Abstract:
A circuit module including at least one Application Specific Integrated Circuit (ASIC) and a plurality of Vertical Cavity Surface-Emitting Laser (VCSEL) array modules is built using a standard ceramic or organic VLSI package substrate, resulting is a high density device with a small footprint. Interconnection between the electronic devices and the VCSEL array modules is accomplished using standard integrated circuit packaging technology and flexible connectors. Optical connections from the VCSEL arrays to fiber optic cables are made possible by integrating industry-standard optical connectors onto the package. Optical receiver and transceiver modules may also be incorporated into the circuit module.

Description:
FIELD OF THE INVENTION 
     The present invention is related generally to the field of integrated circuit modules and more specifically to the field of integrated circuit modules including vertical cavity surface-emitting lasers. 
     BACKGROUND OF THE INVENTION 
     Vertical Cavity Surface Emitting Laser (VCSEL) arrays are often used in fiber optic communications. These VCSEL arrays are capable of transmitting large amounts of data over small optical fibers. A single ⅛ inch fiber bundle may carry an entire 12–20 bit logical port running at relatively high speeds. VCSEL arrays are constructed using semiconductor process techniques similar to those used in silicon integrated circuits, however, the process techniques used for VCSEL arrays may not be optimal for construction of high speed silicon integrated circuits. This makes it difficult to integrate VCSEL arrays and high speed circuits on the same silicon device. 
     Many current uses of VCSEL technology require precise performance specifications in order to transmit signals over long distances via optical fibers. However, in situations where only short distances are required, such as within a computer server or within a single data center, less stringent performance specifications are required of the VCSEL arrays. 
     Currently, some circuit boards include VCSEL array modules and receiver modules for communication between computers. Typically, these modules are placed along one edge of the board and electrically connected to one or more electronic devices attached to the board. These solutions work well, however as computer speeds continue to increase, the delay inherent in driving signals out of an electronic device, into a board, along a board electrical connector, and into a VCSEL array module becomes increasingly troublesome to engineers designing high-speed computers. 
     Further, board space may be very expensive and in short supply especially in devices such as desktop systems or blade servers. The footprint of separate VCSEL array modules and, if needed, their translator/terminator devices may become a substantial portion of total board area, thus increasing size and costs of the computer. 
     SUMMARY OF THE INVENTION 
     A circuit module including at least one Application Specific Integrated Circuit (ASIC) and a plurality of Vertical Cavity Surface-Emitting Laser (VCSEL) array modules is built using a standard ceramic or organic VLSI package substrate, resulting is a high density device with a small footprint. Interconnection between the electronic devices and the VCSEL array modules is accomplished using standard integrated circuit packaging technology and flexible connectors. Optical connections from the VCSEL arrays to fiber optic cables are made possible by integrating industry-standard optical connectors onto the package. Optical receiver and transceiver modules may also be incorporated into the circuit module. 
     Other aspects and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. 
         FIG. 2  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. 
         FIG. 3A  is a cross-sectional view of an example embodiment of a prior art circuit module connecting to an external VCSEL. 
         FIG. 3B  is a cross-sectional view of the external VCSEL shown in  FIG. 2A . 
         FIG. 4  is a top view of an example embodiment of a VLSI circuit module before attachment of a plurality of integrated VCSEL array modules according to the present invention. 
         FIG. 5A  is a cross-sectional view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. 
         FIG. 5B  is a cross-sectional view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. 
         FIG. 6  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. 
         FIG. 7  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. 
         FIG. 8  is a flowchart representing a method for the construction of a VLSI circuit module a plurality of including integrated VCSEL array modules according to the present invention. 
         FIG. 9  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. 
         FIG. 10  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. 
         FIG. 11  is a flowchart representing a method for the construction of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. A standard VLSI package substrate  100  constructed of a common package material, such as a ceramic or organic material, is shown in this example embodiment of the present invention with a single large application specific integrated circuit (ASIC)  102  attached to the substrate  100  underneath a standard heat spreader  114 . Another invention including integrated VCSELs is described in a U.S. patent application, Ser. No. 10/318,473. “Circuit Module Including Integrated VCSELs”, filed on Dec. 12, 2002, and incorporated herein by reference. Another invention including VCSELs on ASIC substrates is described in a U.S. patent application, Ser. No. 10/355,663, “Integrated VCSELs on ASIC Module Using Flexible Electrical Connections”, filed on Jan. 31, 2003, and incorporated herein by reference. The ASIC  102  may be any one of a number of integrated circuit devices, such as a microprocessor, memory, cross-bar, cache controller, FPGA, or any of a number of large scale integrated (LSI) or very large scale integrated (VLSI) circuits. Also present on the substrate are a quantity of VCSEL array modules  106 , receivers  108 , and transceivers  110 . Signal ports  112  connect the ASIC  102  to the VCSEL array modules  106 , receivers  108 , and the transceivers  110  through small flexible connectors  104 . The small flexible connectors  104  allow a 90-degree transition in signal direction in an electrical rather than an optical path resulting in less complexity and ease of manufacturing. Since the light beam from a VCSEL is emitted perpendicular to the surface of the VCSEL, when a VCSEL is attached to the flexible connector  104  which includes a 90-degree bend, the VCSEL itself is now perpendicular to the plane of the ASIC substrate  100  and the light from the VCSEL is emitted in a plane parallel to that of the ASIC substrate  100 . The plurality of signal lines connecting the ASIC  102  to the signal ports  112  within the substrate  100  are not shown in this figure for clarity reasons. In an example embodiment of the present invention the VCSEL array modules  106  may incorporate industry standard optical connectors into the module allowing optical connection from the VCSEL array modules  106  using industry standard connections. In this example embodiment of the present invention, the VCSEL circuit is perpendicular to the plane of the substrate  100  and the industry standard connectors are attached such that light is transmitted in a plane parallel to that of the substrate  100 . Note that this example embodiment shows a total of 16 VCSEL ray modules  106 , receivers  108  and transceivers  110 , Those of skill in the art will recognize that any number and any combination of VCSEL array modules  106 , receivers  108 , and transceivers  110  may be used within the scope of the present invention. 
       FIG. 2  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. The example embodiment of the present invention shown in  FIG. 2  is similar to that of  FIG. 1  with the exception that instead of a single ASIC  102  attached to a substrate  100 , a first ASIC  202 , a second ASIC  204 , a third ASIC  206 , and a fourth ASIC  208  are attached to the substrate  200 . Also,  FIG. 2  does not include a heat spreader so that the individual ASICs and their interconnections are visible. Signal ports  212  connect the ASICs  202 ,  204 ,  206 , and  208  to the VCSEL array modules  216 , receivers  218 , and the transceivers  220  through small flexible connectors  214 . The small flexible connectors  214  allow a 90-degree transition in signal direction in an electrical rather than an optical path resulting in less complexity and ease of manufacturing. The plurality of signal lines connecting the ASICs  202 ,  204 ,  206 , and  208  to the signal ports  212  within the substrate  200  are not shown in this figure for clarity reasons. In an example embodiment of the present invention the VCSEL array modules  216  may incorporate industry standard optical connectors into the module allowing optical connection from the VCSEL array modules  216  using industry standard connections. Similar to  FIG. 1 , in this example embodiment of the present invention, the VCSEL circuit is perpendicular to the plane of the substrate  200  and the industry standard connectors are attached such that light is transmitted in a plane parallel to that of the substrate  200 . Note that this example embodiment shows a total of 16 VCSEL array modules  216 , receivers  218  and transceivers  220 . Those of skill in the art will recognize that any number and any combination of VCSEL array modules  216 , receivers  218 , and transceivers  220  may be used within the scope of the present invention. Also present in this example embodiment of the present invention are a plurality of signal lines  210  electrically connecting the four ASICs  202 ,  204 ,  206 , and  208  to each other. 
       FIG. 3A  is a cross-sectional view of an example embodiment of a prior art circuit module connecting to an external VCSEL. An electronic device  306  is shown attached to a first package  302  through a C4 attach bump  308 . Within the first package  302 , a package trace  310  electrically connects the electronic device  306  to a first ball grid array (BGA) ball  312 . This first BGA ball  312  electrically connects the first package  302  to a board  300 . Within the board  300 , a first board via  314  electrically connects the BGA ball  312  to a board trace  316 , and through the board trace  316  to a second board via  318 . This second board via  318  is electrically coupled to a second BGA ball  320  attached to a second package  304  containing a VCSEL. 
       FIG. 3B  is a cross-sectional view of the external VCSEL shown in  FIG. 3A . Within the second package  304  a second package via  326  electrically couples the second BGA ball  320  to a package pad  328 , which is in turn electrically connected to a VCSEL  332  through a second package trace  330  and a flexible electrical conductor  334 . The VCSEL  332  is then optically coupled to an industry standard optical connector  322 . Note that in this example embodiment of a VCSEL module, the VCSEL  332  is configured perpendicular to the board  300 . Thus the light emitted from the VCSEL is in a plane parallel to the board  300  and the industry standard optical connector  322  is configured to route any optical conductors in a plane parallel to the board  300 . 
       FIG. 4  is a top view of an example embodiment of a VLSI circuit module substrate before attachment of a plurality of integrated VCSEL array modules according to the present invention. A standard VLSI circuit substrate  400  is shown including a cavity  402  and a plurality of signal ports  404 . Within the cavity  402  are a plurality of VLSI signal ports  406  that are electrically connected to the signal ports  404  through conductors within the substrate  400 . These conductors are not shown in this figure for clarity. 
       FIG. 5A  is a cross-sectional view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. A substrate  500  is shown including a cavity  506 . Those of skill in the art will recognize that alternate package and heat spreader arrangements without a cavity may be used within the scope of the present invention. Within the cavity  506  is an ASIC  504  electrically connected to VLSI signal ports  508  on the substrate  500 . A heat spreader  502  is thermally coupled to the ASIC and mechanically coupled to the substrate  500  sealing the cavity  506 . ASIC signal lines  512  run through the substrate  500  to standard package pads  510 . Those of skill in the art will recognize that these package pads  510  may be constructed in a wide variety of styles and configurations within the scope of the present invention. For example, the package may be a ball grid array (BGA) package and the package pads  510  would then comprise individual solder balls. VCSEL signal lines  514  run through the substrate  500  to VCSEL signal ports  516 . A VCSEL array  522  is electrically connected to the VCSEL signal ports  516 . Note that in this example embodiment of the present invention, the VCSEL array  522  is in a plane parallel to that of the substrate  500  and the light emitted from the VCSEL array  522  is in a plane perpendicular to that of the substrate  500 . 
       FIG. 5B  is a cross-sectional view of an example embodiment of a VLSI circuit module including an integrated VCSEL array module according to the present invention.  FIG. 5B  is identical to  FIG. 5A  with the exception that the VCSEL array is attached to the substrate  500  through a flexible connector  518  rather than directly. A substrate  500  is shown including a cavity  506 . Those of skill in the art will recognize that alternate package and heat spreader arrangements without a cavity may be used within the scope of the present invention. Within the cavity  506  is an ASIC  504  electrically connected to VLSI signal ports  508  on the substrate  500 . A heat spreader  502  is thermally coupled to the ASIC and mechanically coupled to the substrate  500  sealing the cavity  506 . ASIC signal lines  512  run through the substrate  500  to standard package pads  510 . Those of skill in the art will recognize that these package pads  510  may be constructed in a wide variety of styles and configurations within the scope of the present invention. For example, the package may be a ball grid array (BGA) package and the package pads  510  would then comprise individual solder balls. VCSEL signal lines  514  run through the substrate  500  from the ASIC  504  to VCSEL signal ports  516 . A VCSEL array  520  is electrically connected to the VCSEL signal ports  516  through a small flexible circuit board  518 . Since the light beam from a VCSEL is emitted perpendicular to the surface of the VCSEL, when a VCSEL is attached to the flexible circuit board  518  which includes a 90-degree bend, the VCSEL itself is now perpendicular to the plane of the substrate  500  and the light from the VCSEL is emitted in a plane parallel to that of the substrate  500 . The small flexible circuit board  518  contains electrical traces configured to connect the VCSEL array  520  to the VCSEL signal ports  516 . 
       FIG. 6  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. A standard VLSI package substrate  600  constructed of a common package material, such as a ceramic or organic material, is shown in this example embodiment of the present invention with a single large application specific integrated circuit (ASIC)  602  attached to the substrate  600  underneath a standard heat spreader  614 . The ASIC  602  may be any one of a number of integrated circuit devices, such as a microprocessor, memory, cross-bar, cache controller, FPGA, or any of a number of large scale integrated (LSI) or very large scale integrated (VLSI) circuits. Also present on the substrate are a quantity of VCSEL array modules  606 , receivers  608 , and transceivers  610 . Signal ports  604  connect the ASIC  602  to the VCSEL array modules  606 , receivers  608 , and the transceivers  610  through a single large flexible connector  612 . The plurality of signal lines connecting the ASIC  602  to the signal ports  604  within the substrate  600  are not shown in this figure for clarity reasons. In an example embodiment of the present invention the VCSEL array modules  606  may incorporate industry standard optical connectors into the module allowing optical connection from the VCSEL array modules  606  using industry standard connections. In this example embodiment of the present invention, the VCSEL circuit is perpendicular to the plane of the substrate  600  and the industry standard connectors are attached such that light is transmitted in a plane parallel to that of the substrate  600 . Note that this example embodiment shows a total of 16 VCSEL array modules  606 , receivers  608  and transceivers  610 . Those of skill in the art will recognize that any number and any combination of VCSEL array modules  606 , receivers  608 , and transceivers  610  may be used within the scope of the present invention. 
       FIG. 7  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention.  FIG. 7  is identical to  FIG. 6  with the exception that a plurality of terminators, translators, or other components are attached to the flexible connector. A standard VLSI package substrate  700  constructed of a common package material, such as a ceramic or organic material, is shown in this example embodiment of the present invention with a single large application specific integrated circuit (ASIC)  702  attached to the substrate  700  underneath a standard heat spreader  716 . The ASIC  702  may be any one of a number of integrated circuit devices, such as a microprocessor, memory, cross-bar, cache controller, FPGA, or any of a number of large scale integrated (LSI) or very large scale integrated (VLSI) circuits. Also present on the substrate are a quantity of VCSEL array modules  706 , receivers  708 , and transceivers  710 . Signal ports  704  connect the ASIC  702  to the VCSEL array modules  706 , receivers  708 , and the transceivers  710  through a single large flexible connector  714 . Also present on the large flexible connector  714  are a plurality of components  712  such as terminators or translators as needed between the ASIC  702  and the VCSEL array modules  706 . The plurality of signal lines connecting the ASIC  702  to the signal ports  704  within the substrate  700  are not shown in this figure for clarity reasons. In an example embodiment of the present invention the VCSEL array modules  706  may incorporate industry standard optical connectors into the module allowing optical connection from the VCSEL array modules  706  using industry standard connections. In this example embodiment of the present invention, the VCSEL circuit is perpendicular to the plane of the substrate  700  and the industry standard connectors are attached such that light is transmitted in a plane parallel to that of the substrate  700 . Note that this example embodiment shows a total of 16 VCSEL array modules  706 , receivers  708  and transceivers  710 . Those of skill in the art will recognize that any number and any combination of VCSEL array modules  706 , receivers  708 , and transceivers  710  may be used within the scope of the present invention. 
       FIG. 8  is a flowchart representing a method for the construction of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. In a step  800  a VLSI package substrate is provided. In a step  802  at least one ASIC is attached to the substrate. In a decision step  804  if VCSEL array modules are to be used, control is passed to step  806 , if not, control is passed to step  810 . In a step  806 , a plurality of VCSEL array modules are attached to a flexible connector. In a step  808 , the VCSEL array modules are electrically connected to the ASICs through the flexible connector. In a decision step  810  if VCSEL transceiver modules are to be used, control is passed to step  812 , if not, control is passed to step  816 . In a step  812  a plurality of VCSEL transceiver modules are attached to a flexible connector. In a step  814  the VCSEL transceiver modules are electrically connected to the ASICs through the flexible connector. In a decision step  816  if optical receiver modules are to be used, control is passed to step  818 , if not, control is passed to step  822 . In a step  818  a plurality of optical receiver modules are attached to a flexible connector. In a step  820  the optical receiver modules are electrically connected to the ASICs through the flexible connector. In a decision step  822  if a heat spreader is to be added to the module, control is passed to step  824 , if not, control is passed to the end step  826 . In a step  824  a heat spreader is mechanically attached to the substrate such that it is thermally coupled to at least one ASIC. Those of skill in the art will recognize that the steps in this method may be performed in a very wide variety of different orders within the scope of the present invention. 
       FIG. 9  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. A standard VLSI package substrate  900  constructed of a common package material, such as a ceramic or organic material, is shown in this example embodiment of the present invention with a single large application specific integrated circuit (ASIC)  902  attached to the substrate  900  underneath a standard heat spreader  904 . The ASIC  902  may be any one of a number of integrated circuit devices, such as a microprocessor, memory, cross-bar, cache controller, FPGA, or any of a number of large scale integrated (LSI) or very large scale integrated (VLSI) circuits. Also present on the substrate are a quantity of VCSEL array modules  906 , receivers  908 , and transceivers  910 . Note that in this example embodiment of the present invention the VCSEL array modules  906 , receivers  908 , and transceivers  910  are attached directly to the VLSI package substrate in a vertical configuration through a plurality of signal ports. The plurality of signal lines connecting the ASIC  902  to signal ports within the substrate  900  are not shown in this figure for clarity reasons. In an example embodiment of the present invention the VCSEL array modules  906  may incorporate industry standard optical connectors into the module allowing optical connection from the VCSEL array modules  906  using industry standard connections. In this example embodiment of the present invention the VCSEL array modules  906  are configured in a plane parallel to that of the substrate  900 . The light emitted from the VCSEL array modules  906  will be in a plane perpendicular to that of the substrate  900 , and any industry standard connections attached to the VCSEL arrays will be in a vertical configuration. Note that this example embodiment shows a total of 16 VCSEL array modules  906 , receivers  908  and transceivers  910 . Those of skill in the art will recognize that any number and any combination of VCSEL array modules  906 , receivers  908 , and transceivers  910  may be used within the scope of the present invention. 
       FIG. 10  is a top view of an example embodiment of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention.  FIG. 10  is identical to  FIG. 9  with the exception that the VCSEL array modules  1006 , receivers  1008 , and transceivers  1010  are attached to the substrate in a horizontal configuration. A standard VLSI package substrate  1000  constructed of a common package material, such as a ceramic or organic material, is shown in this example embodiment of the present invention with a single large application specific integrated circuit (ASIC)  1002  attached to the substrate  1000  underneath a standard heat spreader  1004 . The ASIC  1002  may be any one of a number of integrated circuit devices, such as a microprocessor, memory, cross-bar, cache controller, FPGA, or any of a number of large scale integrated (LSI) or very large scale integrated (VLSI) circuits. Also present on the substrate are a quantity of VCSEL array modules  1006 , receivers  1008 , and transceivers  1010 . Note that in this example embodiment of the present invention the VCSEL array modules  1006 , receivers  1008 , and transceivers  1010  are attached directly to the VLSI package substrate  1000  in a plane parallel to that of the substrate  1000  through a plurality of signal ports. The plurality of signal lines connecting the ASIC  1002  to signal ports within the substrate  1000  are not shown in this figure for clarity reasons. In an example embodiment of the present invention the VCSEL array modules  1006  may incorporate industry standard optical connectors into the module allowing optical connection from the VCSEL array modules  1006  using industry standard connections. The light emitted from the VCSEL array modules  1006  will be in a plane perpendicular to that of the substrate  1000 , and any industry standard connections attached to the VCSEL arrays will be in a vertical configuration. Note that this example embodiment shows a total of 16 VCSEL array modules  1006 , receivers  1008  and transceivers  1010 . Those of skill in the art will recognize that any number and any combination of VCSEL array modules  1006 , receivers  1008 , and transceivers  1010  may be used within the scope of the present invention. 
       FIG. 11  is a flowchart representing a method for the construction of a VLSI circuit module including a plurality of integrated VCSEL array modules according to the present invention. The method shown in  FIG. 11  is identical to the method shown in  FIG. 8  with the exception that the VCSEL modules are directly attached to the VLSI package substrate instead of being attached through a flexible connector. In a step  1100  a VLSI package substrate is provided. In a step  1102  at least one ASIC is attached to the VLSI package substrate. In a decision step  1104  if VCSEL array modules are to be used, control is passed to step  1106 , if not, control is passed to step  1110 . In a step  1106 , a plurality of VCSEL array modules are attached to the VLSI package substrate. In a step  1108 , the VCSEL array modules are electrically connected to the ASICs through the VLSI package substrate. In a decision step  1110  if VCSEL transceiver modules are to be used, control is passed to step  1112 , if not, control is passed to step  1116 . In a step  1112  a plurality of VCSEL transceiver modules are attached to the VLSI package substrate. In a step  1114  the VCSEL transceiver modules are electrically connected to the ASICs through the VLSI package substrate. In a decision step  1116  if optical receiver modules are to be used, control is passed to step  1118 , if not, control is passed to step  1122 . In a step  1118  a plurality of optical receiver modules are attached to the VLSI package substrate. In a step  1120  the optical receiver modules are electrically connected to the ASICs through the VLSI package substrate. In a decision step  1122  if a heat spreader is to be added to the module, control is passed to step  1124 , if not, control is passed to the end step  1126 . In a step  1124  a heat spreader is mechanically attached to the substrate such that it is thermally coupled to at least one ASIC. Those of skill in the art will recognize that the steps in this method may be performed in a very wide variety of different orders within the scope of the present invention. 
     The foregoing description of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and other modifications and variations may be possible in light of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the appended claims be construed to include other alternative embodiments of the invention except insofar as limited by the prior art.