Tunable Laser Calibration via Reference Lasing Member
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Solution Overview
Problem
The manufacturing process of tunable laser devices results in inconsistent wavelength characteristics, requiring wavelength measurement equipment during installation in PON systems, which complicates the calibration and adjustment of these devices.
Innovation Solution
A method involving the manufacturing of two identical DFB-lasing members with wavelength-selective structures on a common substrate using lithographic processes, where one member is calibrated using UV-light from a UV-LED source, generating data for adjusting the other member's laser beam, and storing this data for future tuning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a common lithographic manufacturing process is used for multiple lasing members, then manufacturing consistency and productivity are improved, but wavelength characteristic consistency deteriorates due to variations in emission characteristics
Solution Approach 1:
The patent applies preliminary action by introducing a calibration step before final product completion. A calibration lasing member is manufactured alongside production lasing members, and its wavelength characteristics are measured and stored in advance. This calibration data is then used to adjust the production lasing members, eliminating the need for time-consuming real-time wavelength measurements during installation and thereby resolving the contradiction between manufacturing efficiency and wavelength consistency.
Solution Approach 2:
The patent uses copying by creating a calibration lasing member that replicates the structure and characteristics of production lasing members. This calibration copy is used to establish reference wavelength data that can be applied to adjust multiple production units, ensuring consistent wavelength characteristics across all devices manufactured through the common lithographic process without requiring individual wavelength measurements.
2Measurement precision
If wavelength measurement equipment is used during installation, then wavelength calibration accuracy is improved, but device complexity and installation time increase
Solution Approach 1:
The patent performs wavelength calibration in advance during the manufacturing process rather than during installation. The calibration lasing member's wavelength characteristics are measured and stored in a database before the production lasing members are deployed. This preliminary calibration action eliminates the need for wavelength measurement equipment during installation, reducing device complexity and installation time while maintaining calibration accuracy through the use of stored reference data.
Solution Approach 2:
The system enables self-service calibration by using the calibration lasing member to generate reference wavelength data that automatically adjusts the production lasing members. This self-calibration mechanism eliminates the need for external wavelength measurement equipment during installation, as the system uses its own calibration data to ensure accurate wavelength characteristics.
3Manufacturing precision
If individual wavelength calibration is performed for each lasing member, then wavelength precision is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent performs wavelength calibration in advance during the manufacturing process using a calibration lasing member. The calibration data is measured and stored in a database before production lasing members are deployed. This preliminary calibration action allows multiple production units to be adjusted using the pre-established reference data, eliminating the need for individual time-consuming wavelength measurements for each device and thereby resolving the contradiction between wavelength accuracy and manufacturing time.
Solution Approach 2:
The calibration lasing member serves as a reference copy whose wavelength characteristics are measured once and then used to adjust multiple production lasing members. This copying approach allows the wavelength calibration to be performed a single time for the calibration member rather than individually for each production unit, significantly reducing total calibration time while maintaining wavelength accuracy through the use of the calibration reference.
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
This approach ensures consistent emission characteristics and simplifies the calibration process by using stored calibration data to adjust the tunable laser device, improving manufacturing efficiency and reducing the need for real-time wavelength measurement equipment.
Implementation Method 1
the light source is a UV-light source for emitting ultraviolet light, wherein the UV-light source is a UV-LED
Implementation Method 2
wherein the chemical and/or mechanical structure of the lasing member may be changed because of the photo energy of the light emitted by the light source
Data Source
Figure 1~2
AI summary
The invention relates to a method for manufacturing and calibrating a tunable laser device (10) comprising a lasing member (14) with a wavelength-selective structure and a light source for illuminating said lasing member (14), wherein said lasing member (14) is manufactured on a substrate (12) by a lithographic manufacturing process. The method comprises the steps of: - manufacturing an arrangement (18) of the lasing member (14) and at least one other lasing member (16) with another wavelength-selective structure on the substrate (12) by means of a common manufacturing process, wherein the other lasing member (16) is substantially identical to the one lasing member (14) and wherein the lasing members (14, 16) of the arrangement (18) are illuminatable by the light source with the substantially same intensity of light; and - generating calibration data of the tunable laser device (10) by illuminating the other lasing member (16) with light emitted by the light source, which light is tuned by the use of the other wavelength-selective structure. The invention further relates to a corresponding tunable laser device (10).