Patent ID: 7772085

Claim:
A manufacturing method, comprising: (A) forming first and second device bars, each having an array of semiconductor lasers, wherein: each of the first and second device bars has a respective first side corresponding to a first conductivity type and a respective second side corresponding to a second conductivity type; and for each of the first and second device bars, the first side comprises a respective first plurality of pads corresponding to the semiconductor lasers; (B) bonding the first device bar to the second device bar to form a bonded bar pair, wherein at least some pads from the first plurality of pads in the first device bar are attached to corresponding pads from the first plurality of pads in the second device bar; and (C) coating one or more facets of the bonded bar pair with one or more coating materials, wherein step (B) comprises: depositing a solder material onto pads adapted for attachment to the corresponding pads; placing the second device bar onto the first device bar to mate the pads adapted for attachment, wherein the first side of the first device bar faces the first side of the second device bar; heating the first and second device bars to liquefy the solder material, wherein surface tension of the liquefied solder material aligns the first device bar with respect to the second device bar; and forming solidified solder bonds between the mated pads of the first and second device bars to bond the first and second device bars to each other.