Cylindrical two-dimensional diode-laser arrays and method for making same

A diode-laser array made by the method comprising the following steps:

• (a) providing a metal heat-sink having a first length and a longitudinal axis, and having a circular aperture extending therethrough, said aperture defining a cylindrical inner wall of said heat-sink;
• (b) providing a cylindrical tube of a dielectric material, said tube having a wall, and having a second length greater than said first length;
• (c) cutting a plurality of longitudinal slots through a first portion of said tube wall, each of said first longitudinal slots having a third length about equal to or greater than said first length and less than said second length, said first longitudinal slots dividing said first portion of said tube wall into a plurality of fractionally cylindrical segments of said dielectric material and leaving a second portion of said tube substantially intact and attached to said plurality of fractionally cylindrical segments, each of said segments having an inner surface, an outer surface and longitudinal edges, said longitudinal edges of adjacent said segments facing each other and spaced apart defining a gap therebetween;
• (d) metallizing said inner surface and said longitudinal edges of each of said segments;
• (e) inserting said metallized segments in said circular aperture of said heat-sink with said intact portion of said tube still attached to said segments and outside of said circular aperture;
• (f) bonding said metallized segments to said inner wall of said heat-sink;
• and
• (g) following step (f) separating said substantially intact portion of said tube from said bonded segments.

A diode laser array made by the a method comprising the following steps:

• (a) providing a heat-sink having a circular aperture extending therethrough, said aperture defining a cylindrical inner wall of said heat-sink;
• (b) providing a cylindrical tube of a dielectric material, said tube having a wall;
• (c) forming a plurality of longitudinal slots along a portion of the axial length of the tube to divide the tube wall into a plurality of fractionally cylindrical segments of said dielectric material and leaving a second portion of said tube substantially intact and supporting said segments, each of said segments having an inner surface, an outer surface and longitudinal edges, said longitudinal edges of adjacent said segments facing each other and spaced apart defining a gap therebetween, with the length of each slot and the width of said each gap being configured to receive a laser diode bar therein;
• (d) metallizing said inner surface and said longitudinal edges of each of said segments;
• (e) inserting said metallized segments in said circular aperture of said heat-sink in a manner so that at least a portion of the substantially intact portion of the tube remains outside of said circular aperture;
• (f) bonding said metallized segments to said inner wall of said heat-sink;
• and
• (g) mounting a plurality of laser diode bars in said gaps.