Cost-effective integration of plastic optical fiber and total internal reflection mirrors in printed circuit boards for parallel optical interconnects

A novel method of integrating a total internal reflection (TIR) mirror into an optical waveguide embedded in a printed circuit board (PCB) was demonstrated for application in chip-to-chip optical interconnects. Plastic optical fiber (POF) was placed into channels that were mechanically machined into FR-4 composite plates. The TIR mirror was created by a second mechanical machining. The mirror loss was measured to be approximately −1.6 dB per reflection. The use of POF resulted in attenuation losses in the waveguide over an order of magnitude lower than what is obtainable with typical planar waveguides that are integrated into PCBs. Monte Carlo ray tracing was used to determine the theoretical efficiency of the system as well as cross talk between channels due to optical device alignment tolerances.

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