Efficient and compact green laser for micro-projector applications

— Efficient and compact green lasers are keystone components for micro‐projector applications in mobile devices. An architecture that consists of an infrared‐producing DBR (distributed Bragg reflector) laser with a frequency‐doubling crystal is used to synthesize a green laser that has high electrical‐to‐optical conversion efficiency and can be modulated at speeds required for scanner‐based projectors. The design and performance of a green‐laser package that uses adaptive optics to overcome the challenge of maintaining alignment between the waveguides of the DBR laser and the frequency‐doubling crystal over temperature and lifetime is described. The adaptive optics technology that is employed uses the piezo‐based smooth impact drive mechanism (SIDM) actuators that offer a very small step size and a range of travel adequate for the alignment operation. The laser is shown to be compact (0.7 cm3 in volume) and capable of a wall‐plug efficiency approaching 10% (at 100‐mW green power). It was demonstrated that the adaptive optics enables operation over a wide temperature range (10–60°C) and provides the capability for low‐cost assembly of the device.