Stackable Diode-Laser Bar Assembly with Laminated Connector
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Solution Overview
Problem
Diode-laser bar packaging faces challenges with cooling water causing electrical shorts and metal corrosion due to galvanic action, requiring de-ionized water that is expensive and inconvenient, and necessitating electrical isolation between the n-side and p-side potentials.
Innovation Solution
A diode-laser bar assembly with a laminated connector and submount configuration that includes electrically-insulating and conducting layers, ensuring electrical isolation of the cooling water from both sides, allowing for the use of non-de-ionized water and enabling thin, stackable designs with minimal bar-to-bar pitch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling water is used to cool the diode-laser bar, then cooling efficiency is improved, but electrical shorts and metal corrosion occur due to electrical contact between cooling water and diode-laser bar
Solution Approach 1:
The patent introduces an electrically insulating layer as an intermediary between the cooling water and the diode-laser bar. This insulating layer allows thermal energy to be transferred from the diode-laser bar to the cooling water while preventing electrical contact, thus resolving the contradiction between cooling efficiency and electrical isolation.
Solution Approach 2:
The patent segments the contact interface between cooling water and diode-laser bar into distinct functional layers: a thermal contact layer for heat transfer and an electrical insulating layer for electrical isolation. This segmentation allows simultaneous achievement of effective cooling and electrical protection.
2Reliability
If de-ionized water is used as coolant, then electrical conductivity is reduced preventing shorts, but cost and convenience deteriorate
Solution Approach 1:
The electrically insulating layer serves as a mediator that enables the use of conventional, inexpensive water as coolant by blocking electrical contact while allowing thermal contact. This eliminates the need for costly de-ionized water processing while maintaining electrical isolation.
Solution Approach 2:
The patent changes the electrical conductivity parameter of the interface between cooling water and diode-laser bar by introducing the insulating layer. This allows the use of high-conductivity conventional water while maintaining effective electrical isolation, avoiding the need for de-ionized water.
3Power
If diode-laser bars are stacked vertically to increase power, then power output is improved, but bar-to-bar pitch must be minimized increasing packaging complexity
Solution Approach 1:
The patent creates a universal mounting structure with standardized electrical connection interfaces that can accommodate multiple diode-laser bars in vertical stacks. The insulating layer and mounting configuration serve multiple functions simultaneously: thermal management, electrical isolation, and mechanical support, simplifying the packaging of high-power stacks.
Solution Approach 2:
The patent segments the vertical stack into modular units, each with its own insulating layer and electrical connection interface. This modular segmentation allows systematic assembly of multiple bars while maintaining consistent electrical isolation and thermal management across the entire stack, reducing packaging 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 effectively prevents electrical shorts and corrosion, allowing for efficient cooling and high-power operation without the need for de-ionized water, while maintaining electrical isolation and facilitating vertical stacking for power scaling.
Implementation Method 1
an electrically-insulating layer bonded to a top surface of the cooler... The second electrically-conducting sheet is also bonded to the electrical-insulator
Implementation Method 2
A submount is provided having an electrically-conducting layer overlying an electrically-insulating layer... The first electrically-conducting sheet is in electrical contact with the second side of the diode-laser bar
Implementation Method 3
a cooler having first and second opposite ends... cooled by a liquid coolant that flows through a micro-channel arrangement
Implementation Method 4
The coolant is usually water, or water with various additives... flows through a micro-channel arrangement
Implementation Method 5
The diode-laser bar is soldered 'p-side down', either directly onto the heat-sink or via a submount
Data Source
AI summary
A diode-laser bar assembly comprises a diode-laser bar mounted onto a cooler by way of an electrically-insulating submount. A laminated connector is provided that includes two electrically-conducting sheets bonded to opposite sides on an electrically-insulating sheet. An electrical insulator is located between the laminated connector and the cooler. One electrically-conducting sheet is connected to n-side of the diode-laser bar and the other electrically-conducting sheet is connected to p-side of the diode-laser bar.