The desire for high-performance computing and networking is ubiquitous and seemingly ever-present. Prominent applications include data center servers, high-performance computing clusters, artificial neural networks, and network switches.
For decades, dramatic integrated circuit (IC) performance and cost improvements were driven by shrinking transistor dimensions combined with increasing die sizes, summarized in the famous Moore's Law. Transistor counts in the billions have allowed consolidation onto a single system-on-a-chip (SoC) of functionality that was previously fragmented across multiple ICs. However, the benefits of further transistor shrinks are decreasing dramatically as decreasing marginal performance benefits combined with decreased yields and increased per transistor costs. Independent of these limitations, a single IC can only contain so much functionality, and that functionality is constrained because the IC's process cannot be simultaneously optimized for different functionality, for example logic requires a different process than memory and high speed I/O.
Some embodiments provide a microLED-based optical interconnect including an optical coupling assembly, comprising: a first array of optoelectronic devices on an integrated circuit (IC); a first fiber optic bundle comprised of multiple fiber elements, with a first face for coupling light into or out of the fiber elements at a first end of the first fiber optic bundle and a second face for coupling light into or out of the fiber elements at a second end of the first fiber optic bundle; a first optical coupling subassembly on the IC, the first optical coupling assembly including at least one first optical element positioned in an optical path of light between the first array of optoelectronic devices and the first face of the first fiber optic bundle; and a second optical coupling subassembly coupled to an end of the first optical coupling subassembly distal from the IC and coupled to the fiber optic bundle, the second optical subassembly including at least one second optical element positioned in the optical path of light between the first array of optoelectronic devices and the first face of the first fiber optic bundle.
In some embodiments the first optical coupling subassembly and/or the second optical coupling subassembly includes at least one recess for receiving the other optical coupling subassembly.
In some embodiments the first array of optoelectronic devices comprises an array of microLEDs. In some embodiments the first array of optoelectronic devices comprises an array of photodetectors. In some embodiments the at least one first optical element comprises a first lens. In some embodiments the at least one second optical element comprises a second lens. In some embodiments the at least one second optical element comprises a first mirror and second lens. In some embodiments the second optical coupling subassembly further includes a recess for receiving the first fiber optic bundle.
Some embodiments further comprise: a second array of optoelectronic devices on the integrated circuit (IC); a second fiber optic bundle comprised of multiple fiber elements, with a first face for coupling light into or out of the fiber elements at a first end of the second fiber optic bundle and a second face for coupling light into or out of the fiber elements at a second end of the second fiber optic bundle; a third optical coupling subassembly on the IC, the third optical coupling assembly including at least one third optical element positioned in an optical path of light between the second array of optoelectronic devices and the first face of the second fiber optic bundle; and a fourth optical coupling subassembly coupled to an end of the third optical coupling subassembly distal from the IC and coupled to the second fiber optic bundle, the fourth optical subassembly including at least one fourth optical element positioned in the optical path of light between the second array of optoelectronic devices and the first face of the second fiber optic bundle;
In some embodiments the third optical coupling subassembly and/or the fourth optical coupling subassembly include at least one recess for receiving the other optical coupling subassembly.
In some embodiments the first array of optoelectronic devices comprises an array of microLEDs and the second array of optoelectronic devices comprises an array of photodetectors. In some embodiments the at least one third optical element comprises a third lens. In some embodiments the at least one fourth optical element comprises a fourth lens. In some embodiments the at least one fourth optical element comprises a second mirror and fourth lens. In some embodiments the fourth optical coupling subassembly further includes a recess for receiving the second fiber optic bundle.
These and other aspects of the invention are more fully comprehended upon review of this disclosure.
interfaced to an IC.
There may be significant benefits to “de-integrating” SoCs into smaller “chiplets,” including: (1) the process for each chiplet can be optimized to its function; (2) chiplets are well-suited to reuse in multiple designs; and (3) chiplets are less expensive to design.
Chiplets may have higher yield because they are smaller with fewer devices. However, a major drawback to chiplets compared to SoCs may be that use of chiplets generally requires far more chip-to-chip connections. Compared to the on-chip connections between functional blocks in SoCs, chip-to-chip connections may be typically much less dense and require far more power (for example normalized as energy per bit).
Though optics has been a candidate for chip-to-chip interconnects for decades, coupling optical sources and detectors to waveguides (including fibers) may frequently dominate the cost of optical links and limits their density for this application.
Optical interconnects based on microLED (μLED) sources may offer a way to overcome some or all of the limitations described herein. A microLED may be generally defined as an LED with an overall diameter/lateral dimension of <100 μm in some embodiments, <20 μm in some embodiments, <4 μm in some embodiments, and <1 μm in some embodiments. In some embodiments the μLED sources can support optical links with lengths of >1 m at >1 Gbps with lower drive power and very high density.
One aspect of practical realizations of a microLED link may be the way in which the microLED and photodetector (PD) arrays are coupled to the optical transmission medium that carries light between the transmitter and receiver ends of the link.
A parallel optical interconnect comprises a plurality of optical communication channels. In some embodiments, each communication channel comprises: an optical transmitter comprising a drive circuit that causes its input electrical signal to be modulated onto the optical output of an optical emitter (e.g. a microLED, LED or laser); input coupling optics that couple light from the emitter into a first (input) face of an optical transmission medium; an optical transmission medium; output coupling optics that couple light from a second (output) face of the optical transmission medium to an optical receiver; an optical receiver comprising photodetector (PD) coupling optics, a PD, and a receiver circuit that produces an output electrical signal. In some embodiments, the drive circuit of the optical transmitter may be integrated with an optoelectronic IC connected to the optical emitter, and the receiver circuit may be integrated with a second optoelectronic IC connected to the photodetector. In some embodiments, the photodetector may be monolithically integrated with the second optoelectronic IC.
In some embodiments of a parallel optical interconnect, the optical emitters are microLEDs made from direct gap semiconductors such as GaN/InGaN, InGaAlAs, InGaP, or InGaAsP. A parallel optical interconnect using microLED optical emitters may be referred herein as a microLED parallel optical interconnect. In some embodiments, the microLEDs are made from GaN/InGaN and emit light at wavelengths in the 400 nm-500 nm range. In some embodiments, the PDs are made from Si.
In some embodiments, the array of emitters and the array of PDs are located on some regular grid. In some embodiments, the emitter and PD grids are hexagonal close-packed (HCP), square, or rectangular grids. In some embodiments, the center-to-center spacing of grid elements are in the range of 10 μm-100 μm.
Some embodiments of an optical coupling assembly comprise one lens element 311a, for example as illustrated in
An optical coupling assembly using lenses and/or mirrors to image light between an OE device array and a transmission medium may provide a number of significant benefits compared to butt-coupling the transmission medium directly to the OE device array, such as: (1) increased alignment tolerances between the OE device array and the transmission medium; (2) ability to turn an angle between the OE device array and the transmission medium, for instance a right angle; (3) variable magnification, which provides flexibility in optical design and potentially can increase connection density (channels per unit area); (4) ability to attach the fiber as a relatively late assembly step, providing more flexibility in the packaging process; and (5) ability to couple through transparent substrates or transparent package windows.
In some embodiments, the magnification of an optical coupling assembly is 1. In some embodiments, the magnification of the optical coupling assembly is greater than 1 while in some embodiments the magnification is less than 1. Varying the magnification of the optical coupling assembly allows the each of the OE device array grids and the transmission medium grid to be different, which provides flexibility in component design and fabrication, and can provide system design flexibility.
In some optical coupling assembly embodiments comprising one optical element with optical “power” (e.g. a lens or curved mirror), as shown in
In some embodiments of an optical coupling assembly comprising two optical elements with optical “power” (e.g. each optical element is a lens or curved mirror), as shown in
In some embodiments of a parallel optical interconnect, the optical transmission medium for each channel comprises an optical waveguide, for instance an optical fiber or a planar optical waveguide. In some embodiments of a parallel optical interconnect, the transmission medium comprises an array of optical fibers (a fiber “bundle”) or an array of optical waveguides. In some embodiments, a fiber optic bundle (FOB) comprises multiple fiber elements (FEs) that are packed into a bundle, and comprises two optical “faces” at the two ends of the FOB where light is coupled into and out of the FOB. In some embodiments, each FE comprises a core surrounded by a concentric cladding layer with a lower index of refraction than the core, enabling the guiding of light in the core. In some embodiments, FEs in a FOB may be arranged in a regular pattern such as a square grid or a hexagonal grid. In some embodiments of a FOB, the positions of each FE relative to the other FEs are the same at each packing segment such that the FE positions are not “mixed” at each packing segment. An FOB in which the relative positions of the FEs are preserved is referred to as a “coherent” FOB. In some embodiments, the grid pattern of the FEs in a FOB matches that of the emitter array and PD array elements. In some embodiments, the FEs are on a finer grid than the emitter and PD array elements such that each emitter and PD couples to more than one FE in the FOB.
In some embodiments, the optical coupling assembly comprises one or more reflective surfaces.
In some embodiments, an optical coupling assembly comprises two separate optical coupling subassemblies (OCSAs). This may enable flexibility in the sequence in which the different parts are assembled, which can be very useful given, for instance, high processing temperatures used during certain assembly steps. In some embodiments, the optical design is such that the alignment tolerances between the two optical coupling subassemblies are large relative to the alignment tolerances between the elements within each optical subassembly. These large alignment tolerances may be desirable to improve manufacturing yield and decrease manufacturing costs.
In some embodiments of an optical coupling assembly, for example as shown in
An optical coupling assembly typically also comprises one or more optomechanical structures, the purpose of which is to hold and accurately position the various optical elements relative to each other.
In some embodiments of an optical coupling assembly, a subassembly or assembly comprising one or more optical elements (e.g. lenses and/or mirrors) comprises a single block of a single material (e.g. molded plastic) with both optical and optomechanical functionality. In some embodiments, the surfaces of reflective elements, which may be formed inside the opto-mechanical structure, may comprise reflective coatings and the surfaces of refractive elements, which may be inside the optomechanical structure, may comprise anti-reflective (AR) coatings.
In some embodiments, the optomechanical structures also comprise features that enable the optical coupling assembly to be accurately positioned relative to the OE device array, the transmission medium, and to other optomechanical structures. Such features may be mechanical keying features or may be fiducial features that allow, for instance, a machine vision system or human operator to accurately position the optical coupling assembly. In some embodiments, one of the optomechanical structures being part of an optical coupling subassembly may have a one or more connecting recesses, e.g., recess 713a for connecting and receiving another optomechanical structure being part of another optical coupling subassembly. In some embodiments, and as shown in
In some embodiments, one or more parallel optical interconnects may be interfaced to the surface of an IC. Each of these parallel optical interconnect interfaces comprise an OE device array, an optical coupling assembly that may have one or more optical coupling subassemblies, and a transmission medium.
In some embodiments, the optical coupling assembly comprises an optical path bent through some angle between 0° and 90° using one or more reflective surfaces in the optical coupling subassemblies, for example as generally discussed with respect to
For a straight optical path, the optical coupling assemblies may be designed such that they can be placed close to each other, which enables a high connection density (in channels per unit area). For the bent optical path, the optical coupling assemblies may be placed next to each other but the maximum achievable density may be reduced by mechanical interference constraints, but lower acute bending angles (e.g., 0° to 45°) between the optical coupling subassemblies of an assembly may typically enable higher connection densities. In some embodiments, parallel optical interconnect interfaces are arranged in a linear array while in some embodiments they are arranged in a two-dimensional array.
In some embodiments of an optical coupling assembly, the optical coupling assembly is comprised of four optical coupling subassembly (OCSA) stages, which each stage/section may have its own optical components and optomechanical structures.
Although the invention has been discussed with respect to various embodiments, it should be recognized that the invention comprises the novel and non-obvious claims supported by this disclosure.
This application claims the benefit of U.S. Provisional Patent Application No. 63/607,790, filed on Dec. 8, 2023, the disclosure of which is incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63607790 | Dec 2023 | US |