Design Guidelines for Efficient Eutectic Soldering Onto Low Tg Polymeric Multimode Light Waveguides

In this work, we conduct a numerical investigation of the structural feasibility of a flexible, monolithic and planar opto-electronic system based on low Tg polymers using ANSYS™. In particular, we explore the effectiveness of two eutectic compounds 52w.%In 48w.%Sn and 58w.%Bi 42w.%Sn to solder light sources and sinks to multimode light waveguides. First, we analyze the warpage of the optical structures due to eutectic soldering. Furthermore, we study the spectrum of mechanical stresses within the eutectic layer. Then, we investigate the possibility of roll-to-roll mass production. Finally, we establish design guidelines for decreasing the system warpage, and consequently preserving optical alignment, while complying with the ultimate shear strength of the eutectic material.