coupling efficiency toa great extent. The optimized lensed POF design confers an 85%coupling efficiency. Lensed POFs are realized with two low-costfabrication methods. The characterization of the lensed POF arecarried out to evaluate the lensing properties and hence to opti-mize the fabrication process.
Index TermsCharacterization, detector, fabrication, lensedfiber, optical coupling, polymer optical fiber, simulation.
I. INTRODUCTION
IN the recent past, polymer optical fibers POFs found
exciting applications as a low-cost alternative in home
network, automotive, and short reach applications [1], [2].
The lower connection costs and other low cost factors made
large-core multimode POFs attractive over single-mode fibers
for short-distance communications [4]. POFs are large-coremultimode optical fibers with very high numerical apertures.
They have the advantages of optical fibers while maintaining
the flexibility of copper cables in installation [3]. The major
challenges for POF networks are low-cost components, their
packaging, and the interfacing with the existing networks [5].
At present, both light emitting diodes (LEDs) and vertical
cavity surface emitting lasers (VCSEL) are being used as the
light source. They give the cost advantage over laser diode as
Manuscript received March 19, 2008; revised August 25, 2008 and October08, 2008. First published March 16, 2009; current version published August26, 2009. This work was supported by the Science and Engineering Research
Council (SERC) of Agency for Science, Technology, and Research (A*STAR),Singapore. This work was recommended for publication by Associate Editor F.Shi upon evaluation of the reviewers comments.
J. Chandrappan, Z. Jing, P. V. Ramana, J. H, Lau, and D. L. Kwong arewith the Institute of Microelectronics, A*STAR, Singapore 117685 (e-mail:
[email protected]).R. V. Mohanis with theDepartment of Electrical andComputer Engineering,
National University of Singapore, Singapore 119077.P. O. Gomez is with the School of Electrical and Electronics Engineering,
Nanyang Technological University, Singapore 639798.T. A. Aung is with the School of Engineering, Ngee Ann Polytechnic, Sin-
gapore S599489.X. Yongfei is with the School of Electrical Engineering, National University
of Singapore, Singapore 119077.Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TCAPT.2008.2011559
the light source. Availability of high speed, high-performance
VCSELs, and resonant cavity LEDs (RCLED) at a reasonable
cost keep POF networks attractive for gigabit applications.
Since POFs have a large core diameter, the coupling with the
transmitter does not raise any serious light coupling issues.
However, the large core diameters always results in severe
power coupling losses at the receiver side. This in turn re-
duces the maximum communication link distance achievable.
Realization of additional coupling elements brings in process
complexities at an added cost. All these factors necessitate acost effective coupling method along with ease of installation,
fiber plug-in modules, to keep POFs attractive in the market [6].
II. COUPLING METHODS
The conventional connector-less transceiver packages for
POF communication use an aspherical lens or ball lens as an
additional coupling element between the light source and POF
or POF and detector [7]. The drawbacks of an external passive
coupling element like a ball lens or an aspherical lens is that
it requires additional structures in the package to house the
coupling elements. Again, the integration of these componentsrequires precision assembly which comes at an additional cost
of manpower and time. Moreover, it becomes necessary to
study the alignment requirements of the stand-alone optical
coupling elements at the transmitter and receiver side in great
detail. Hence, the total cost of the system will be increased by
the cost of additional coupling components, the cost necessary
to model and fabricate the substrate to assemble these com-
ponents. At the receiver side of the POF, coupling takes place
from a large core diameter to a small area photo detector. If
precision subassemblies and precise component placements are
not employed, optical coupling with an external element at this
point becomes a tedious task.
Plastic fiber with a lensed tip is a cost-effective couplingmethod for coupling light from the transmitter to the POF and
from POF to the receiver [8], [9]. In this coupling scheme, the
hemispherical lens fabricated at the tip of the fiber makes the
system simple and efficient [10]. This eliminates precision sub-
assembly and alignment, thereby lowering the manufacturing
cost. In addition to this, it is seen that reflections and scattering
are greatly reduced at transition surfaces in this hemispherical
model since the lens and the fiber are of precisely the same
material. Since POF has a large core radius, the hemispherical
addendum will also have greater dimensions which will help to
collect and focus light effectively at the ease of manufactura-
bility. Besides, the device will be more mechanically stable and
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594 IEEE TRANSACTIONS ON COMPONENTS AND PACKAGING TECHNOLOGIES, VOL. 32, NO. 3, SEPTEMBER 2009
Fig. 1. Direct coupling of POF with source and detector.
less prone to shock and vibrations as external components are
minimized.
The conventional lensed fiber fabrication methods include
fiber grinding, wet etching, hot melting, etc. [11][13]. Since
the core diameter of the plastic fiber is very high compared to
its counterparts, it is easier to fabricate the hemispherical lenses
at the tip. The manufacturing cost is lower since the fabrication
is simple and does not require highly sophisticated equipment.
This also gives the freedom to re-engineer the lens formed as
and when it is required. The fabrication methods adopted are
discussed in detail in the following sections.
III. POF MODELING, SIMULATION, AND ANALYSIS
Geometrical image analysis in ZEMAX software is an effec-
tive tool for computing the multimode fiber coupling efficiency.
This analysis can generate the irradiance at any surface from an
extended source with specific size and shape at the object sur-
face. We have simulated the parameters of MH4001 Esaka fiber
from Mitsubishi Rayon. The POF we modeled has a core diam-
eter of 980 m, cladding diameter of 1000 m, and numerical
aperture of 0.3. The core material is poly methyl methacrylate
(PMMA) with an index of refraction 1.49. Simulations are done
for direct coupling, fiber bends, light coupling with an external
lens, and lensed fiber.The direct coupling model, as shown in Fig. 1, involves a light
source of 850-nm wavelength coupled to the input end of bare
POF with flat ends, and the output of fiber is coupled to a de-
tector of 50- m radius. The simulations show a coupling effi-
ciency of only 9.38%, which reflects the need for an additional
coupling optics for the fiber. At this juncture, the two possible
ways of improving the coupling efficiency is to use either an ex-
ternal discrete lens attached to the fiber or by making lens at the
tip of the fiber.
To enhance the coupling efficiency, we amended the model
by placing an external spherical ball lens between POF and de-
tector. Since the diameter of the POF is large, a large ball lens
is required for better light coupling to the detector, but as thesize of the coupling lens increases the package dimensions also
becomes larger. Various dimensions of ball lenses are evaluated
and a tradeoff between the package size and coupling efficien-
cies are arrived at. Based on these studies, an optimum value
of 2-mm radius lens is simulated and it yielded a power output
coupling efficiency of 37.45%. Fig. 2 shows that a discrete large
ball lens would achieve good coupling efficiency in comparison
to the bare fiber, but this coupling scheme will increase the di-
mensions of the transceiver module since the ball lens radius is
large compared to the dimensions of the fiber, which is undesir-
able.
On the other hand, a discrete ball lens of radius 0.48 mm, as
shown in Fig. 3, would be a better fit since it will not increase
the housing size required to hold the fiber-lens system. How-ever, the difficulty is that the lenses of small radii have a shorter
focal distance. A small radius lens can focus the beam to a nearer
point at the expense of power output, while a large radius lens
will focus at a longer distance from the lens, but maintain the
power output to a high value. This can be observed with the fall
in power to 18.81% in comparison to the larger lens radius cou-
pling efficiency of 37.45%. Furthermore, using an aspherical
lens to improve the coupling efficiency instead of a large ball
lens, it becomes necessary to concentrate on the alignment and
orientation of the lens in the module, which would require ad-
ditional cost and effort, for the sake of increasing power output.
The following analysis discusses the proposed coupling
method, namely the hemispherical structures integrated to both
side of the fiber, as shown in Fig. 4. Here, a plastic fiber of 0.49
mm radius is modeled with hemispherical ball lenses attached
to both end of the fiber. The refractive indices of the fiber
core and the hemispheres are made identical. Simulations are
carried out to optimize the distance between the lensed fiber
and detector, which would maximize the power output. The
beam focusing distance from the lens at the receiver side is
found to be 0.7 mm. A dummy surface with a circular aperture
of 50- m radius is inserted just before the image surface to
simulate the power incident on the surface of the photo detector
of radius 50 m.
The simulations yielded a higher power coupling efficiencyof 85%. The power is concentrated in the 20- m radius, and
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CHANDRAPPAN et al.: OPTICAL COUPLING METHODS FOR COST-EFFECTIVE POLYMER OPTICAL FIBER COMMUNICATION 595
Fig. 2. POF coupling using an external ball lens of radius 2 mm.
Fig. 3. POF coupling using an external ball lens of radius 0.48 mm.
Fig. 4. POF coupling using hemispherical lenses formed at the tip.
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596 IEEE TRANSACTIONS ON COMPONENTS AND PACKAGING TECHNOLOGIES, VOL. 32, NO. 3, SEPTEMBER 2009
Fig. 5. Coupled power versus radius for hemispherical lensed fiber.
hence shifting of the fiber by 20 m on either side of the de-
tector will not affect the coupling efficiency of the system. Sincethe POF diameter is inherently large, the hemispheres radius is
also large, thereby improving the spatial resolution of the image.
Besides this, the whole system is spherically symmetric. This
eliminates the need for orientation, unlike in the case of an as-
pherical lens.
An optimization algorithm is run for optimizing the radius of
curvature of the lens. The radius of the integrated hemispherical
lens is varied from 0.40 to 0.55 mm, to identify the optimum
radius of the lens for the maximum output power coupling. A
graph plotted with radius of lens curvature versus coupled power
is shown in Fig. 5.
The results shown here reveal that the best case scenario formaximizing the power output is when the radius of the half lens
at both ends is equal to the radius of the fiber. On either side of
the radius, the output power drops sharply.
In the second optimization step, we analyzed whether the
power output can be improved with a change in the refractive
index of the hemispherical lens. It is observed that when the
hemispherical lens is of the same material as that of the fiber,
output power coupling is 85.445%. By increasing the refractive
index 20% higher than that of the fiber, the power output can be
increased to 88.67%.
IV. FABRICATION METHODS
Various methods have been reported in the literature for the
fabrication of light coupling elements for POFs [14]. We have
selected two fabrication methods based on the ease of fabrica-
tion and lower manufacturing cost.
The first method involves formation of the lens at the fiber
edge by pressing the end face on a hot lens forming mold. The
second method involves dipping the polished fiber tip in an op-
tically transparent organic liquid [15]. The process of fabrica-
tion of a lens by hot melting method onto a fiber of plastic or
glass origins would include the mechanical process of injection
molding or compression [16]. The physical property of either a
PMMA or perfluorinated polymer fiber and their lower fabrica-
tion temperatures have made the fabrication of lenses onto thefiber much easier. PMMA material is less dense with density
Fig. 6. Steel cylinder with mechanical mold.
Fig. 7. Lensed tip POF with unpolished edges.
range from 11501190 kg/m . This is less than half the den-sity of glass which ranges 2400 to 2800 kg/m . More impor-
tantly, PMMA has higher impact strength than glass and does
not shatter but instead breaks into large, dull pieces.
The hot plate method requires melting the fiber tip at its ma-
terial melting point temperature and molding it with suitable
cavity to form thelens. Based on the simulation results, we fabri-
cated a die in steel material by precisely machining the required
geometries, as shown in Fig. 6. Apart from this, the setup re-
quires a hot plate to heat the mold and an arrangement to hold the
POF vertically to the cavity. This simple fabrication setup and
highly repeatable process makes the fabrication method cheap
and attractive.The steel mold is heated to the required temperature initially.
The temperature of the mold is cross checked with the help of a
thermocouple to reaffirm the required temperature level. Once
the temperature reaches an approximate levelof 150 C160 C,
the fiber is lowered towards the mold and allowed to take the
shape of the mold. The fiber is subsequently allowed to cool to
normal room temperature for 34 min. The fiber under micro-
scopic view clearly shows the formation of a lens at the fiber tip,
as shown in Fig. 7.
However, due to the small geometry of the mold cavity and
the large diameter of the POF, the POF comes in contact not
only with the semispherical cavity of the mold but also with the
entire top surface of the steel structure. This makes the edgesof the POF melt outwards, and it requires additional polishing.
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CHANDRAPPAN et al.: OPTICAL COUPLING METHODS FOR COST-EFFECTIVE POLYMER OPTICAL FIBER COMMUNICATION 597
Fig. 8. Lensed tip POF with polished edges.
Fig. 9. Hemispherical lens formed by polymer dipping.
Fig. 10. From flat polished POF.
Fig. 8 shows the fiber tip after polishing. Another phenomenon
of the plastics behavior towards the heating and cooling processis the shrinkage of the fiber. Due to the lack of a surmountable
pressure on the POF, the fiber warps and shrinks, this prevents
the fiber in assuming the exact shape of the mold.
The second method describes a way of forming a spherical
convex contour at the tip of POF by immersing the fiber in an
optically transparent organic liquid and bonding this properly to
the end face soon after the optical fiber is lifted from the liquid.
The refractive index of the polymer material is matched to the
refractive index of the POF core. In this process, the fiber tip is
polished initially by mechanical polishing. Once the polishing
is done, the fiber ends are cleaned and dipped to the polymer
liquid. Now the fiber is taken out from the liquid and allowed
to form the lens shape under surface tension. The shape of thelens depends on the viscosity of the liquid and the time given to
settle down. Once the required shape is reached, the fiber tip is
irradiated with UV light to make a proper adhesion. Many ex-
periments have been carried out to optimize the required profile
by using various viscous liquids and variable time for settling.
The lens formed is as shown in the Fig. 9.
V. RESULTS AND DISCUSSIONS
The lenses formed by various methods are being character-
ized to evaluate its performance. The evaluation is done based
on their effectiveness to converge the large spot size of POF
output to a considerably smaller spot size and hence to improve
the coupling efficiency. Initially, the POF with lensed tip is illu-
minated with the light at the 850-nm wavelength. The distance
from the beam profiler is adjusted in such a way that the output
beam spot is reduced to the minimum size possible. Now the
lensed POF is replaced with a flat polished POF, and the output
spot is captured at the same distance using beam profiler. The
output spot size profile for a flat polished POF and lensed POF
formed by polymer dip method are as shown in Figs. 10 and 11.
The captured spot sizes at 1.6-mm distance from the profiler
are compared, and it clearly shows a reduction in the spot size of
the order of one-fourth of the original dimension. The coupling
efficiency has improved by 27% with the lensed fiber fabricated.
The experimental result shows that there is a major varia-
tion from the output spot size predicted by simulation. The light
beam is not converging to the smaller dimension, and hence the
coupling efficiency is much below the expected value. As per
our understanding, the minor variations in the lens parameters
cannot be responsible for such a larger deviation in the coupling
efficiency.
Closely analyzing the results, it is realized that the initial sim-ulations are done assuming that the fiber is straight, an ideal
state. It did not include any fiber bends, but in the real case,
the fiber has random bends. In addition, the lens structure at the
input side generates a restricted mode launch situation under
center launch conditions. Due to these factors, straight fiber
status and restricted mode launch conditions, light is confined
to the lower order modes lying at the center of the core which
results in a lower divergence beam exit [17]. Under the random
bends, all possible fiber modes are excited, and this leads to
larger divergence and hence a larger beam size at the exit.
In order to verify this fact, we modeled the same lens under
bend fiber conditions. This resulted in a lower coupling effi-
ciency of 34%, which very agrees well with the experimental
results under the fabrication limitations.
The lenses fabricated with the hot melting method did not
show a better convergence, as the lens curvatures could not be
controlled since the whole fiber tip was getting deformed during
the fabrication process. A new mold with wider aperture is being
considered to avoid these problems. Another concern is that, if
the molded portions are not allowed to cool down properly, in-
stead of a perfect smooth spherical surface, a lot of fiber hairs
will be formed. This reduces the lensing effect and further pol-
ishing is required to make the surface perfect. In this case, the
polymer dip method seems to be much better for the fabrica-
tion of lensed POFs. The variables for optimization vary withthe liquid properties and the final lens shape to be fabricated.
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598 IEEE TRANSACTIONS ON COMPONENTS AND PACKAGING TECHNOLOGIES, VOL. 32, NO. 3, SEPTEMBER 2009
Fig. 11. From the lensed tip.
VI. CONCLUSION
We have analyzed various cost-effective coupling methodsfor POF communication by optical simulations. The simulations
showed an improved light coupling efficiency with the lensed
POF. The lensedtips arerealized using hot blowing and polymer
dip fabrication techniques. The experimental evaluation of op-
timized lens structures resulted in an improved coupling effi-
ciency of 27%. It is also eminent that the fiber bends play an
important role in deciding the actual divergence of the beam at
the exit end. The variation of light coupling efficiency from the
simulation results are attributed to the higher order mode excita-
tion and divergence associated with the fiber bends. Therefore,
it is advised to take care of this fact while designing the coupling
optics. Comparing the two fabrication methods, the polymer dipmethod is preferred over the hot blowing technique. Another
added advantage of this method is that it can be used to fabri-
cate lenses of any refractive index.
In general, the use of lensed POF improves the coupling ef-
ficiency, reduces assembly costs, and also helps to maintain the
package dimensions to minimum. They also offer ease of instal-
lation and altogether become a cost-effective solution for POF
communications
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Jayakrishnan Chandrappan (M07) received theM.Tech. degree in optoelectronics and laser tech-nology from the International School of Photonics,
Cochin University of Science and Technology,Cochin, India, in 1999 and the M.Sc degree inphysics from Cochin University of Science andTechnology in 1997.
He has been with the Micro Module Components(MMC) Laboratory, Institute of Microelectronics(IME), Singapore, since January 2007. Prior to that,he was with SAMEER, R&D Lab, Government of
India, Indian Institute of Technology (I.I.T), Mumbai.
Zhang Jing, photograph and biography not available at the time of publication.
Ramkumar Veppathur Mohan completed sixmonth internship during his undergraduate studies atthe Institute of Microelectronics in 20072008.
He graduated with Honors in Bachelor of Elec-trical Engineering from the National University ofSingapore in 2008 with Optoelectronics Specializa-tion. He is currently employed with Credit Suisse.
Philbert Oliver Gomez graduated in 2008 from School of Electrical and Elec-tronics Engineering, Nanyang Technological University, Singapore.
He completed a six-month internship during his undergraduate studies at theInstitute of Microelectronics in 20072008. Currently, he is working with Eco-nomic Development Board, Government of Singapore.
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CHANDRAPPAN et al.: OPTICAL COUPLING METHODS FOR COST-EFFECTIVE POLYMER OPTICAL FIBER COMMUNICATION 599
Than Aye Aung, photograph and biography not available at the time ofpublication.
Xiao Yongfei, photograph and biography not available at the time ofpublication.
Pamidighantam V. Ramana, photograph and biography not available at thetime of publication.
John H. Lau (F94) received three M.S. degreesin structural engineering, engineering physics, andmanagement science and the Ph.D. degree in theo-retical and applied mechanics from the University ofIllinois, Urbana Champaign.
He has been the Director of the MMC Laboratoryof the Institute of Microelectronics (IME), A*STAR,Singapore, since January 2007, and prior to that hewas with HP and Agilent. With more than 30 years of
R&D and manufacturing experience, he has authoredor coauthored more than 300 peer-reviewedtechnical
publications and more than 100 book chapters, and given more than 250 presen-tations. He has authored and coauthored 16 textbooks on advanced packagingsolder joint reliability and lead-free soldering and manufacturing.
He is an elected ASME Fellow.
Dim Lee Kwong (F09) is the Executive Directorof Institute of Microelectronics (IME), Agencyfor Science, Technology and Research (A*STAR),Singapore, a Professor of Electrical and ComputerEngineering at National University of Singapore,an Adjunct Professor of Electrical and ComputerEngineering at the University of Texas at Austin,and Distinguished Scientist at Republic Polytechnic,
Singapore. He was Earl N. and Margaret BransfieldEndowed Professor at The University of Texasat Austin from 1990 to 2007, and the Temasek
Professor of the National University of Singapore from 2001 to 2004. Heis the author of more than 900 referred archival publications (500 journaland 400 conference proceedings), has presented more than 70 invited talksat international conferences, and has been awarded with more than 23 U.S.patents. He has been a consultant to government research labs, semiconductorIC manufacturers, and materials and equipment suppliers in U.S. and overseas.More than 55 students received their Ph.D. degrees under his supervision. Hisareas of current research interest include CMOS-compatible Si/Ge nanowiredevices and circuits for future CMOS technology and applications, siliconelectronicphotonic integrated circuit technology and applications, Si-basedbiosensors and integrated lab-on-chip, and sensors, actuators, and integratedmicrosystems.
Prof. Kwong received the IBM Faculty Award in 1984 to 1986, the Semi-conductor Research Corporation (SRC) Inventor Award in 1993 and 1994, the
General Motors Foundation Fellowship in 1992 to 1995, the Halliburton Foun-dation Excellent Teaching Award in 1994, the Engineering Foundation Awardin 1995, and IEEE George Smith Award in 2007.