Fast Ethernet Operation of a Printed Optical Transmission Path Using Industrial Integration Technologies

Printing optical waveguides is an approach to the high volume implementation of optical data transmission in conventional electronic systems. Flexographic printing enables the manufacturing of circular segment-shaped polymer waveguides on planar substrates, which show great potential as economic Gbit/s-capable short-range networks. This work describes a process chain to manufacture and integrate a printed optical data transmission path in conventional printed circuit boards (PCB). This sequence of processes gives an outlook on up-scaling utilizing printed optical waveguides to mass manufacturing. Since the significant challenge in integration is achieving sufficient optical coupling, geometrical tolerances are investigated using raytracing simulation. Relevant degrees of freedom of the laser diode and waveguide are varied and validated by measuring alignment profiles. As a result, the mechanical interface provided by the PCB is presented and validated by confocal measurements. An innovative pick and place tool assembles the separated flexible waveguide to realize a demonstration system. As a validation, Fast Ethernet data transmission is presented over a flexible optical connection. In further steps, a miniaturization of the system is the goal to achieve a standardized system for applications like galvanic isolation.