Polymer Optical Waveguide Digital Fabrication for High-Speed Interconnects
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Solution Overview
Problem
Current electrical interconnects face limitations in high-frequency data transmission due to signal attenuation and size constraints, while traditional optical interconnects face challenges in routing optics through tight spaces and increasing the number of modes for higher data transmission.
Innovation Solution
A novel optical interconnect is developed using digitally manufactured polymer waveguides with a micro-dispensed UV optical adhesive as cladding and a fused deposition modeling process for the core, combined with a subtractive laser process to finish the end facets, enabling high transmission rates and minimal bending losses in small diameter fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cross-sectional area of electrical conductor is increased to reduce resistance, then signal attenuation is reduced, but the physical size and cost are increased
Solution Approach 1:
The patent replaces electrical conductors with optical waveguides, substituting electrical signal transmission with optical signal transmission. This fundamental substitution allows for smaller尺寸的 interconnects while achieving better signal transmission quality, as optical signals are not subject to resistive losses that plague electrical conductors at high frequencies
Solution Approach 2:
The patent changes the transmission medium from electrical to optical, fundamentally altering the physical parameters governing signal transmission. This parameter change enables high-frequency signal transmission without the resistance-capacitance limitations that constrain electrical interconnects
2Volume of moving object
If electrical conductor size is scaled down to meet size constraints, then physical dimensions are reduced, but bit rate capacity is limited by resistance x capacitance time constant
Solution Approach 1:
The patent substitutes optical waveguides for electrical conductors, replacing the RC-limited electrical transmission system with an optical transmission system that is not constrained by resistance-capacitance time constants, thereby achieving high bit rate capacity in small dimensions
Solution Approach 2:
The patent changes the fundamental transmission parameter from electrical to optical, eliminating the RC time constant limitation that prevents small electrical conductors from achieving high bit rates. Optical transmission enables gigabit per second data rates in compact waveguide structures
3Productivity
If traditional optical fiber is used for interconnects, then high data transmission rate is achieved, but routing through tight spaces and increasing number of modes for higher capacity is challenging
Solution Approach 1:
The patent changes the waveguide material from traditional silica optical fiber to polymer materials, enabling flexible routing through tight spaces while maintaining high data transmission rates. The polymer waveguides can be fabricated with precise control over geometry and refractive index profiles
Solution Approach 2:
The patent divides the optical interconnect system into modular polymer waveguide segments that can be independently fabricated and assembled, simplifying routing through complex three-dimensional pathways and enabling flexible system integration
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 achieves transmission rates of at least 25% with minimal bending losses, capable of transmitting large amounts of data through small diameter polymer waveguides, with potential for mass production and applications in various board-to-board or chip-to-chip connections.
Implementation Method 1
micro-dispensed UV optical adhesive as cladding
Implementation Method 2
optical waveguide...Light rays propagate via discreate paths through a fiber where each path is called a mode
Data Source
AI summary
A novel polymer optical waveguide and method of manufacturing is presented herein. A digitally manufactured process is described which utilizes a micro-dispensed UV optical adhesive as the contour guiding cladding, a fused deposition modeling technology for creating a core, additional optical adhesive to complete the cladding and a subtractive laser process to finish the two ends of the optical interconnect.