Laser Module Heat Sink Design for High-Power Thermal Management
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Solution Overview
Problem
Designing a heat radiating structure for high-power laser diodes that minimizes electrical/optical interference and heat storage effects, while optimizing the efficiency of optical source chip integration with optical fibers, is challenging, particularly for semiconductor lasers outputting 1 W or more.
Innovation Solution
A laser module incorporating a Transmitter Optical Sub-assembly (TOSA) with a heat radiating means, including a TO-CAN optical module, optical fiber, and an external housing, along with a heat sink formed by first and second heat sink blocks and fixing screws, which also incorporates a Thermal Electric Cooler (TEC), chiller, or heat radiating plate to efficiently discharge heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a high-power laser diode is integrated to increase output power, then the laser output power is improved, but heat storage increases causing performance deterioration
Solution Approach 1:
The patent extracts the heat management function from the laser diode assembly by attaching a separate heat radiating means (heat sink) to the TOSA. This allows the laser diode to operate at high power while the heat sink independently manages the thermal load, preventing heat storage-induced performance deterioration.
Solution Approach 2:
The heat sink acts as an intermediary between the laser diode and the environment. It receives heat from the TOSA through thermal contact and dissipates it to the surrounding air, mediating the thermal management process and enabling sustained high-power operation without direct thermal interference with the laser chip.
2Productivity
If electrical/optical integration is implemented to improve efficiency, then the combination efficiency is improved, but electrical/optical mutual interference occurs
Solution Approach 1:
The patent segments the laser module into distinct functional components: the TOSA (containing the laser diode and optical elements), the heat sink (for thermal management), and the optical fiber (for light transmission). This segmentation allows each component to be optimized independently, reducing electrical/optical mutual interference while maintaining high combination efficiency through precise alignment interfaces.
3Temperature
If a complex heat radiating structure is designed to improve heat dissipation, then heat dissipation performance is improved, but device complexity increases
Solution Approach 1:
The patent merges the heat radiating function with the existing TOSA housing structure. The heat sink is designed to integrate with the cylindrical block of the TOSA, combining thermal management with the mechanical housing rather than adding a completely separate complex cooling system. This approach improves heat dissipation while minimizing increases in device complexity.
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 the production of high-power laser modules capable of operating at 1 W or more with improved reliability and efficiency, effectively managing heat dissipation and maintaining performance by using a simple manufacturing process for the TO-CAN optical module.
Implementation Method 1
The heat radiating means is in contact with the TOSA to discharge heat generated by the plurality of TOSAs
Implementation Method 2
a heat sink formed to surround at least a part of the TOSA
Implementation Method 3
at least one of a Thermal Electric Cooler (TEC), a chiller, and a heat radiating plate, which are attached to the heat sink to reduce heat generated by the TOSA
Data Source
AI summary
A laser module includes a Transmitter Optical Sub-Assembly (TOSA) and a heat radiating means. The TOSA generates light by an electrical signal and transmits the generated light through an optical fiber. The heat radiating means is in contact with the TOSA to discharge heat generated by the TOSA.