Forming reflective materials on surfaces of optical elements

A laser-based light source, comprising:

• a package base;
• a laser diode chip coupled to the package base, the laser diode chip configured to output a laser beam of electromagnetic radiation from an output facet;
• the laser diode chip configured to emit the electromagnetic radiation at a first wavelength;
• a material coupled to the package base and arranged on the package base adjacent to the laser diode chip;
• an optical element coupled to a top surface of the material, wherein at least one of a top surface of the material or a bottom surface of the optical element is reflective, wherein the optical element is aligned with the laser diode chip to receive the electromagnetic radiation from the laser diode chip, the optical element including a wavelength conversion material configured to convert at least a fraction of the electromagnetic radiation in the laser beam with a first wavelength to a second wavelength that is longer than the first wavelength;
• and
• a reflective material surrounding sides of the optical element, the reflective material configured to reflect portions of the electromagnetic radiation incident on the sides of the optical element, wherein the optical element is configured to emit a light from a top surface, the light including a first portion having the first wavelength and a second portion having the second wavelength, wherein the reflective material is a dielectric reflective material formed by securing the optical element between carriers using pressure-sensitive adhesives, applying a liquid form of the dielectric reflective material to exposed sides of the optical element using a spray process, and curing the applied dielectric reflective material at an elevated temperature.

A method of forming a reflective material on surfaces of optical elements, the optical elements each comprising a wavelength conversion material configured to convert electromagnetic radiation from a laser beam with a first wavelength to a second wavelength that is longer than the first wavelength, the method comprising:

• adhering a first adhesive material to a first carrier and a second adhesive material to a second carrier;
• placing a plurality of un-coated optical elements on the first adhesive material;
• adhering the second adhesive material to the plurality of un-coated optical elements so that the plurality of un-coated optical elements are sandwiched between the first carrier and the second carrier;
• applying a liquid form of the reflective material to exposed surfaces of the plurality of un-coated optical elements using a spray process to create a plurality of coated optical elements;
• and
• removing the plurality of coated optical elements from the first and second adhesive materials, each of the plurality of coated optical elements being substantially free from the reflective material on surfaces that were adjacent to the adhesive materials and having the reflective material on the surfaces that were exposed during the spray process.