Coextruded Dielectric Waveguide With Conductive Outer Layer
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Solution Overview
Problem
Traditional electrical cabling for high-speed interconnections in server systems is becoming expensive and power-hungry, while optical solutions are costly and power-intensive, necessitating a more efficient method for data transmission.
Innovation Solution
The use of waveguides with a conductive outer layer coextruded with a dielectric core, which allows for improved signal propagation and mechanical support, along with notches in the cross-section to accommodate bending, enabling tighter bending radii and reduced signal loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional electrical cabling is used for high-speed interconnections, then data transmission can be achieved, but power consumption increases and cost becomes expensive
Solution Approach 1:
The patent replaces traditional electrical signal transmission through copper cables with electromagnetic wave propagation through a waveguide structure. This substitution transitions from conventional electrical interconnection to a wave-based transmission medium, enabling higher data rates with lower power consumption by utilizing the waveguide's ability to transmit millimeter-wave signals efficiently over longer distances without the resistive losses inherent in electrical cables
Solution Approach 2:
The waveguide employs a composite structure consisting of a dielectric core material surrounded by a conductive outer layer. This composite construction combines the insulating properties of the dielectric with the electromagnetic shielding and signal confinement capabilities of the conductive layer, creating an optimized transmission medium that reduces signal loss and enables efficient high-speed data transmission with lower power requirements
2Speed
If optical fiber solutions are used for long-distance interconnect, then bandwidth is improved, but power consumption and cost increase severely
Solution Approach 1:
The patent substitutes optical fiber transmission with a metal waveguide-based electromagnetic wave transmission system. This replacement enables millimeter-wave signal propagation through the waveguide structure, achieving high bandwidth comparable to optical solutions but with significantly lower power consumption and cost, as the waveguide can transmit signals over long distances without the complex optical transceivers and power-hungry components required by fiber optic systems
Solution Approach 2:
The waveguide design utilizes millimeter-wave frequency parameters (30 GHz to 300 GHz) to achieve high bandwidth transmission. By operating in this frequency range and optimizing the waveguide dimensions and materials for this band, the system achieves optical-like bandwidth performance while consuming far less power, as the electromagnetic waves propagate efficiently through the waveguide structure without requiring optical conversion infrastructure
3Speed
If hollow metal waveguide is used, then signal propagation is achieved, but mechanical stability deteriorates due to buckling and kinking
Solution Approach 1:
The patent transforms the hollow metal waveguide into a composite structure with a dielectric core and conductive outer layer. The dielectric core provides mechanical strength and structural stability, preventing buckling and kinking, while the conductive outer layer maintains the electromagnetic wave propagation characteristics. This composite construction combines the mechanical advantages of solid structures with the electromagnetic performance of hollow waveguides
Solution Approach 2:
The waveguide structure assigns different functional properties to different regions: the inner dielectric core provides mechanical support and structural integrity, while the outer conductive layer provides electromagnetic shielding and signal confinement. This spatial differentiation of material properties optimizes both mechanical stability and signal propagation performance simultaneously
4Adaptability or versatility
If waveguide bending is required for physical connection, then adaptability is improved, but signal loss increases due to deformation
Solution Approach 1:
The patent employs a flexible waveguide design where the dielectric core and conductive outer layer are constructed with sufficient flexibility to allow bending and deformation without compromising structural integrity. The thin-walled construction and material selection enable the waveguide to be routed around corners and through tight spaces while maintaining signal propagation quality and minimizing insertion loss through controlled bending radii
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides efficient and cost-effective high-speed data transmission with reduced power consumption and latency, addressing the limitations of traditional electrical and optical interconnects.
Implementation Method 1
A waveguide can be used to propagate electromagnetic waves including electromagnetic waves having a wavelength in millimeters (mm) or micrometers (μm)
Implementation Method 2
coextruding an outer layer with the waveguide core, wherein the outer layer is arranged around the waveguide core
Data Source
AI summary
A method of making a waveguide, comprises: extruding a first dielectric material as a waveguide core of the waveguide, wherein the waveguide core is elongate; and coextruding an outer layer with the waveguide core, wherein the outer layer is arranged around the waveguide core.