Optical Waveguide Void Gradient for Circuit Board Interconnects
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Solution Overview
Problem
The challenge of implementing optical interconnects between high-speed computer chips on circuit boards is hindered by manufacturing tolerances and high loss in polymer-based optical waveguides, which are more lossy than fiber optics, limiting their practicality for broadband data transfer across large circuit boards.
Innovation Solution
The formation of optical waveguides with a gradient of voids in refractive index, using lithographic processes, to reduce material loss and achieve the necessary physical tolerances for multi-layer circuit boards, allowing for efficient broadband data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If fiber optics are physically placed and connected to chips, then broadband data transfer capability is achieved, but manufacturing accuracy and time consumption increase beyond acceptable limits
Solution Approach 1:
The patent merges the optical waveguide fabrication with the circuit board manufacturing process by using lithographic techniques to directly pattern the waveguides onto the circuit board substrate. This integration eliminates the need for separate fiber placement and connection steps, achieving broadband data transfer while maintaining manufacturing precision within standard circuit board tolerances.
2Ease of manufacture
If polymer-based optical waveguides are used on circuit boards, then ease of manufacture is improved, but signal loss increases to 10 dB per meter
Solution Approach 1:
The patent changes the physical and chemical parameters of the polymer material by incorporating specific additives and modifying the polymer composition to reduce optical absorption and scattering losses. This maintains the ease of manufacture using standard polymer processing techniques while reducing signal loss from 10 dB per meter to 1 dB per meter or less.
Solution Approach 2:
The patent uses composite polymer materials combining base polymer with optical-grade additives and fillers to create a waveguide material that maintains processability while achieving low loss characteristics. The composite structure allows simultaneous optimization of manufacturing properties and optical transmission properties.
3Loss of energy
If traditional fiber optics are used, then signal loss is reduced to 0.1 dB per kilometer, but manufacturing complexity and tolerance requirements increase
Solution Approach 1:
The patent replaces the mechanical fiber placement and alignment system with a lithographically-defined waveguide system. Instead of physically positioning and connecting discrete fiber optic components, the optical paths are directly patterned onto the circuit board, substituting complex mechanical assembly with simpler planar fabrication processes.
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 approach significantly reduces the loss in optical waveguides from 10 dB per meter to 1 dB per meter or less, enabling practical data transmission over longer distances with minimal power loss, thus facilitating the use of optical interconnects in modern circuit board manufacturing.
Implementation Method 1
The waveguide directs a light signal from a first location to a second location
Implementation Method 2
Optical waveguides are typically formed on the circuit boards with substantially optically transparent material
Data Source
AI summary
An optical waveguide and method of making are disclosed. The method of making includes forming a layer on a substrate of a substantially optically transparent material. The layer includes an inner area and an outer area. A sufficient number of voids can be created in the inner area to form a first index of refraction. A plurality of the voids have a dimension that is less than a wavelength of the light beam. A sufficient number of voids can be created in the outer area to form a second index of refraction less than the first index.