Patent ID: 7724791

Claim:
A method for manufacturing a laser diode package comprising a laser diode bar and a first heat-sinking structure, the method comprising: depositing a quantity of solder material on a surface of said first heat-sinking structure to form a heat-sinking solder layer that is attached to said surface of said first heating-sinking structure, said quantity of solder material being deposited to create a thickness of less than 5 microns of said heat-sink solder layer; depositing a quantity of exothermic material on said heat-sinking solder layer to form a first exothermic layer that is attached to said heat-sinking solder layer, said depositing of said exothermic material occurring as said exothermic material is in a heated vaporous form to create said first exothermic layer having a thickness less than said heat-sink solder layer; depositing a second quantity of solder material on said first exothermic layer to form a bar solder layer that is attached to said first exothermic layer, said second quantity of solder material being deposited to create a thickness of less than 5 microns of said bar solder layer; after said three previous acts of depositing, positioning said laser diode bar on said bar solder layer; exposing said first exothermic layer to a known energy source to cause liquidification of at least a portion of said heat-sinking solder layer and said bar solder layer; and after said exposing, allowing said heat-sinking solder layer and said bar solder layer to solidify to join said first heat-sinking structure to said laser diode bar.