Optical Coupling Structure With Lens Alignment for Low-Loss Packaging

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Solution Overview

Problem

Existing solutions using copper interconnects fail to meet low insertion loss, low latency, and low power consumption requirements while providing increased bandwidth and data rate for high bandwidth networking and high performance computing applications.

Innovation Solution

An optical coupling structure is integrated into an optical engine to facilitate optical signal transmission between optical fibers and optical components, allowing for improved alignment and flexible package design, which includes a separate structure for optical coupling that enhances alignment and reduces optical coupling loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If copper interconnects are used for signal transmission, then device complexity is reduced and ease of manufacture is improved, but insertion loss increases, latency increases, and power consumption increases while bandwidth and data rate requirements cannot be met

Engineering Contradiction:

Improveease of manufactureVSAvoidinsertion loss

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent substitutes electrical signal transmission through copper interconnects with optical signal transmission through waveguides. This replacement eliminates the limitations of copper interconnects regarding insertion loss, latency, and power consumption while enabling high bandwidth networking and high performance computing applications. The optical engine converts electrical signals to optical signals for transmission through the waveguide coupling structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If copper interconnects are used for signal transmission, then device complexity is reduced, but bandwidth and data rate requirements cannot be met

Engineering Contradiction:

Improvedevice complexityVSAvoidbandwidth

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent replaces copper interconnect-based electrical signaling with optical signaling through waveguides. This substitution enables significantly higher bandwidth and data rates required for high bandwidth networking and high performance computing applications, while the modular optical engine design keeps the overall device complexity manageable.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If copper interconnects are used for signal transmission, then ease of manufacture is improved, but latency increases

Engineering Contradiction:

Improveease of manufactureVSAvoidlatency

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent substitutes electrical signal propagation through copper interconnects with optical signal propagation through waveguides. Optical signals travel at higher speeds and experience less delay, thereby reducing latency while meeting the requirements for high performance computing and high bandwidth networking applications.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If copper interconnects are used for signal transmission, then ease of manufacture is improved, but power consumption increases

Engineering Contradiction:

Improveease of manufactureVSAvoidpower consumption

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent replaces electrical signal transmission through copper interconnects with optical signal transmission through waveguides. Optical transmission consumes less power compared to electrical transmission over long distances, thereby reducing power consumption while enabling high bandwidth networking and high performance computing applications.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The optical coupling structure improves signal transmission efficiency by reducing optical coupling loss and enabling flexible package design, meeting the requirements of high bandwidth and low latency while maintaining low power consumption.

Implementation Method 1

a grating coupler optically coupled to the waveguide

Methodology Applied

Scientific EffectGrating coupling: Diffraction Grating

Implementation Method 2

The optical coupling structure includes a lens optically aligned to the grating coupler

Methodology Applied

Scientific EffectOptical focusing: Lens

Data Source

PatentUS20250347868A1Optical coupling structure for semiconductor device

Publication Date: 2025.11.13 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD

AI summary

A package includes a routing structure including a first waveguide and a photonic device; an electronic die bonded to the routing structure, wherein the electronic die is electrically connected to the photonic device; and an optical coupling structure bonded to the routing structure adjacent the electronic die, wherein the optical coupling structure includes a first lens in a first side of a substrate.