Materials and Reliability of Optical Packages

The purpose of the project was to develop a knowledge and database system enabling materials selection for assembly of dimensionally stable optical and optoelectronic modules and to propose suitable approaches for modeling non-elastic deformation of polymers in optical modules.

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Idea Information

Background: 

The purpose of the project was to develop a knowledge and database system enabling materials selection for assembly of dimensionally stable optical and optoelectronic modules and to propose suitable approaches for modeling non-elastic deformation of polymers in optical modules.

Definition Information

Approach: 

The project will consist of three main components, (a) materials database generation as a function of cure (thermal or photochemical) (b) modeling of opto assemblies (c) alignment testing

(a) Materials database generation The main focus was on accurately measuring the viscoelastic properties of thin layers under realistic conditions. The data should be generated through interaction of materials suppliers, interested HDPUG member companies and/or selected university resources specializing in materials characterization. EFOS Inc has a program in this area and expressed interest in joining the project at no charge. Adhesive suppliers should be also actively involved and so far Dexte/Loctite would like to be involved. Agilent would also provide a list of other materials that may be impacted by higher assembly temperatures and should to be included in the characterization process.

(b) Modeling of opto assemblies. Modeling was done on specially designed test structures that are expected to clearly exhibit the above discussed phenomena which later will allow experimental verification of the results (program component (c)). Modeling can be done numerically (FEM) and/or, with structures simple enough, analytically. Nortel Networks at Harlow has already significant expertise in FEM modeling of optoelectronic assemblies in the elastic regime. They have also significant knowledge on relationship between mechanical misalignment and optical losses. This can be extended to the viscoelastic regime, based on assumed properties and/or the data generated from (a). Universal Consortium (Binghamton, NY) has expertise in viscoelastic modeling and expressed interest in joining the project, paid for by Nortel membership fees. There are also numerous university resources capable of this type of activity (such as Carleton University). The analytical modeling would greatly increase level of understanding of the system. Some HDPUG members (e.g. Lucent) have this type of capability but the system may be too complex for analytic modeling requiring a FEM approach.

(c) Alignment testing. This testing was necessary to verify and improve modeling results described above. It is important that in the design and production of the test vehicle the amount and distribution of applied adhesive is controlled as tightly as possible. Microjetting technology may be the appropriate tool to achieve this accuracy. As a possible resource for this type of activity Nortel UK (Harlow) identified Nottingham University (UK) where interferometry would be used to measure sub-micrometer displacements.

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