PCB Optical Waveguides via Nanocomposite Inkjet Printing

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Solution Overview

Problem

Manufacturing hybridized printed circuit boards with integrated optical components is challenging due to compatibility issues with current PCB manufacturing technology, difficulty in waveguide integration, and creating robust interconnecting waveguides, as well as integrating optical coupling connectors and adapters.

Innovation Solution

The use of nanocomposite-ink with a nanofiller dispersed in an organic matrix, which forms optical waveguides and components with a gradient refractive profile, integrated into the PCB layers through additive manufacturing processes like inkjet printing, allowing for both electrical and optical functionality without electrical conversion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If photolithography techniques are used to create waveguides, then optical waveguides can be formed on PCB, but manufacturing complexity and time increase

Engineering Contradiction:

Improvewaveguide formationVSAvoidmanufacturing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent changes the material parameter from conventional photolithography resists to nanocomposite inks containing optical waveguide materials. This parameter change enables direct printing of waveguides with controlled refractive indices, eliminating complex photolithography steps while maintaining manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical and chemical photolithography process with an additive manufacturing (inkjet printing) process. This substitution simplifies the manufacturing system by directly depositing waveguide materials layer-by-layer without requiring photolithography equipment, multiple development steps, or complex alignment mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If conventional PCB manufacturing processes are used, then electrical pathways can be created, but optical waveguide integration is difficult

Engineering Contradiction:

Improveoptical functionalityVSAvoidwaveguide integration

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges electrical and optical manufacturing processes into a single additive manufacturing workflow. Both conductive and optical waveguide materials are deposited using the same inkjet printing system, allowing simultaneous creation of electrical pathways and optical waveguides on the PCB substrate without separate manufacturing lines or complex integration steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a universal manufacturing platform that can produce both electrical conductors and optical waveguides using the same additive manufacturing equipment. The system handles multiple material types (conductive inks, nanocomposite optical materials) through a single process, enabling versatile PCB fabrication with integrated electrical and optical functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If through-holes and blind-holes are created by mechanical milling or laser drilling, then electrical interconnection between layers is achieved, but optical waveguide interconnection becomes difficult

Engineering Contradiction:

Improveelectrical interconnectionVSAvoidoptical interconnection

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical drilling and laser processing with additive manufacturing for creating optical interconnections. The inkjet printing system deposits waveguide materials directly through and along PCB layers, forming continuous optical pathways without requiring physical holes or complex drilling operations. This maintains reliability while dramatically simplifying the manufacturing process.

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

Enables efficient integration of optical components onto PCBs, enhancing data transmission capabilities by overcoming previous manufacturing challenges and enabling robust optical interconnects within the PCB structure.

Implementation Method 1

The plurality of cured nanocomposite-inks comprises a nanofiller dispersed in an organic matrix

Methodology Applied

Scientific EffectNanocomposite: Nanocomposite

Implementation Method 2

each of the plurality of nanocomposite-inks having optical dispersion different from the other nanocomposite-inks

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 3

The plurality of cured nanocomposite-inks

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS11180668B2Printed circuit board with integrated optical waveguides

Publication Date: 2021.11.23 VADIENT OPTICS LLC

AI summary

An apparatus with integrated optical waveguides. The apparatus has: a plurality of layers, wherein a conductive pathway is patterned on a surface of at least one of the plurality of layers. The plurality of layers are laminated together. A plurality of nanocomposite-inks, each with a nanofiller dispersed in an organic matrix have optical dispersion different from the other plurality of nanocomposite-ink, form the optical waveguides. The optical waveguides are formed on the surface of, or within, at least one of the plurality of layers.