IP Library Granted Patent US 12674933
Granted Patent B2
US 12674933 · App. 17/561,683 · Granted Jul 7, 2026

Low-loss waveguide with undercut

Inventors: Harel Frish (Albuquerque, NM); John M. Heck (Berkeley, CA); Duanni Huang (San Jose, CA); Hari Mahalingam (San Jose, CA); Haisheng Rong (Pleasanton, CA)
Assignee: Intel Corporation
G02B6/12007G02B6/136
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Quick Facts
Patent No.
US 12674933
App. No.
17/561,683
Granted
Jul 7, 2026
Kind
B2
Abstract

An apparatus comprising a substrate; a waveguide above the substrate; and an undercut into the substrate, the undercut beneath at least a portion of the waveguide, wherein a magnitude of a maximum length of the undercut is lower than a magnitude of a maximum depth of the undercut.

Claims (33)

1 . An apparatus comprising:

a substrate;

a waveguide above the substrate;

an undercut into the substrate, the undercut beneath at least a portion of the waveguide, wherein a magnitude of a maximum length of the undercut is higher than a magnitude of a maximum depth of the undercut, wherein the magnitude of the maximum depth of the undercut is less than 5 microns; and

an oxide layer on top of the substrate, wherein the oxide layer surrounds the waveguide.

2 . The apparatus of claim 1 , wherein the waveguide comprises silicon nitride (Si 3 N 4 ).

3 . The apparatus of claim 1 , the waveguide comprising a core material and a cladding material, wherein the cladding material is an electrically insulating material that surrounds at least a portion of the core material.

4 . The apparatus of claim 1 , further comprising a second waveguide to transfer light to the waveguide, wherein the second waveguide is on a slab comprising silicon, the slab formed above the substrate, the second waveguide and the slab surrounded by the oxide layer.

5 . The apparatus of claim 1 , wherein the undercut comprises a material other than air, the material having a lower refractive index than the substrate.

6 . The apparatus of claim 1 , further comprising a plurality of metal-oxide semiconductor field-effect transistors formed over the oxide layer.

7 . The apparatus of claim 1 , wherein the oxide layer seals off an air gap of the undercut.

8 . The apparatus of claim 1 , wherein the magnitude of the maximum length of the undercut is more than five times the magnitude of the maximum depth of the undercut.

9 . The apparatus of claim 1 , further comprising a second waveguide above the substrate, wherein the oxide layer is in contact with the second waveguide.

10 . The apparatus of claim 9 , wherein the second waveguide has a higher effective index than the waveguide.

11 . The apparatus of claim 1 , wherein the waveguide has a lower effective index than a refractive index of the substrate.

12 . The apparatus of claim 1 , wherein the oxide layer on top of the substrate and surrounding the waveguide comprises silicon dioxide.

13 . A system comprising:

a semiconductor die comprising:

a substrate comprising silicon;

a waveguide above the substrate;

an undercut into the substrate, the undercut beneath at least a portion of the waveguide, wherein a magnitude of a maximum length of the undercut is higher than a magnitude of a maximum depth of the undercut;

an oxide layer comprising silicon dioxide, the oxide layer on top of the substrate, wherein the oxide layer surrounds the waveguide; and

a second waveguide above the substrate, wherein the oxide layer is in contact with the second waveguide.

14 . The system of claim 13 , wherein the semiconductor die comprises an optical transceiver comprising an optical transmitter comprising a plurality of integrated lasers and an optical receiver comprising a demultiplexer comprising the waveguide.

15 . The system of claim 13 , wherein the system further comprises a processor.

16 . The system of claim 15 , wherein the system further comprises a second semiconductor die coupled to the semiconductor die, the second semiconductor die comprising the processor.

17 . The system of claim 15 , further comprising a battery communicatively coupled to the processor, a display communicatively coupled to the processor, or a network interface communicatively coupled to the processor.

18 . A method comprising:

forming a waveguide above a substrate comprising silicon;

forming an undercut into the substrate beneath at least a portion of the waveguide, wherein a magnitude of a maximum length of the undercut is higher than a magnitude of a maximum depth of the undercut;

forming an oxide layer comprising silicon dioxide on top of the substrate, wherein the oxide layer surrounds the waveguide; and

forming a second waveguide above the substrate, wherein the oxide layer is in contact with the second waveguide.

19 . The method of claim 18 , wherein forming the undercut comprises applying an anisotropic etch to the substrate.