High-density active optical cable: from a new concept to a prototype

Evolution in high performance computing (HPC) leads to increasing demands on bandwidth, connectivity and flexibility. Active optical cables (AOC) are of special interest, combining the benefits of electrical connectors and optical transmission. Optimization and development of AOC solutions requires enhancements concerning different technology barriers. Area and volume occupied by connectors is of special interest within HPC networks. This led to the development of a 12x AOC for the mini-HT connector creating the densest AOC available. In order to integrate electrical optical conversion into a module not higher than 3 mm, a new concept of coupling fibers to VCSELs or photodiodes had to be developed. This unique concept is based on a direct replication process of an integrated fiber coupler consisting of a 90° light deflecting and focusing mirror, a fiber guiding structure, and a fiber funnel. The integrated fiber coupler is directly replicated on top of active components, reducing the distance between active components and fibers to a minimum, thus providing a highly efficient light coupling. As AOC prototype, multi-chipmodules (MCM) including the complete electrical to optical conversion for send and receive connected by two 12x fiber ribbons have been developed. The paper presents the integrated fiber coupling technique and also design and measurement data of the prototype.