Unibody plastic injection-molded optical sub-assembly for large core fiber

The worldwide optoelectronics community has devoted a significant amount of time and energy in the pursuit of low-cost of optoelectronic data links. This is not surprising when one realizes that the optical subassemblies (OSA), comprising the OE device, lens, bores and stops, and the fiber optic cable account for well over half the cost of a link. A significant cost reduction can be realized by considering the use of large core fiber and the appropriate exploitation of its properties. For example, a 200/230 micron Step Index (SI) or Graded Index (GI) fiber significantly increases the requisite optical alignment tolerances in the optical subassembly to the point where components can be fabricated using high-volume plastic molding manufacturing techniques. In addition, the fiber is suited to a simple "crimp and cleave" termination. This paper reports on the demonstration of a low cost OSA for use in high bandwidth short distance simplex data links with 200/230 micron SI fiber. The OSA is a single molded plastic structure which integrates the functionality of a lens, an OE device receptacle, and fiber connector mating structure. Component assembly is thereby reduced to a single step operation: press fitting a laser packaged in a TO-can into the OSA body. Results have demonstrated repeatable coupling efficiencies of over 25% with no alignment and reliable 266 Mb/s data links over 100 meters. Gb/s data rates are obtainable on links up to 20 meters long.