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, leading to inefficiencies in optical signal transmission and processing.

Innovation Solution

Implementing reconfigurable optical interconnects with tunable components such as optical switches and multiplexers, utilizing interferometers and ring-assisted interferometers, to dynamically route optical signals to multiple photonic integrated circuits (PICs) via evanescent wave coupling, enabling scalable and efficient optical signal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional optical fiber-to-waveguide connections are used, then optical signal transmission is achieved, but dense scaling becomes difficult due to limitations in cladding layer diameters and connection complexity

Engineering Contradiction:
Improveoptical signal transmission efficiencyVSAvoidoptical fiber-to-waveguide connection complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the optical interconnect system into multiple functional components: optical switches for signal routing, multiplexers for wavelength combination, and demultiplexers for wavelength separation. This segmentation allows each component to be optimized independently and enables dense scaling by distributing the connection complexity across multiple simpler elements rather than requiring complex one-to-one fiber-to-waveguide connections.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent implements dynamic reconfigurability through optical switches that can dynamically route optical signals between different waveguides and PICs based on real-time demand. This dynamic switching capability replaces static fiber-to-waveguide connections, enabling flexible resource allocation and dense scaling without increasing connection complexity, as the system can reconfigure itself rather than requiring fixed physical connections for all possible paths.

Inventive Principle:
Principle #15Dynamics

2Area of moving object

If cladding layer diameter is increased to accommodate more waveguides, then waveguide routing density improves, but manufacturing precision requirements increase

Engineering Contradiction:
Improvewaveguide routing densityVSAvoidcladding layer fabrication precision
Core Design Contradiction:
Area of moving objectVSManufacturing precision

Solution Approach 1:

The patent transitions from two-dimensional planar waveguide routing to three-dimensional vertical stacking by integrating multiple PICs and waveguide layers at different heights. This vertical dimensionality allows increased waveguide routing density without proportionally increasing the lateral cladding layer diameter, thereby maintaining manufacturing precision requirements while achieving higher routing capacity through vertical integration rather than horizontal expansion.

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

3Productivity

If more PICs are integrated on the optical interconnect, then area bandwidth density increases, but interference between waveguides increases

Engineering Contradiction:
Improvearea bandwidth densityVSAvoidwaveguide interference
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent implements nested integration by placing multiple PICs and waveguide structures within a hierarchical framework of optical switches and multiplexers. The optical switch fabric provides an outer nesting layer that organizes and isolates inner waveguide paths, allowing multiple PICs to be integrated without direct interference. The multiplexer/demultiplexer structures create nested wavelength channels that isolate signals spatially and spectrally, enabling high area bandwidth density while maintaining signal isolation.

Inventive Principle:
Principle #7Nested doll (Nesting)

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, improving the ability to transmit optical signals and reducing the size of PICs, thereby increasing area bandwidth density and energy efficiency.

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

utilizing interferometers and ring-assisted interferometers, to dynamically route optical signals to multiple photonic integrated circuits (PICs) via evanescent wave coupling

Methodology Applied
Scientific EffectEvanescent wave coupling:

Data Source

PatentUS12578527B2Reconfigurable optical interconnects for co-packaged devices including photonic integrated circuits
Publication Date: 2026.03.17 APPLIED MATERIALS INC
  • US12578527B2 patent drawing
  • US12578527B2 patent drawing
  • US12578527B2 patent drawing

AI summary

A system includes an optical interconnect and a set of photonic integrated circuits (PICs) integrated within the optical interconnect. The optical interconnect includes a plurality of optical switches, a plurality of multiplexers, and a plurality of sets of optical splitters. Each multiplexer of the plurality of multiplexers is coupled to each optical switch of the set of optical switches, and each set of optical splitters of the plurality of sets of optical splitters is coupled to a respective multiplexer of the plurality of multiplexers.