Reconfigurable Optical Interconnects for Dense PIC Waveguide Routing

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Solution Overview

Problem

Existing optical systems face challenges in scaling up multichannel wavelength division multiplexing systems due to limitations in cladding layer diameters and the difficulty in densely scaling up one-to-one optical fiber-to-waveguide connections, which consume significant spatiotemporal resources and interfere with high-speed interconnects.

Innovation Solution

Implementing reconfigurable optical interconnects with tunable components and fixed components, including optical switches like Mach-Zehnder interferometers and ring-assisted interferometers, along with multiplexers and waveguides, to enable flexible routing of optical signals to photonic integrated circuits (PICs) via evanescent coupling, using multi-core single-mode fibers and advanced waveguide routing solutions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If one-to-one optical fiber-to-waveguide connections are used, then optical signals can be transmitted to PICs, but the connections consume significant spatiotemporal resources and interfere with high-speed interconnects

Engineering Contradiction:
Improveoptical signal transmissionVSAvoidspatiotemporal resources consumption
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent segments the optical connection system by separating the fiber-to-waveguide connection function from the high-speed interconnect function. The waveguide routing infrastructure is divided into dedicated paths for optical signals and high-speed data paths, allowing both functions to operate simultaneously without interference. This segmentation enables the optical interconnect to handle wavelength division multiplexing while maintaining high-speed communication capabilities.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent introduces waveguide routing solutions as an intermediary structure between the optical fibers and the PICs. This intermediary infrastructure provides a dedicated pathway that mediates the connection between external optical fibers and the PICs, isolating the high-speed interconnect traffic from the optical signal transmission. The waveguide routing acts as a buffer that prevents direct interference between the two signal types.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If cladding layer diameters are increased, then optical signals can be transmitted, but the system cannot scale up densely

Engineering Contradiction:
Improveoptical signal transmissionVSAvoidscaling capability
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent transitions from planar, two-dimensional fiber-to-waveguide connections to three-dimensional waveguide routing solutions. By utilizing vertical stacking and multi-layer waveguide structures, the system achieves dense scaling in the vertical dimension while maintaining optical signal transmission quality. This dimensional transition allows multiple optical channels to be packed more efficiently without increasing the horizontal footprint or requiring larger cladding layer diameters.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent implements nested waveguide structures where smaller waveguides are integrated within larger waveguide paths, and multiple optical channels are nested within a compact three-dimensional space. This nesting approach allows dense packing of optical components while maintaining the necessary optical transmission pathways, enabling scaling without proportionally increasing cladding layer diameters.

Inventive Principle:
Principle #7Nested doll (Nesting)

3Ease of operation

If evanescent coupling is used for waveguide routing, then optical signals can be transmitted, but evanescent wave decay occurs

Engineering Contradiction:
Improvewaveguide routing flexibilityVSAvoidevanescent wave decay
Core Design Contradiction:
Ease of operationVSLoss of energy

Solution Approach 1:

The patent optimizes the coupling parameters between waveguides to minimize evanescent wave decay. By carefully adjusting the spacing, alignment, and material properties at coupling interfaces, the system reduces energy loss while maintaining the flexibility of evanescent coupling for waveguide routing. Parameter optimization includes controlling the evanescent field distribution and coupling strength to achieve efficient signal transmission.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional mechanical coupling methods with evanescent coupling mechanisms that leverage optical field interactions. This substitution allows for more flexible and compact waveguide routing while reducing mechanical sensitivity and associated losses. The evanescent coupling mechanism substitutes direct mechanical alignment requirements with field-based coupling, improving both flexibility and energy efficiency.

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 solution allows for dense waveguide routing with reduced interference, enabling high data rates and energy-efficient operation by minimizing evanescent wave decay and reducing the size of PICs, thereby increasing area bandwidth density.

Implementation Method 1

when an optical signal traveling in a waveguide is incident on the boundary between the inner core and the outer cladding at an angle exceeding the critical angle, the optical signal can exhibit total internal reflection

Methodology Applied
Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 2

enabling flexible routing of optical signals to photonic integrated circuits (PICs) via evanescent coupling

Methodology Applied
Scientific EffectEvanescent coupling:

Implementation Method 3

Each optical switch of the set of optical switches is implemented using an interferometer

Methodology Applied
Scientific EffectInterference: Interference

Data Source

PatentUS20260023215A1Reconfigurable optical interconnects for co-packaged devices including photonic integrated circuits
Publication Date: 2026.01.22 APPLIED MATERIALS INC
  • US20260023215A1 patent drawing
  • US20260023215A1 patent drawing
  • US20260023215A1 patent drawing

AI summary

A method includes forming a first cladding layer on a substrate, forming a second cladding layer on the waveguide, and connecting a plurality of waveguides, including the waveguide, to a plurality of optical switches and a plurality of multiplexers to form an optical interconnect. Each multiplexer of the plurality of multiplexers is coupled to an optical switch in a set of optical switches.