We report the latest development of a high power conductively cooled laser module using a novel design approach. The laser bar is directly bonded to two heatsinks in a sandwich configuration without employing submounts as buffers for stress relief caused by CTE mismatch. Simulations were performed to aid the laser module design. The accuracy of the simulations was verified by experimental tests on the laser modules. Production data were collected and used to determine the key performance parameters, statistical distribution, lifetime, and failure mechanism. The laser module thermal rollover could reach 480W at 500A drive current under CW running mode. Furthermore, it could continuously operate under a harsh-hard pulse driving condition at 300A drive current with 300ms pulse width and 1Hz repetition rate.
We have simulated and optimized a conductive cooling structure including the distribution of temperature in active layer, and the deformation of laser to achieve high power operation with low SMILE value. Unlike the traditional conductive cooling structure, our structure improves the heat dissipation efficiency from three aspects: with angle structure in the front of heat sink; double side heat dissipation and without submount packaging technology. In this report, an output power of more than 250W CW from a 4 mm long laser bar with a filling factor of 50% is shown at 240A driving current with a power conversion efficiency of 65%. The thermal rollover of this packaging conductive cooling device can reach 385W at 400A driving current.
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