Staggered Electronic Interconnect Layout for Higher I/O Density

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Solution Overview

Problem

Conventional electronic package designs face challenges in input/output (I/O) interconnect density scaling, leading to increased package and PCB footprint, which inhibits device miniaturization and affects reliability and manufacturability.

Innovation Solution

A staggered liquid metal interconnect structure with a dielectric layer, featuring first and second conductive segments spaced apart by different spacings, allowing for increased I/O density without enlarging the package and PCB form-factor, and providing enhanced electrical performance through additional ground shielding and improved power integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If liquid metal interconnect pitch geometry is down-scaled to increase I/O density, then I/O interconnect density is improved, but device reliability and manufacturability deteriorate

Engineering Contradiction:
ImproveI/O interconnect densityVSAvoidsolder joint reliability
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent transitions from a two-dimensional planar interconnect layout to a three-dimensional stacked configuration. Multiple layers of conductive segments are vertically arranged with staggered positioning, allowing I/O interconnects to extend through the vertical dimension. This enables increased I/O density without reducing the pitch geometry of individual interconnects, thereby maintaining solder joint reliability and manufacturability while achieving higher overall interconnect density.

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

Solution Approach 2:

The patent implements a nested structure where multiple conductive segments are arranged in stacked layers within a compact vertical space. Each layer contains conductive segments that are staggered relative to adjacent layers, creating a nested configuration that maximizes space utilization. This nested arrangement allows multiple I/O interconnects to be packed into a smaller footprint without requiring aggressive pitch down-scaling.

Inventive Principle:
Principle #7Nested doll (Nesting)

2Quantity of substance

If package and PCB footprint is increased to accommodate higher I/O count, then I/O density is improved, but device form-factor miniaturization is inhibited

Engineering Contradiction:
ImproveI/O countVSAvoidpackage and PCB footprint
Core Design Contradiction:
Quantity of substanceVSArea of stationary object

Solution Approach 1:

The patent utilizes the vertical dimension by implementing multiple stacked layers of conductive segments. This three-dimensional arrangement allows a high number of I/O interconnects to be accommodated within a compact horizontal footprint. The staggered configuration across layers enables efficient space utilization, achieving high I/O count without proportionally increasing the package and PCB area.

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

Solution Approach 2:

The patent divides the interconnect structure into multiple discrete layers of conductive segments. Each layer contains a subset of the total I/O interconnects, and the layers are stacked vertically with staggered arrangements. This segmentation allows the total I/O count to be distributed across multiple levels, enabling high I/O density within a reduced horizontal footprint compared to a single-layer configuration.

Inventive Principle:
Principle #1Segmentation

3Ease of manufacture

If conventional interconnect structure is used, then manufacturing simplicity is maintained, but electrical performance and power integrity deteriorate

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidpower integrity
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent segments the power and ground functions into separate dedicated layers. Power conductive segments are arranged in specific layers while ground conductive segments are arranged in adjacent layers, creating a controlled impedance structure. This segmentation improves power integrity by providing dedicated return paths and reducing electromagnetic interference, while the standardized stacked configuration maintains manufacturing simplicity through repeatable layering processes.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent introduces dielectric layers as intermediaries between conductive segments. These dielectric layers provide electrical isolation and controlled impedance matching between adjacent power and ground segments. The intermediary dielectric structure improves power integrity by preventing unwanted coupling and signal interference, while the use of standard dielectric materials and deposition processes maintains manufacturing simplicity.

Inventive Principle:
Principle #24Intermediary (Mediator)

Data Source

PatentUS20240145365A1Electronic interconnect and method of forming the same
Publication Date: 2024.05.02 INTEL CORP
  • US20240145365A1 patent drawing
  • US20240145365A1 patent drawing
  • US20240145365A1 patent drawing

AI summary

A device is provided, including a dielectric layer, a plurality of first conductive segments within the dielectric layer and spaced apart from each other by respective first spacings, and a plurality of second conductive segments within the dielectric layer and spaced apart from each other by respective second spacings. The plurality of second conductive segments may be over and spaced apart from the plurality of first conductive segments by the dielectric layer. A respective one of the first conductive segments may at least partially extend across a corresponding one of the second spacings, and a respective one of the second conductive segments may at least partially extend across a corresponding one of the first spacings.