Compact RGB Laser Module With Thermal Interposer Beam Combining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing visible laser technologies, such as diode-pumped solid-state lasers with second harmonic generation, face inefficiencies, size constraints, and high costs due to the need for specialty diodes and crystals, limiting their deployment in broad applications.
Innovation Solution
A small form factor RGB laser module utilizing gallium and nitrogen containing laser diodes with an interposer substrate for thermal energy dissipation, featuring short cavity lengths and a hermetically sealed package, which combines red, green, and blue laser outputs using spatial, polarization, or spectral beam combining techniques, and employs thermal interposers to manage heat and reduce cross-talk between diodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If diode-pumped solid-state lasers with second harmonic generation are used to produce visible laser light, then green and blue laser output can be achieved, but the wall plug efficiency is only about 1% and the device size is large
Solution Approach 1:
The patent extracts and eliminates the intermediate 1064 nm laser stage and frequency conversion crystal from the traditional DPSS-SHG architecture. By directly emitting green (532 nm) and blue (450 nm) wavelengths from the laser gain medium without requiring second harmonic generation, the design removes unnecessary components and improves overall system efficiency while reducing device size.
Solution Approach 2:
The patent changes the operating parameters of the laser system by using specific pump wavelengths (808 nm for green, 445 nm for blue) that directly excite the laser gain medium to emit the desired visible wavelengths. This parameter optimization eliminates the need for frequency conversion and improves wall plug efficiency from 1% to potentially much higher values.
2Use of energy by moving object
If specialty diodes and crystals are used to improve laser efficiency, then visible laser output can be achieved, but the cost increases and the device becomes more fragile
Solution Approach 1:
The patent uses common, commercially available laser diodes (808 nm for green laser, 445 nm for blue laser) as pump sources instead of requiring specialty diodes. The laser gain medium performs multiple functions: it absorbs pump energy, generates laser oscillation, and directly emits the desired visible wavelength, eliminating the need for separate frequency conversion crystals and reducing overall system complexity.
Solution Approach 2:
The patent replaces expensive, fragile specialty components with more robust, commercially available alternatives. By using standard laser diodes and a laser gain medium that directly emits visible light, the system becomes more durable and easier to manufacture, even if individual components have shorter lifetimes, the overall system reliability improves due to reduced complexity.
3Volume of moving object
If multiple laser diodes are integrated in a small form factor module, then compactness is achieved, but thermal energy dissipation becomes challenging
Solution Approach 1:
The patent segments the thermal management system by providing individual heat dissipation paths for each laser diode and the laser gain medium. The substrate is designed with separate thermal conduction paths that channel heat from each component to dedicated heat sink regions, preventing thermal interference between closely spaced laser diodes while maintaining a compact overall module size.
Solution Approach 2:
The patent introduces a substrate as a thermal intermediary between the laser diodes/gain medium and the heat sink. This substrate acts as a thermal management interface that efficiently conducts heat away from the active components while electrically isolating them, enabling compact integration by mediating the thermal interaction between heat-generating components and the external heat dissipation system.
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 enables efficient thermal management, reduces the size and cost of the laser module, and improves deployment possibilities across various applications by achieving high thermal energy dissipation and maintaining spectral stability, thus overcoming the inefficiencies and size constraints of previous technologies.
Implementation Method 1
A small form factor RGB laser module utilizing gallium and nitrogen containing laser diodes with an interposer substrate for thermal energy dissipation
Implementation Method 2
a red, green, and blue ("RGB") laser module comprising a gallium and nitrogen containing laser device
Implementation Method 3
which combines red, green, and blue laser outputs using spatial, polarization, or spectral beam combining techniques
Data Source
AI summary
In an example, the present invention provides a small form factor package comprising RGB laser diode devices configured with short cavity lengths. In an example, the present laser module includes at least a first red laser diode device, at least a second green laser diode device, and at least a third red laser diode device. At least one of the laser diode devices has a cavity length of less than 200 um, or less than 150 um, or less than 100 um. The optical output beams of the red, green, and blue laser diodes are combined into a single beam or colinear beams using optical techniques. The laser diode devices and the optical combining optics contained in a sealed package device. The sealed package device has a small form factor volume.