Patent ID: 7432132
Filing Date: 2008-10-07
Classification: H01S

Abstract:
1. The method of fabricating an integral laser diode array-mounting and cooling diamond heat sink structure comprising the steps of: forming a semiconductor mold member having a complementary inverse pattern surface region with respect to a configuration needed for said diamond heat sink structure; pretreating said semiconductor mold member complementary inverse pattern surface region to achieve a covering selected thickness film of diamond seeding elemental carbon powder thereon; said pretreating step including generating, with one of a chemical vapor deposition process and a multiple hot gas decomposition process, said elemental carbon powder film on said mold member complementary inverse pattern surface region; seeding said pretreated semiconductor mold member complementary inverse pattern surface region with a coating of diamond powder; said seeding step including suspending said pretreated semiconductor mold member in a liquid suspension of diamond powder; growing a dense smooth film of diamond over said elemental carbon powder film covered and seeded semiconductor mold member, said growing step including growth rates commencing with a slow first rate and progressing through a plurality of faster subsequent growth rates; continuing said growing step at said faster subsequent growth rate until a diamond film layer of selected thickness between 50 and 3000 micrometers is achieved; dissolving said semiconductor mold member from said diamond film layer to achieve said laser diode array-mounting and cooling diamond heat sink structure.