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A cost-effective optical sub-assembly (OSA) for high-speed optical interconnections using lens-integrated surface-emitting lasers (LISELs) is demonstrated. Two concepts of the OSA, one based on a direct-modulation (DM)-LISEL and the other based on a continuous-wave (CW)-LISEL for a silicon-photonics (SiP) platform, are proposed. The design parameters of the integrated lens that enable low fiber-coupling loss and the SiP platform are described. Coupling losses, as low as 4.9 dB for the single mode fiber and 4 dB for the SiP platform, were experimentally confirmed. Furthermore, theoretical and experimental evidence that demonstrates the OSA does not require an optical isolator (i.e., it is “isolator-free”) is presented. A DFB laser used for the LISEL had a low relative intensity noise (less than −140 dB/Hz), even with a back reflection of more than −20 dB. For non-Hermetic packaging, 500 h, 85°C/85% relative humidity storage tests experimentally demonstrated no degradation in the lasing characteristics.

Technologies for high-density integration of optical and electrical components are indispensable for next-generation optical transceivers whose capacity will exceed 400 Gbps. 3-D vertical integration technology with high optical coupling efficiency between a single mode fiber (SMF) array and lens-integrated surface emitting laser (LISEL) array using micro electro mechanical system (MEMS)-based movable micro-mirrors can meet this requirement. Light emitted from the LISEL is reflected at the micro-mirror and coupled to the SMF. Since the micro-mirror can steer the beam emitted from the LISEL to the SMF, the coupling efficiency that depends on the alignment accuracy between the LISEL and SMF is adjustable. After the alignment is completed, the position of the micro-mirror is fixed to keep high coupling efficiency. An optical sub-assembly (OSA) incorporating the LISEL, micro-mirror, and SMF array was fabricated using surface mount technology. All optical components were passively aligned, and the positions of micro-mirrors were adjusted to make a precise optical coupling to the SMFs as a post alignment. To confirm the effectiveness of this post-alignment system, the characteristics of the optical coupling to the SMF array were measured. It was found that the position of the reflected beam could be controlled to sub-micro-meter accuracy.

As a solution to provide a small-size and low-cost 100-Gb/s optical module, direct optical coupling between a lens-integrated surface-emitting DFB laser (LISEL) array and a single-mode fiber (SMF) array is demonstrated. A very-small far-field angle ( $\sim 2$ °) was obtained by monolithic integration of an InP lens with a laser chip. As a result, each channel of the LISEL array can directly couple to an SMF without any additional external optical components. The measured misalignment tolerance between the LISEL array and an SMF array was sufficiently large, namely, $\pm 5.5~\mu \text{m}$ , at excess loss of 1 dB over all four channels with the maximum coupling efficiency of 8.4 dB. These measurement results are in good agreement with a theoretical calculation based on Gaussian optics. These results demonstrate that high coupling efficiency (−3 dB) can be achieved while large misalignment tolerance ( $\pm 4.5~\mu \text{m}$ ) at excess loss of only 1 dB is maintained.

Technologies for creating cost-effective light-emission optical sub-assemblies (OSAs) are discussed from the point of view of laser diodes. A lens-integrated surface-emitting laser (LISEL), consisting of a DFB laser, integrated mirror, and integrated convex lens, has the potential to achieve light-emission OSAs. An OSA based on the LISEL is proposed, and the capabilities of direct and passively aligned optical coupling, isolator-free operation, non-hermetic packaging, and on-wafer testing are introduced.

A passive optical alignment based on a lens-integrated surface-emitting laser array and a single-mode fiber array was demonstrated. The proposed alignment technique enables better coupling efficiency than that of conventional DFB laser with active alignment.

Two multichannel 1.3-μ m lens integrated surface-emitting laser arrays for massive data links were fabricated. The basic structure of the lasers consists of a short InGaAlAs multiple-quantum-well distributed-feedback (DFB) active-stripe array monolithically integrated with both a 45° total reflection mirror and an aspheric collimation lens. One of them, a four-channel laser array based on this structure, exhibited clear 25-Gb/s eye openings up to 50°C over all four channels and achieved a total output of 100 Gb/s. The other laser, a multiple-wavelength array for wavelength-division-multiplexing applications, produces multiple-wavelength emission thanks to precisely modified DFB gratings by electron beam lithography. It exhibited nine-wavelength stable single-mode operation (side-mode suppression ratio >; 40 dB) between 1260 and 1290 nm at 3.7-nm intervals, and a clear 25-Gb/s eye opening for each wavelength. These two surface-emitting laser arrays have demonstrated their suitability for next-generation multichannel data links (including 100-Gb Ethernet and optical interconnects).

As a solution to provide small-footprint and low-cost light sources for silicon platforms, light sources using a lens-integrated surface-emitting laser (LISEL), and a grating coupler fabricated on a silicon-on-insulator substrate is proposed. Light emitted from the LISEL (based on an InP distributed feedback laser) has a narrow far-field pattern, so the LISEL can be directly mounted on the silicon platform with no additional external optical components. The alignment tolerance between the LISEL and grating coupler was experimentally measured. This measurement confirmed large alignment tolerance. The excess loss due to misalignment of ±5 μm is only 1.5 dB.

We proposed a perfectly facet-free surface-emitting 1.3-μm DFB laser toward cost-effective light source, and confirmed the same performances as the usual DFB lasers and an on-wafer measurement.

A simple and practical method for integrating a DFB laser and a silicon photonics platform without additional optical components such as lenses and an isolator is proposed. Optical-coupling and feedback-tolerance characteristics arc experimentally measured.

Low-cost optical assemblies for optical interconnections using lens-integrated surface-emitting laser are proposed. High coupling efficiency with single-mode-fibers of over −1.9dB and RIN below −140dB/Hz with large back reflection and 85°C/85% storage test are demonstrated.

A 103.2 (25.8 × 4)-Gb/s optical link using a 1.3-µm lens-integrated surface-emitting laser array was demonstrated. A power penalty after 2-km transmission was small (

40-Gb/s (4-ch x 10-Gb/s) operation of a 1.3-µm lens-integrated surface-emitting laser diode array was demonstrated by a CMOS shunt driver. Clearly opened eyes at 10-Gb/s were obtained for 4 channel simultaneous operation at 95°C.

40-Gb/s/ch direct modulation of multi-wavelength 1.3-μm surface-emitting laser array is demonstrated. Fabricated laser array consisting of four-channel DFB stripes with modified gratings, 45° mirror, and integrated lens, exhibited clear 40-Gb/s eye openings over all four channels.

Uncooled 25-Gb/s operation of a multi-wavelength 1.3-µm surface-emitting-laser array was demonstrated. This array–consisting of four distributed-feedback (DFB) active stripes, 45° mirrors and integrated lenses–exhibited 25-Gb/s operation up to 85°C over all channels.

Circular, narrow beam emission of a lens-integrated surface-emitting laser operated at 1.3-µm wavelength was demonstrated. The laser consists of a distributed feedback laser cavity monolithically integrated with an etched 45° total reflection mirror and an etched InP lens. The profile of the etched InP lens was estimated to be a highly symmetrical parabolic shape that is ideal for the collimation of a Gaussian beam. A fabricated lens-integrated surface-emitting laser exhibited a circular, narrow far-field pattern with full-width at half-maximums of 3.9° × 3.5°. A highly efficient direct coupling to a single-mode fiber with a coupling efficiency of − 2.7 dB was also confirmed.

A novel 1.3-µm surface-emitting laser integrated with a monolithic InP bulk lens was demonstrated. The laser achieved very narrow far-field angles of around 2° leading to a −2.7 dB direct coupling to a single-mode fiber.

Monolithically lens-integrated surface-emitting distributed-feedback (DFB) laser arrays and p–i–n photodiode arrays were developed. A combination of dry etching and wet chemical etching was used to fabricate a monolithic InP lens. The lens profile within ±10 µm from the lens center was estimated to be parabolic shape, which is ideal for the collimation of a Gaussian beam. A fabricated lens-integrated surface-emitting DFB laser exhibited a circular, narrow far-field pattern with full-width at half maximums of 3.9×3.5°. An efficient direct coupling of the lens-integrated DFB laser to a single-mode fiber with a coupling efficiency of -3 dB was confirmed. A four-channel lens-integrated surface-emitting laser array and a lens-integrated p–i–n photodiode array were used to fabricate a very compact 100 Gbps (25 Gbps × 4 channel) optical transceiver with 14×9 mm2 footprint.