WO2007061509A2

WO2007061509A2 - Modular diode laser assembly

Info

Publication number: WO2007061509A2
Application number: PCT/US2006/038430
Authority: WO
Inventors: Derek E. Schulte; Yu Yan; Robert J. Martinsen; Aaron L. Hodges; Scott R. Karlsen
Original assignee: NLight Photonics Corp
Current assignee: NLight Inc
Priority date: 2005-11-22
Filing date: 2006-09-29
Publication date: 2007-05-31
Anticipated expiration: 2008-05-22
Also published as: WO2007061509A3

Abstract

An extremely versatile diode laser assembly is provided, the assembly comprised of a plurality of diode laser subassemblies (100) mounted to a stepped cooling block (700, 900, 1100, 1400, 1700 and 1800). The stepped cooling block allows the fabrication of a close packed and compact assembly in which individual diode laser subassembly output beams do not interfere with one another.

Description

Modular Diode Laser Assembly

FIELD OF THE INVENTION

The present invention relates generally to semiconductor lasers and, more particularly, to a laser assembly that permits the output from multiple diode lasers to be effectively and efficiently combined.

BACKGROUND OF THE INVENTION

High power diode lasers have been widely used in industrial, graphics, medical and defense applications. The beam divergence and the relatively low output power of such lasers has, however, limited their usefulness. The output beam of a diode laser is asymmetric due to the beam having a higher angular divergence in the direction perpendicular to the diode junction of the emitter (i.e., the fast axis of the emitter) than in the direction parallel to the diode junction (i.e., the slow axis of the emitter). As a result of the differences in beam divergence, the cross section of the output beam of a diode laser has an elliptical shape, typically requiring the use of a cylindrical lens or other optics to alter the divergence characteristics and shape the output beam for its intended use. Although beam optics can be used on individual diode lasers, in the past the use of such optics has made it difficult to combine multiple diode laser beams into a single beam of sufficient output power to suit many applications.

One method of combining the output beams from multiple lasers is disclosed in U.S. Patent No. 4,828,357. As shown, the output from each laser is directed using multiple mirrors in order to form a bundle of parallel beams or to cause the beams to converge into a relatively narrow region. The patent discloses that if greater power is required than can be generated by a single beam bundle, multiple bundles of parallel beams can be combined to form a beam bundle of even greater power. The patent does not specifically disclose the use of laser diodes nor does the patent disclose altering the beam shape of the individual laser beams prior to directing the beams into the beam bundle.

U.S. Patent No. 6,075,912 discloses an alternate technique for combining the output beams from multiple lasers into a single beam. In the disclosed system the output beam of each laser impinges on a discrete facet of a multi-faceted beam deflector. By properly positioning each laser relative to the facets of the beam deflector, all of the output beams are deflected into an optical fiber. The patent discloses interposing an optical system between each laser source and the corresponding beam deflector facet in order to properly image the output beam onto the deflector facet. The patent also discloses interposing an output optical system between the beam deflector and the optical fiber, the output optical system imaging the deflected output beams as a focused group of beam images into the core of the input face of the optical fiber.

U.S. Patent No. 4,716,568 discloses a laser array assembly formed from a plurality of linear diode laser array subassemblies stacked one above the other, each of the subassemblies electrically connected to the adjacent subassembly. Each linear diode laser array subassembly is made up of a plurality of individual laser emitters mounted in thermal communication with a conductive plate. Although the patent discloses several ways of stacking the subassemblies in order to form the desired 2-D laser array, the patent does not disclose any optical systems for use in combining the output beams of the individual emitters and/or subassemblies.

U.S. Patent No. 5,887,096 discloses an optical system that is used to guide the output beams from a rectilinear diode laser array to form a substantially uniform radiation field or pattern. In one disclosed embodiment, the optical system utilizes a plurality of reflectors where each reflector corresponds to an individual diode laser. In a preferred embodiment, the centers of the irradiated surface areas of the individual reflectors are situated in a straight line with the distance between a reflector and the corresponding diode laser exit facet being the same for each diode laser/reflector pair.

U.S. Patent No. 6,240,116 discloses a diode laser array designed to achieve high beam quality and brightness. In one embodiment, the array includes a pair of diode arrays in which the emitting surface planes of the two arrays are displaced from one another in a direction parallel to the one of the optical axes defined by the arrays. The optical axes of the two arrays are offset from each other in a direction perpendicular to one of the optical axes. Lenses are used to reduce the divergence of the output beams. In at least one embodiment, reflectors are ' used to reduce or eliminate the dead spaces between adjacent collimated beams.

Although a variety of diode laser arrays and beam combining systems have been designed, what is needed in the art is a versatile diode laser assembly which can be easily tailored to specific application needs. The present invention provides such a diode laser assembly.

SUMMARY OF THE INVENTION

The present invention provides a diode laser assembly comprised of a plurality of diode laser subassemblies mounted to a stepped cooling block. In at least one embodiment, the stepped cooling block includes at least three stepped regions, the center region of which is recessed relative to the adjacent regions. In at least one other embodiment, the stepped cooling block includes at least three stepped regions, the center region of which is raised relative to the adjacent regions. In at least one other embodiment, the stepped cooling block is comprised of two adjacent sections, with each section including a plurality of mounting surfaces arranged in a stepped, or staircase, fashion. The mounting surfaces of the two adjacent sections are non- coplanar with the mounting surfaces of one of the sections being higher than the adjacent mounting surfaces of the other section.

Each diode laser subassembly of the diode laser assembly includes a mounting block which, during diode laser subassembly mounting, is coupled to the corresponding mounting surface of the stepped cooling block. Although the diode laser subassemblies are coupled to the cooling block, liquid coolant does not flow through the subassembly mounting blocks, rather the mounting blocks are merely in thermal contact with the cooling block.

Mounted to a surface of the mounting block is a diode laser submount. The diode laser submount can be fabricated from either an electrically insulating material or an electrically conductive material. Mounted to a surface of the diode laser submount is the diode laser. The diode laser can be either a single emitter diode laser or a multi-emitter diode laser. In at least one embodiment the diode laser submount includes a pair of contact pads that are electrically coupled to the diode laser, thus providing a means of supplying power to the individual lasers.

In at least one preferred embodiment of the invention, clamping members, for example a pair of clamping members, compresses the diode laser submount against the mounting block, and the mounting block against the mounting surface of the stepped cooling block. Preferably the clamping member or members are held in place with bolts coupled to the cooling block regions located on either side of the mounting surface of the stepped cooling block. The clamping members preferably hold electrical interconnects against electrical contact pads located on the diode laser submount. In an alternate embodiment, at least one threaded means (e.g., bolt, all-thread and nut assembly, etc.) attaches each diode laser subassembly to a mounting surface of the stepped block.

In at least one preferred embodiment of the invention, a beam conditioning lens is attached, for example by bonding, to each diode laser subassembly mounting block such that the output beam(s) of the diode laser passes through the lens. In one embodiment the beam conditioning lens is a cylindrical lens. Preferably a second beam conditioning lens is also attached, for example by bonding, to each diode laser subassembly mounting block such that the output beam(s) of the diode laser from a different diode laser subassembly passes through the lens. The different diode laser subassembly can be an adjacent subassembly. Alternately one or more diode laser subassemblies can be located between the second beam conditioning lens and the subassembly containing the diode laser that produces the output beam that passes through the second beam conditioning lens.

In at least one embodiment of the invention, a cooling source is coupled to the cooling block. The cooling source can be coupled to the cooling block bottom surface, one or more cooling block side surfaces, or both. The cooling source can be integrated within the cooling block. The cooling block can have a flat bottom surface, thus creating different separation distances between each mounting surface of the recessed cooling block region and the cooling block bottom surface. Alternately the cooling block can have an inclined bottom surface, thus causing the separation distances between each mounting surface of the recessed cooling block region and the cooling block bottom surface to be the same.

A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of the primary components of a diode laser subassembly in accordance with the invention;

Fig. 2 is a perspective view of the assembled diode laser subassembly of Fig. 1, minus the second conditioning lens;

Fig. 3 is a perspective view of the assembled diode laser subassembly of Fig. I₅ including the second conditioning lens associated with another (not shown) diode laser subassembly;

Fig. 4 illustrates the relationship between the second conditioning lens and a specific diode laser subassembly;

Fig. 5 illustrates the relationship between the second conditioning lens and a specific diode laser subassembly different from that shown in Fig.4; Fig. 6 is an illustration of a diode laser subassembly similar to that shown in

Figs. 1-3, utilizing a three-stripe diode laser rather than a single stripe diode laser;

Fig. 7 is an illustration of a cooling block for use with a diode laser subassembly such as those shown in Figs. 1-6;

Fig. 8 is an illustration of the cooling block shown in Fig. 7 with multiple diode laser subassemblies clamped in place;

Fig. 9 is an illustration of an alternate cooling block for use with a diode laser subassembly such as those shown in Figs. 1-6;

Fig. 10 is an illustration of the cooling block shown in Fig. 9 with multiple diode laser subassemblies clamped in place; Fig. 11 is an illustration of an alternate cooling block for use with a diode laser subassembly such as those shown in Figs. 1-6;

Fig. 12 is an illustration of the cooling block shown in Fig. 11 with multiple diode laser subassemblies clamped to the upper cooling block section; Fig. 13 is an illustration of the cooling block shown in Fig. 11 with multiple diode laser subassemblies clamped to the lower cooling block section;

Fig. 14 is an illustration of an alternate cooling block for use with a diode laser subassembly such as those shown in Figs. 1-6;

Fig. 15 is an illustration of the cooling block shown in Fig. 14 with multiple diode laser subassemblies clamped in place;

Fig. 16 is an illustration of the cooling block shown in Fig. 14 with multiple diode laser subassemblies clamped in place using a single clamping member per subassembly;

Fig. 17 illustrates a cooling block similar to that shown in Figs. 7 and 8 except for the use of an inclined cooling plane; Fig. 10 illustrates a cooling block similar to that shown in Fig. 7 configured to accommodate two rows of diode laser subassemblies;

Fig. 19 illustrates portions of a diode laser subassembly that utilizes an electrically conductive submount;

Fig. 20 illustrates portions of a diode laser subassembly that utilizes a pair of attachment bolts;

Fig. 21 illustrates portions of a diode laser subassembly that utilizes a single attachment bolt; and

Fig. 22 is a cross-sectional view of a cooling block/mounting block that illustrates an alternate subassembly mounting arrangement.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS

The present invention provides the system designer with the means to tailor a diode laser assembly to the specific needs of a particular application. In order to provide this versatility, the system utilizes a diode laser subassembly that can be mounted in a variety of configurations. Figs. 1-3 illustrate a diode laser subassembly utilizing a single emitter diode laser

101. In addition to the diode laser 101, the primary components associated with the diode laser subassembly are the subassembly mounting block 103, submount 105, first conditioning lens 107 and second conditioning lens 109. As described in detail below, although second conditioning lens 109 is mounted to subassembly mounting block 103, it is used with the output beam of a diode laser mounted to another diode laser subassembly that is not shown in Figs. 1-3.

Subassembly mounting block 103 serves several functions. First, it provides a convenient means for registering the various components of the diode laser assembly, thereby lowering the manufacturing costs associated with the overall assembly. Second, it provides a convenient means for registering the individual diode laser subassemblies within the cooling block as shown below. Third, it provides an efficient thermal path between diode laser 101 and the cooling block shown in later figures. Although subassembly mounting block 103 does not include coolant passages, thus simplifying assembly of the diode laser subassemblies to the stepped cooling block, it is fabricated from a material with a high coefficient of thermal conductivity (e.g., copper), thus providing the desired diode laser cooling.

Diode laser 101 is not attached directly to subassembly mounting block 103, rather it is mounted to submount 105. Preferably submount 105 as well as the means used to attach submount 105 to mounting block 103 are both materials with a high coefficient of thermal conductivity, thus insuring that the heat produced by diode laser 101 is efficiently coupled to mounting block 103. Additionally the coefficient of thermal expansion for the material selected for submount 105 is matched, to the degree possible, to diode laser 101 in order to prevent de-bonding during operation or damage to the laser. In at least one embodiment of the invention, submount 105 is soldered to mounting block 103 using indium solder.

Submount 105 can be fabricated from either an electrically conductive (e.g., copper, copper tungsten, etc.) or an electrically insulative (e.g., aluminum nitride, beryllium oxide, CVD diamond, silicon carbide, etc.) material. In the embodiment illustrated in Figs. 1-3, submount 105 is fabricated from an electrically insulating ceramic. The material used to bond diode laser 101 to submount 105 is selected, at least in part, on the composition of submount 105 and/or the composition of any layers (e.g., contact pads) interposed between submount 105 and diode laser 101. In the illustrated embodiment, electrically conductive contact pads 111/113 are deposited or otherwise formed on the top surface of submount 105. Contact pads 111/113 can be formed, for example, of gold over nickel plating while a gold-tin bonding material can be used to bond diode laser 101 to contact pad 113. It will be appreciated that there are a variety of materials well known in the industry that are suitable for use as contact pads as well as diode laser bonding material.

In a preferred embodiment of the invention, one contact (e.g., anode) of diode laser 101 is on its bottom surface, thus allowing one diode contact to be made by bonding the diode laser to one of the contact pads (e.g., pad 113) using an electrically conductive material. A wire bond or ribbon bond 115 is then used to electrically couple the second contact (e.g., cathode) of each diode laser to the second contact pad 111. It will be appreciated that the invention is not limited to this contact arrangement. For example, a pair of wire or ribbon bonds can be used to couple the diode laser to a pair of contact pads. First conditioning lens 107, which in at least one embodiment is a cylindrical lens, is properly positioned relative to diode laser 101 using the extended arm portions 117 and 119 of mounting block 103. Typically lens 107 is located immediately adjacent to the exit facet of diode laser 101. Once lens 107 is properly positioned, it is bonded into place. The purpose of conditioning lens 107 is to reduce the divergence of diode laser 101 in the fast axis, preferably to a value that is the same as or less than the divergence in the slow axis.

In order to properly condition the output beam of diode laser 101, preferably a second conditioning lens 109 is used. It should be understood that the specific second conditioning lens 109 shown in Figs. 1-3, although mounted to the top surfaces 121 and 123 of respective arm portions 117 and 119, is not used to condition the beam from the illustrated diode laser 101. Rather the illustrated conditioning lens 109 is used to condition the output beam from an adjacent diode laser subassembly (e.g., beam 401 in Fig. 4), or the output beam from a diode laser subassembly that is more than one subassembly removed from the subassembly (e.g., beam 501 in Fig. 5). It will be appreciated that the focal length of second conditioning lens 109 as well as the height of arm portions 117 and 119 is dependent on which diode laser output beam is intended to pass through which second conditioning lens (i.e., the number of diode laser subassemblies separating the second conditioning lens from the diode laser source).

Although the diode laser subassembly shown in Figs. 1-5 utilizes a single emitter, the present invention is equally applicable to multi-emitter diode lasers. For example, Fig. 6 is an illustration of a diode laser subassembly utilizing a three-stripe diode laser 601. Due to the size of diode laser 601, the contact pads 603/605 on submount 607 are typically of a different size than those on submount 105 used with the single emitter diode laser. Additionally the second conditioning lens (i.e., lens 609) is multi-faceted (i.e., facets 611-613) in order to properly condition the individual output beams of diode laser 601. Fig. 7 is a perspective view of a preferred cooling block 700 for use with the previously described diode laser subassemblies. As shown, cooling block 700 includes a series of steps, thus allowing the output beams from a plurality of diode laser subassemblies to exit the assembly unimpeded. Preferably central section 701 of the cooling block is recessed as shown, although other cooling block/diode laser subassembly configurations can be used as described in further detail below. Fitting the diode laser subassemblies within the recessed portion of the cooling block as illustrated in Fig. 8 provides both a means for registering the laser subassemblies within the cooling block and relative to one another. In one embodiment only the bottom surface of each of the individual subassembly mounting blocks (e.g., block 103) is in good thermal contact with cooling block 700, thus providing thermal repeatability for the assembly. It will be appreciated, however, that the assembly can be configured such that both the side surfaces and the bottom surface of each mounting block are in thermal contact with the cooling block.

In the embodiment illustrated in Fig. 8, five diode laser subassemblies 801-805 are positioned within the central recess (e.g., recess 701 shown in Fig. T) of cooling block 807. In the illustrated embodiment, the second conditioning lens for each subassembly is located on the arm portions of the adjacent subassembly mounting block. It will be appreciated that the uppermost subassembly, i.e., subassembly 801, does not include a second conditioning lens and that the second conditioning lens for the lowermost subassembly, i.e., subassembly 805, is simply mounted to a stand alone lens carrier 809. Carrier 809 can either be integral to cooling block 807, i.e., machined from the same material, or it can be an independent carrier that is mounted to cooling block 807.

Although any of a variety of means can be used to mount the subassemblies to the cooling block, in the illustrated embodiment each diode laser subassembly is clamped to the cooling block with a pair of clamp members 811, the clamp members preferably being bolted to the cooling block. Clamp members 811 serve three purposes. First, they hold the diode laser subassemblies in place. Second, by firmly pressing the subassemblies into place, they insure that good thermal contact is made between subassembly mounting block 103 and cooling block 807. Third, clamp members 811 provide a convenient means of electrically contacting the two contact pads 111/113 (or 603/605), either through direct contact or by pressing an electrical contact against the pads, the electrical interconnect being interposed between the clamping member and the contact pad on the submount. During use, preferably either the cooling block is thermally coupled to a cooling source (e.g., thermoelectric cooler), or the cooling source is integrated within the cooling block (e.g., integral liquid coolant conduits coupled to a suitable coolant pump).

Fig. 9 is a perspective view of an alternate cooling block 900 for use with the previously described diode laser subassemblies. As shown, cooling block 900 includes a series of steps, thus allowing the output beams from a plurality of diode laser subassemblies to exit the assembly unimpeded. Preferably central section 901 of the cooling block is raised as shown. Fitting the diode laser subassemblies to the raised portion of the cooling block as illustrated in Fig. 10 provides a means for registering the laser subassemblies to the cooling block as well as relative to one another. In the embodiment illustrated in Fig. 10, five diode laser subassemblies 1001-1005 are positioned on the central raised portion of cooling block 1007 (e.g., raised portion 901 of Fig. 9). In the illustrated embodiment, the second conditioning lens for each subassembly is located on the arm portions of the adjacent subassembly mounting block. It will be appreciated that the uppermost subassembly, i.e., subassembly 1001, does not include a second conditioning lens and that the second conditioning lens for the lowermost subassembly, i.e., subassembly 1005, is simply mounted to a stand alone lens carrier 1009. Carrier 1009 can either be integral to cooling block 1007, i.e., machined from the same material, or it can be an independent carrier that is mounted to cooling block 1007.

Although any of a variety of means can be used to mount the subassemblies to the cooling block, in the illustrated embodiment each diode laser subassembly is clamped to the cooling block with a pair of clamp members 1011, the clamp members preferably being bolted to the cooling block. Clamp members 1011 serve three purposes. First, they hold the diode laser subassemblies in place. Second, by firmly pressing the subassemblies into place, they insure that good thermal contact is made between subassembly mounting block 103 and cooling block 1007. Third, clamp members 1011 provide a convenient means of electrically contacting the two contact pads 111/113 (or 603/605), either through direct contact or by pressing an electrical contact against the pads, the electrical interconnect being interposed between the clamping member and the contact pad on the submount. As in the prior embodiment, preferably during use either the cooling block is thermally coupled to a cooling source (e.g., thermoelectric cooler), or the cooling source is integrated within the cooling block (e.g., integral liquid coolant conduits coupled to a suitable coolant pump). Fig. 11 is a perspective view of an alternate cooling block 1100 for use with the previously described diode laser subassemblies. As shown, cooling block 1100 includes two adjacent sections 1101 and 1103, with one of the sections (i.e., section 1101) raised relative to the other section (i.e., section 1103). Both the mounting surfaces 1105 of upper section 1101 and the mounting surfaces 1107 of lower section 1103 are formed in a staircase, or stepped, fashion. As shown, adjacent mounting surfaces of the two sections are non-coplanar with the mounting surfaces of one of the sections being higher than the adjacent mounting surfaces of the other section.

The previously described diode laser subassemblies can be mounted to either upper section 1101 or lower section 1103 of cooling block 1100. Either section provides a plurality of the desired stair-stepped mounting surfaces, thus allowing the subassemblies to be vertically offset from one another such that the output beams from the diode laser subassemblies can exit the assembly unimpeded.

Exemplary embodiments are shown in Figs. 12 and 13. In Fig. 12 five diode laser subassemblies 1201-1205 are positioned on the upper mounting surfaces (e.g., surfaces 1105) of cooling block 1207 while in Fig. 13 five diode laser subassemblies 1301-1305 are positioned on lower mounting surfaces (e.g., surfaces 1107) of cooling block 1307. In the illustrated embodiments, the second conditioning lens for each subassembly is located on the arm portions of the adjacent subassembly mounting block. It will be appreciated that in the illustrated embodiments the uppermost subassembly, i.e., subassembly 1201 in Fig. 12 and subassembly 1301 in Fig. 13, does not include a second conditioning lens and that the second conditioning lens for the lowermost subassembly, i.e., subassembly 1205 in Fig. 12 and subassembly 1305 in Fig. 13, is simply mounted to a stand alone lens carrier, i.e., lens carrier 1209 in Fig. 12 and lens carrier 1309 in Fig. 13. The stand alone lens carrier, i.e., carrier 1209 or 1309, can either be integral to the cooling block, i.e., machined from the same material, or it can be an independent carrier that is mounted to the cooling block.

Although any of a variety of means can be used to mount the subassemblies to the cooling block, in the embodiments illustrated in Figs. 12 and 13 each diode laser subassembly is clamped to the cooling block with a clamp member, i.e., clamp members 1211 in Fig. 12 and clamp members 1311 in Fig. 13. The clamp members hold the diode laser subassemblies in place and insure that good thermal contact is made between subassembly mounting blocks 103 and the cooling block. Depending upon the size of the clamping members as well as the location of the subassembly contact pads (e.g., pads 111/113), the clamping members can also be used as a means of electrically contacting one or both contact pads. The clamping members can either make electrical contact through direct contact or by pressing an electrical contact against one or both pads, the electrical interconnect being interposed between the clamping members and the contact pads on the submounts. As in the prior embodiments, preferably during use either the cooling block is thermally coupled to a cooling source (e.g., thermoelectric cooler), or the cooling source is integrated within the cooling block (e.g., integral liquid coolant conduits coupled to a suitable coolant pump). Fig. 14 is a perspective view of a preferred cooling block 1400 for use with the previously described, or alternate, diode laser subassemblies. As shown, cooling block 1400 includes a series of stepped mounting surfaces 1401, thus allowing the output beams from a plurality of diode laser subassemblies to exit the assembly unimpeded. The steps also provide a convenient means of registering the laser subassemblies to the cooling block. It will be appreciated that there are numerous techniques that can be used to mount the diode laser subassemblies to the cooling block, these techniques using various arrangements of clamping members, bolts and/or bonding materials (e.g., solder, adhesive). Fig. 15 illustrates one mounting technique in which pairs of clamping members 1501, preferably bolted to the cooling block, hold diode laser subassemblies 1503-1507 in place on cooling block 1509. Clamp members 1501 serve three purposes. First, they hold the diode laser subassemblies in place. Second, by firmly pressing the subassemblies into place, they insure that good thermal contact is made between subassembly mounting blocks 103 and cooling block 1509. Third, clamp members 1501 provide a convenient means of electrically contacting the two contact pads 111/113 (or 603/605), either through direct contact or by pressing an electrical contact against the pads, the electrical interconnect being interposed between the clamping member and the contact pad on the submount. As in the prior embodiments, preferably during use either the cooling block is thermally coupled to a cooling source (e.g., thermoelectric cooler), or the cooling source is integrated within the cooling block (e.g., integral liquid coolant conduits within the cooling block that are coupled to a suitable coolant pump).

In the embodiment illustrated in Fig. 15, the second conditioning lens for each subassembly is located on the arm portions of the adjacent subassembly mounting block. It will be appreciated that the uppermost subassembly, i.e., subassembly 1503, does not include a second conditioning lens and that the second conditioning lens for the lowermost subassembly, i.e., subassembly 1507, is simply mounted to a stand alone lens carrier 1511. Carrier 1511 can either be integral to cooling block 1509, i.e., machined from the same material, or it can be an independent carrier that is mounted to cooling block 1509.

In an alternate embodiment illustrated in Fig. 16, a single clamping member 1601 is used to hold each diode laser subassembly 1603-1607 in place on cooling block 1609. As in the previous embodiment, in addition to holding the diode laser subassemblies in place the clamp members help to insure that good thermal contact is made between subassembly mounting blocks 103 and the cooling block. Depending upon the size of the clamping members as well as the location of the subassembly contact pads, the clamping members can also be used as a means of electrically contacting one or both contact pads. The clamping members can either make electrical contact through direct contact or by pressing an electrical contact against one or both pads, the electrical interconnect being interposed between the clamping members and the contact pads on the submounts.

As the cooling block (e.g., cooling blocks 807, 1007, 1207, 1307, 1509 and 1609) is comprised of a series of steps onto which the diode laser subassemblies are mounted, the cooling rate and thus the operating temperature of the individual laser subassemblies varies depending upon the distance between the cooling source coupled to the cooling block and the individual subassemblies. Since the operating wavelength of a diode laser is temperature dependent, the inventors have found that the operating temperature variations between subassemblies that arise due to the stepped cooling block and the use of a bottom mounted cooling source, alone or in conjunction with a side mounting cooling source, can be used to match diode laser subassembly wavelengths. Accordingly in at least one embodiment of the invention, the output wavelength of each subassembly is determined based on the subassembly' s position within the cooling block. Then each subassembly is positioned within the cooling block to provide the closest possible match to the desired output wavelength of the entire assembly.

Although the figures described above illustrate several preferred embodiments of the invention, it will be appreciated that there are numerous minor variations that are clearly envisioned by the inventors. For example, the bottom surface of the cooling block can be inclined. Although the bottom surface of any of the previously described cooling blocks can be inclined, Fig. 17 illustrates an exemplary embodiment similar to that shown in Figs. 7 and 8. As illustrated, the bottom surface 1701 of cooling block 1700 is inclined. As a result of this configuration, each mounting surface 1703 is the same distance from the bottom surface 1701, thus maintaining the same cooling rate for each mounted diode laser subassembly (not shown) even when thermally coupling the cooling source to the bottom surface (i.e., surface 1701) of the cooling block.

In the exemplary configurations shown in the above figures, each assembly includes only a single row of five subassemblies. It should be appreciated, however, that assemblies in accordance with the invention can include either more or less than the five diode laser subassemblies shown in Figs. 8, 10, 12, 13, 15 and 16. Additionally, assemblies that contain more than a single row of diode laser subassemblies can be fabricated using the present invention. For example, Fig. 18 illustrates an exemplary embodiment of a cooling block 1800 similar to cooling block 700 except that cooling block 1800 is designed for multiple rows of subassemblies; more specifically, two rows of five diode laser subassemblies each. It should be appreciated that multi-row assemblies can use any of the disclosed configurations or mounting techniques, and that the multi-row cooling block shown in Fig. 18 is only illustrative of such an assembly. The output beam from each row can either be combined using known optical techniques, or the assembly can be used to produce multiple separate output beams.

As previously noted, the diode laser subassemblies of the present invention can utilize either electrically insulating or electrically conducting submounts as well as any of a variety of different diode laser contacting arrangements. Thus the submount/contact arrangement shown in Figs. 1-3 and 6 is only an exemplary configuration and should not be viewed as a limitation of the present invention. For example, Fig. 19 illustrates portions of a diode laser subassembly that utilizes an electrically conductive submount 1901. In this embodiment diode laser 101 is attached to submount 1901 with an electrically and thermally conductive solder or bonding material. As a consequence, one contact to diode laser 101 is made via electrically conductive submount 1901, directly or via subassembly mounting block 103 and/or the cooling block (not shown). Of course if electrical contact is made via subassembly mounting block 103, then an electrically conductive solder or bonding material must be used to attach submount 1901 to the subassembly mounting block. Similarly if electrical contact is made via the cooling block (not shown), then an electrically conductive solder or bonding material must be used both to attach submount 1901 to the subassembly mounting block and to attach the subassembly mounting block to the cooling block. The second contact to the diode laser is made via a contact pad 1903, each diode laser being connected to contact pad 1903 via a wire bond or ribbon bond 1905. Although Figs. 8, 10, 12, 13, 15 and 16 show the use of clamping members to hold the subassemblies to the respective cooling blocks, as previously noted there are numerous other techniques that can be used to mount the subassemblies. For example, Fig. 20 shows a partial diode laser subassembly 2000 in which a first bolt 2001 holds contact pad 2003 and submount 2005 as well as mounting block 2007 to the cooling block (not shown) while a second bolt 2009 holds contact pad 2011 and submount 2005 as well as mounting block 2007 to the cooling block (not shown). Preferably in this configuration submount 2005 is fabricated from an electrically insulating material.

In addition to the above-described approaches, it will be appreciated that there are numerous mounting techniques that can be used to mount the diode laser subassemblies to the cooling block, these techniques using various arrangements of clamping members, bolts and/or bonding materials (e.g., solder, adhesive). For example in the embodiment illustrated in Fig. 21, a single bolt 2101 is used to attach mounting block 2103 to the underlying cooling block (not shown). Submount 2105 is attached to mounting block 2103 by solder or an adhesive. Preferably a pair of contact pads 2107/2109 is used to electrically couple to diode laser 101. In an alternate embodiment illustrated in Fig. 22, at least one bolt 2201 attaches each mounting block 2203 to cooling block 2205, the bolts passing through the bottom of the cooling block and being screwed into the bottom of mounting blocks 2203.

As will be understood by those familiar with the art, the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosures and descriptions herein are intended to be illustrative, but not limiting, of the scope of the invention which is set forth in the following claims.

Claims

WHAT IS CLAIMED IS:

1. A diode laser assembly comprising: a stepped cooling block, said stepped cooling block comprising at least a first cooling block section, a second cooling block section, and a third cooling block section, wherein each of said first, second and third cooling block sections includes a plurality of mounting surfaces of increasing height relative to a plane corresponding to a lowermost portion of a cooling block bottom surface, wherein said first cooling block section is interposed between said second and third cooling block sections, and wherein said first cooling block section is recessed relative to said second and third cooling block sections; a plurality of diode laser subassemblies, wherein each of said diode laser subassemblies is comprised of: a mounting block; a diode laser submount mounted to said mounting block; and a diode laser mounted to said diode laser submount; and means for mounting each of said plurality of diode laser subassemblies onto corresponding mounting surfaces of said first cooling block section of said stepped cooling block, wherein each output beam from said plurality of diode laser subassemblies is displaced relative to an adj acent output beam .

2. The diode laser assembly of claim 1, wherein said diode laser submount of each of said plurality of is comprised of an electrically insulating material.

3. The diode laser assembly of claim 2, wherein said electrically insulating material is selected from the group consisting of aluminum nitride, beryllium oxide, CVD diamond and silicon carbide.

4. The diode laser assembly of claim 1, wherein said diode laser submount of each of said plurality of is comprised of an electrically conductive material.

5. The diode laser assembly of claim 4, wherein said electrically conductive material is selected from the group consisting of copper and copper tungsten.

6. The diode laser assembly of claim 1, wherein each of said diode laser subassemblies further comprises a first beam conditioning lens mounted to said mounting block, wherein an output beam from said diode laser passes through said first beam conditioning lens.

7. The diode laser assembly of claim 6, wherein each of said first beam conditioning lenses comprises a cylindrical lens.

8. The diode laser assembly of claim 6, wherein each of said diode laser subassemblies further comprises a second beam conditioning lens mounted to said mounting block, wherein a second output beam from a different diode laser subassembly of said plurality of diode laser subassemblies passes through said second beam conditioning lens.

9. The diode laser assembly of claim 6, wherein said output beam from said diode laser passes through a second beam conditioning lens mounted to the mounting block of an adjacent diode laser subassembly.

10. The diode laser assembly of claim 1, wherein said mounting means further comprises a plurality of clamping member pairs corresponding to said plurality of diode laser subassemblies.

11. The diode laser assembly of claim 10, wherein a first clamping member of each clamping member pair of said plurality of clamping member pairs is attached to a corresponding mounting surface of said second cooling block section and wherein a second clamping member of each clamping member pair of said plurality of clamping member pairs is attached to a corresponding mounting surface of said third cooling block section.

12. The diode laser assembly of claim 11, wherein said first clamping member of each clamping member pair of said plurality of clamping member pairs compresses a first portion of each diode laser submount against a first portion of each mounting block of each corresponding diode laser subassembly of said plurality of diode laser subassemblies and compresses said first portion of each mounting block against a first portion of each corresponding mounting surface of said first cooling block section, and wherein said second clamping member of each clamping member pair of said plurality of clamping member pairs compresses a second portion of each diode laser submount against a second portion of each mounting block of each corresponding diode laser subassembly of said plurality of diode laser subassemblies and compresses said second portion of each mounting block against a second portion of each corresponding mounting surface of said first cooling block section.

13. The diode laser assembly of claim 12, wherein said first clamping member of each clamping member pair of said plurality of clamping member pairs compresses a first electrical interconnect against a first electrical contact pad on said first portion of each diode laser submount, and wherein said second clamping member of each clamping member pair of said plurality of clamping member pairs compresses a second electrical interconnect against a second electrical contact pad on said second portion of each diode laser submount.

14. The diode laser assembly of claim 11, further comprising a first plurality of bolts attaching said first clamping member of each clamping member pair of said plurality of clamping member pairs to said corresponding mounting surface of said second cooling block section, and further comprising a second plurality of bolts attaching said second clamping member of each clamping member pair of said plurality of clamping member pairs to said corresponding mounting surface of said third cooling block section.

15. The diode laser assembly of claim 1 , wherein said mounting means further comprises at least one attachment bolt per diode laser subassembly.

16. The diode laser assembly of claim 15, wherein said mounting means further comprises at least one attachment bolt per diode laser subassembly.

17. The diode laser assembly of claim 1, further comprising a cooling source coupled to said cooling block.

18. The diode laser assembly of claim 17, wherein said cooling source is coupled to a bottom surface of said cooling block.

19. The diode laser assembly of claim 17, wherein said cooling source is coupled to at least one side surface of said cooling block.

20. The diode laser assembly of claim 17, wherein said cooling source is coupled to both a bottom surface and at least one side surface of said cooling block.

21. The diode laser assembly of claim 17, wherein said cooling source is integrated within said cooling block.

22. The diode laser assembly of claim 1, wherein each of said diode laser submounts further comprises a first electrical contact pad on a first portion of said diode laser submount and a second electrical contact pad on a second portion of said diode laser submount.

23. The diode laser assembly of claim 1, wherein said diode laser is a single emitter diode laser.

24. The diode laser assembly of claim 1, wherein said diode laser is a multi- emitter diode laser.

25. The diode laser assembly of claim 1 , wherein said cooling block bottom surface of said stepped cooling block is inclined.

26. The diode laser assembly of claim 25, wherein a separation distance corresponding to the distance between each of said plurality of mounting surfaces of said first cooling block section and said inclined cooling block bottom surface is the same for each of said plurality of mounting surfaces of said first cooling block section.

27. A diode laser assembly comprising: a stepped cooling block, said stepped cooling block comprising at least a first cooling block section, a second cooling block section, and a third cooling block section, wherein each of said first, second and third cooling block sections includes a plurality of mounting surfaces of increasing height relative to a plane corresponding to a lowermost portion of a cooling block bottom surface, wherein said first cooling block section is interposed between said second and third cooling block sections, and wherein said first cooling block section is raised relative to said second and third cooling block sections; a plurality of diode laser subassemblies, wherein each of said diode laser subassemblies is comprised of: a mounting block; a diode laser submount mounted to said mounting block; and a diode laser mounted to said diode laser submount; and means for mounting each of said plurality of diode laser subassemblies onto corresponding mounting surfaces of said first cooling block section of said stepped cooling block, wherein each output beam from said plurality of diode laser subassemblies is displaced relative to an adjacent output beam.

28. The diode laser assembly of claim 27, wherein said diode laser submount of each of said plurality of is comprised of an electrically insulating material.

29. The diode laser assembly of claim 28, wherein said electrically insulating material is selected from the group consisting of aluminum nitride, beryllium oxide, CVD diamond and silicon carbide.

30. The diode laser assembly of claim 27, wherein said diode laser submount of each of said plurality of is comprised of an electrically conductive material.

31. The diode laser assembly of claim 30, wherein said electrically conductive material is selected from the group consisting of copper and copper tungsten.

32. The diode laser assembly of claim 27, wherein each of said diode laser subassemblies further comprises a first beam conditioning lens mounted to said mounting block, wherein an output beam from said diode laser passes through said first beam conditioning lens.

33. The diode laser assembly of claim 32, wherein each of said first beam conditioning lenses comprises a cylindrical lens.

34. The diode laser assembly of claim 32, wherein each of said diode laser subassemblies further comprises a second beam conditioning lens mounted to said mounting block, wherein a second output beam from a different diode laser subassembly of said plurality of diode laser subassemblies passes through said second beam conditioning lens.

35. The diode laser assembly of claim 32, wherein said output beam from said diode laser passes through a second beam conditioning lens mounted to the mounting block of an adjacent diode laser subassembly.

36. The diode laser assembly of claim 27, wherein said mounting means further comprises a plurality of clamping member pairs corresponding to said plurality of diode laser subassemblies.

37. The diode laser assembly of claim 36, wherein a first clamping member of each clamping member pair of said plurality of clamping member pairs is attached to a corresponding mounting surface of said second cooling block section and wherein a second clamping member of each clamping member pair of said plurality of clamping member pairs is attached to a corresponding mounting surface of said third cooling block section.

38. The diode laser assembly of claim 37, wherein said first clamping member of each clamping member pair of said plurality of clamping member pairs compresses a first portion of each diode laser submount against a first portion of each mounting block of each corresponding diode laser subassembly of said plurality of diode laser subassemblies and compresses said first portion of each mounting block against a first portion of each corresponding mounting surface of said first cooling block section, and wherein said second clamping member of each clamping member pair of said plurality of clamping member pairs compresses a second portion of each diode laser submount against a second portion of each mounting block of each corresponding diode laser subassembly of said plurality of diode laser subassemblies and compresses said second portion of each mounting block against a second portion of each corresponding mounting surface of said first cooling block section.

39. The diode laser assembly of claim 38, wherein said first clamping member of each clamping member pair of said plurality of clamping member pairs compresses a first electrical interconnect against a first electrical contact pad on said first portion of each diode laser submount, and wherein said second clamping member of each clamping member pair of said plurality of clamping member pairs compresses a second electrical interconnect against a second electrical contact pad on said second portion of each diode laser submount.

40. The diode laser assembly of claim 37, further comprising a first plurality of bolts attaching said first clamping member of each clamping member pair of said plurality of clamping member pairs to said corresponding mounting surface of said second cooling block section, and further comprising a second plurality of bolts attaching said second clamping member of each clamping member pair of said plurality of clamping member pairs to said corresponding mounting surface of said third cooling block section.

41. The diode laser assembly of claim 27, wherein said mounting means further comprises at least one attachment bolt per diode laser subassembly.

42. The diode laser assembly of claim 27, further comprising a cooling source coupled to said cooling block.

43. The diode laser assembly of claim 42, wherein said cooling source is coupled to a bottom surface of said cooling block.

44. The diode laser assembly of claim 42, wherein said cooling source is coupled to at least one side surface of said cooling block.

45. The diode laser assembly of claim 42, wherein said cooling source is coupled to both a bottom surface and at least one side surface of said cooling block.

46. The diode laser assembly of claim 42, wherein said cooling source is integrated within said cooling block.

47. The diode laser assembly of claim 27, wherein each of said diode laser submounts further comprises a first electrical contact pad on a first portion of said diode laser submount and a second electrical contact pad on a second portion of said diode laser submount.

48. The diode laser assembly of claim 27, wherein said diode laser is a single emitter diode laser.

49. The diode laser assembly of claim 27, wherein said diode laser is a multi- emitter diode laser.

50. The diode laser assembly of claim 27, wherein said cooling block bottom surface of said stepped cooling block is inclined.

51. The diode laser assembly of claim 50, wherein a separation distance corresponding to the distance between each of said plurality of mounting surfaces of said first cooling block section and said inclined cooling block bottom surface is the same for each of said plurality of mounting surfaces of said first cooling block section.

52. A diode laser assembly comprising: a stepped cooling block, said stepped cooling block comprising at least a first cooling block section and a second cooling block section, wherein each of said first and second cooling block sections includes a plurality of stepped mounting surfaces of increasing height relative to a plane corresponding to a lowermost portion of a cooling block bottom surface, wherein adjacent stepped mounting surfaces of said first and second cooling block sections are non-coplanar with said stepped mounting surfaces of said first cooling block section positioned higher than said adjacent stepped mounting surfaces of said second cooling block section; a plurality of diode laser subassemblies, wherein each of said diode laser subassemblies is comprised of: a mounting block; a diode laser submount mounted to said mounting block; and a diode laser mounted to said diode laser submount; and means for mounting each of said plurality of diode laser subassemblies onto corresponding stepped mounting surfaces of said plurality of stepped mounting surfaces of said first cooling block section of said stepped cooling block, wherein each output beam from said plurality of diode laser subassemblies is displaced relative to an adjacent output beam.

53. The diode laser assembly of claim 52, wherein said diode laser submount of each of said plurality of is comprised of an electrically insulating material.

54. The diode laser assembly of claim 53, wherein said electrically insulating material is selected from the group consisting of aluminum nitride, beryllium oxide, CVD diamond and silicon carbide.

55. The diode laser assembly of claim 52, wherein said diode laser submount of each of said plurality of is comprised of an electrically conductive material.

56. The diode laser assembly of claim 55, wherein said electrically conductive material is selected from the group consisting of copper and copper tungsten.

57. The diode laser assembly of claim 52, wherein each of said diode laser subassemblies further comprises a first beam conditioning lens mounted to said mounting block, wherein an output beam from said diode laser passes through said first beam conditioning lens.

58. The diode laser assembly of claim 57, wherein each of said first beam conditioning lenses comprises a cylindrical lens.

59. The diode laser assembly of claim 57, wherein each of said diode laser subassemblies further comprises a second beam conditioning lens mounted to said mounting block, wherein a second output beam from a different diode laser subassembly of said plurality of diode laser subassemblies passes through said second beam conditioning lens.

60. The diode laser assembly of claim 57, wherein said output beam from said diode laser passes through a second beam conditioning lens mounted to the mounting block of an adjacent diode laser subassembly.

61. The diode laser assembly of claim 52, wherein said mounting means further comprises a plurality of clamping members attached to said plurality of stepped mounting surfaces of said second cooling block section of said stepped cooling block, wherein said plurality of clamping members corresponds to said plurality of diode laser subassemblies.

62. The diode laser assembly of claim 61 , wherein each clamping member of said plurality of clamping members compresses a portion of each diode laser submount against a portion of each mounting block of each corresponding diode laser subassembly of said plurality of diode laser subassemblies and compresses said portion of each mounting block against a portion of each corresponding stepped mounting surface of said first cooling block section.

63. The diode laser assembly of claim 62, wherein each clamping member of said plurality of clamping members compresses at least one electrical interconnect against at least one electrical contact pad on said portion of each diode laser submount.

64. The diode laser assembly of claim 61, further comprising a plurality of bolts corresponding to said plurality of clamping members, wherein said plurality of bolts are attached to said plurality of stepped mounting surfaces of said second cooling block section of said stepped cooling block.

65. The diode laser assembly of claim 52, wherein said mounting means further comprises at least one attachment bolt per diode laser subassembly.

66. The diode laser assembly of claim 52, further comprising a cooling source coupled to said stepped cooling block.

67. The diode laser assembly of claim 66, wherein said cooling source is integrated within said stepped cooling block.

68. The diode laser assembly of claim 52, wherein each of said diode laser submounts further comprises a first electrical contact pad on a first portion of said diode laser submount and a second electrical contact pad on a second portion of said diode laser submount.

69. The diode laser assembly of claim 52, wherein said diode laser is a single emitter diode laser.

70. The diode laser assembly of claim 52, wherein said diode laser is a multi- emitter diode laser.

71. The diode laser assembly of claim 52, wherein said cooling block bottom surface of said stepped cooling block is inclined.

72. The diode laser assembly of claim 71, wherein a separation distance corresponding to the distance between each of said plurality of stepped mounting surfaces of said first cooling block section and said inclined cooling block bottom surface is the same for each of said plurality of stepped mounting surfaces of said first cooling block section.

73. A diode laser assembly comprising: a stepped cooling block, said stepped cooling block comprising at least a first cooling block section and a second cooling block section, wherein each of said first and second cooling block sections includes a plurality of stepped mounting surfaces of increasing height relative to a plane corresponding to a lowermost portion of a cooling block bottom surface, wherein adjacent stepped mounting surfaces of said first and second cooling block sections are non-coplanar with said stepped mounting surfaces of said first cooling block section positioned higher than said adjacent stepped mounting surfaces of said second cooling block section; a plurality of diode laser subassemblies, wherein each of said diode laser subassemblies is comprised of: a mounting block; a diode laser submount mounted to said mounting block; and a diode laser mounted to said diode laser submount; a first beam conditioning lens mounted to said mounting block, wherein an output beam from said diode laser passes through said first beam conditioning lens; a second beam conditioning lens mounted to said mounting block, wherein a second output beam from a different diode laser subassembly of said plurality of diode laser subassemblies passes through said second beam conditioning lens; and means for mounting each of said plurality of diode laser subassemblies onto corresponding stepped mounting surfaces of said plurality of stepped mounting surfaces of said first cooling block section of said stepped cooling block, wherein each output beam from said plurality of diode laser subassemblies is displaced relative to an adjacent output beam.

74. A diode laser assembly comprising: a stepped cooling block, said stepped cooling block comprising at least a first cooling block section and a second cooling block section, wherein each of said first and second cooling block sections includes a plurality of stepped mounting surfaces of increasing height relative to a plane corresponding to a lowermost portion of a cooling block bottom surface, wherein adjacent stepped mounting surfaces of said first and second cooling block sections are non-coplanar with said stepped mounting surfaces of said first cooling block section positioned lower than said adjacent stepped mounting surfaces of said second cooling block section; a plurality of diode laser subassemblies, wherein each of said diode laser subassemblies is comprised of: a mounting block; a diode laser submount mounted to said mounting block; and a diode laser mounted to said diode laser submount; and means for mounting each of said plurality of diode laser subassemblies onto corresponding stepped mounting surfaces of said plurality of stepped mounting surfaces of said first cooling block section of said stepped cooling block, wherein each output beam from said plurality of diode laser subassemblies is displaced relative to an adjacent output beam.

75. The diode laser assembly of claim 74, wherein said diode laser submount of each of said plurality of is comprised of an electrically insulating material.

76. The diode laser assembly of claim 75, wherein said electrically insulating material is selected from the group consisting of aluminum nitride, beryllium oxide, CVD diamond and silicon carbide.

77. The diode laser assembly of claim 74, wherein said diode laser submount of each of said plurality of is comprised of an electrically conductive material.

78. The diode laser assembly of claim 77, wherein said electrically conductive material is selected from the group consisting of copper and copper tungsten.

79. The diode laser assembly of claim 74, wherein each of said diode laser subassemblies further comprises a first beam conditioning lens mounted to said mounting block, wherein an output beam from said diode laser passes through said first beam conditioning lens.

80. The diode laser assembly of claim 79, wherein each of said first beam conditioning lenses comprises a cylindrical lens.

81. The diode laser assembly of claim 79, wherein each of said diode laser subassemblies further comprises a second beam conditioning lens mounted to said mounting block, wherein a second output beam from a different diode laser subassembly of said plurality of diode laser subassemblies passes through said second beam conditioning lens.

82. The diode laser assembly of claim 79, wherein said output beam from said diode laser passes through a second beam conditioning lens mounted to the mounting block of an adjacent diode laser subassembly.

83. The diode laser assembly of claim 74, wherein said mounting means further comprises a plurality of clamping members attached to said plurality of stepped mounting surfaces of said second cooling block section of said stepped cooling block, wherein said plurality of clamping members corresponds to said plurality of diode laser subassemblies.

84. The diode laser assembly of claim 83, wherein each clamping member of said plurality of clamping members compresses a portion of each diode laser submount against a portion of each mounting block of each corresponding diode laser subassembly of said plurality of diode laser subassemblies and compresses said portion of each mounting block against a portion of each corresponding stepped mounting surface of said first cooling block section.

85. The diode laser assembly of claim 84, wherein each clamping member of said plurality of clamping members compresses at least one electrical interconnect against at least one electrical contact pad on said portion of each diode laser submount.

86. The diode laser assembly of claim 83, further comprising a plurality of bolts corresponding to said plurality of clamping members, wherein said plurality of bolts are attached to said plurality of stepped mounting surfaces of said second cooling block section of said stepped cooling block.

87. The diode laser assembly of claim 74, wherein said mounting means further comprises at least one attachment bolt per diode laser subassembly.

88. The diode laser assembly of claim 74, further comprising a cooling source coupled to said stepped cooling block.

89. The diode laser assembly of claim 88, wherein said cooling source is integrated within said stepped cooling block.

90. The diode laser assembly of claim 74, wherein each of said diode laser submounts further comprises a first electrical contact pad on a first portion of said diode laser submount and a second electrical contact pad on a second portion of said diode laser submount.

91. The diode laser assembly of claim 74, wherein said diode laser is a single emitter diode laser.

92. The diode laser assembly of claim 74, wherein said diode laser is a multi- emitter diode laser.

93. The diode laser assembly of claim 74, wherein said cooling block bottom surface of said stepped cooling block is inclined.

94. The diode laser assembly of claim 20, wherein a separation distance corresponding to the distance between each of said plurality of stepped mounting surfaces of said first cooling block section and said inclined cooling block bottom surface is the same for each of said plurality of stepped mounting surfaces of said first cooling block section.

95. A diode laser assembly comprising: a stepped cooling block, said stepped cooling block comprising at least a first cooling block section and a second cooling block section, wherein each of said first and second cooling block sections includes a plurality of stepped mounting surfaces of increasing height relative to a plane corresponding to a lowermost portion of a cooling block bottom surface, wherein adjacent stepped mounting surfaces of said first and second cooling block sections are non-coplanar with said stepped mounting surfaces of said first cooling block section positioned lower than said adjacent stepped mounting surfaces of said second cooling block section; a plurality of diode laser subassemblies, wherein each of said diode laser subassemblies is comprised of: a mounting block; a diode laser submount mounted to said mounting block; and a diode laser mounted to said diode laser submount; a first beam conditioning lens mounted to said mounting block, wherein an output beam from said diode laser passes through said first beam conditioning lens; a second beam conditioning lens mounted to said mounting block, wherein a second output beam from a different diode laser subassembly of said plurality of diode laser subassemblies passes through said second beam conditioning lens; and means for mounting each of said plurality of diode laser subassemblies onto corresponding stepped mounting surfaces of said plurality of stepped mounting surfaces of said first cooling block section of said stepped cooling block, wherein each output beam from said plurality of diode laser subassemblies is displaced relative to an adjacent output beam.

96. A diode laser assembly comprising: a cooling block comprised of a plurality of stepped mounting surfaces of increasing height relative to a plane corresponding to a lowermost portion of a cooling block bottom surface; a plurality of diode laser subassemblies, wherein each of said diode laser subassemblies is comprised of: a mounting block, wherein said mounting block does not include integral coolant passages; a diode laser submount mounted to said mounting block; and a diode laser mounted to said diode laser submount; and means for mounting said plurality of diode laser subassemblies onto said plurality of stepped mounting surfaces of said cooling block, wherein each output beam from said plurality of diode laser subassemblies is displaced relative to an adjacent output beam.

97. The diode laser assembly of claim 96, wherein said diode laser submount of each of said plurality of is comprised of an electrically insulating material.

98. The diode laser assembly of claim 97, wherein said electrically insulating material is selected from the group consisting of aluminum nitride, beryllium oxide, CVD diamond and silicon carbide.

99. The diode laser assembly of claim 96, wherein said diode laser submount of each of said plurality of is comprised of an electrically conductive material.

100. The diode laser assembly of claim 99, wherein said electrically conductive material is selected from the group consisting of copper and copper tungsten.

101. The diode laser assembly of claim 96, wherein each of said diode laser subassemblies further comprises a first beam conditioning lens mounted to said mounting block, wherein an output beam from said diode laser passes through said first beam conditioning lens.

102. The diode laser assembly of claim 101, wherein each of said first beam conditioning lenses comprises a cylindrical lens.

103. The diode laser assembly of claim 101, wherein each of said diode laser subassemblies further comprises a second beam conditioning lens mounted to said mounting block, wherein a second output beam from a different diode laser subassembly of said plurality of diode laser subassemblies passes through said second beam conditioning lens.

104. The diode laser assembly of claim 101, wherein said output beam from said diode laser passes through a second beam conditioning lens mounted to the mounting block of an adjacent diode laser subassembly.

105. The diode laser assembly of claim 96, wherein said mounting means further comprises a plurality of clamping members attached to said plurality of mounting surfaces of said cooling block, wherein said plurality of clamping members corresponds to said plurality of diode laser subassemblies.

106. The diode laser assembly of claim 105, wherein each clamping member of said plurality of clamping members compresses a portion of each diode laser submount against a portion of each mounting block of each corresponding diode laser subassembly of said plurality of diode laser subassemblies and compresses said portion of each mounting block against a portion of each corresponding stepped mounting surface of said cooling block.

107. The diode laser assembly of claim 106, wherein each clamping member of said plurality of clamping members compresses at least one electrical interconnect against at least one electrical contact pad on said portion of each diode laser submount.

108. The diode laser assembly of claim 105, further comprising a plurality of bolts corresponding to said plurality of clamping members, wherein said plurality of bolts are attached to said plurality of stepped mounting surfaces of said cooling block.

109. The diode laser assembly of claim 105, wherein at least two of said plurality of clamping members corresponds to each of said plurality of diode laser subassemblies.

110. The diode laser assembly of claim 96, wherein said mounting means further comprises at least one attachment bolt per diode laser subassembly.

111. The diode laser assembly of claim 96, further comprising a cooling source coupled to said cooling block.

112. The diode laser assembly of claim 111, wherein said cooling source is integrated within said cooling block.

113. The diode laser assembly of claim 96, wherein each of said diode laser submounts further comprises a first electrical contact pad on a first portion of said diode laser submount and a second electrical contact pad on a second portion of said diode laser submount.

114. The diode laser assembly of claim 96, wherein said diode laser is a single emitter diode laser.

115. The diode laser assembly of claim 96, wherein said diode laser is a multi- emitter diode laser.

116. The diode laser assembly of claim 96, wherein said cooling block bottom surface is inclined.

117. The diode laser assembly of claim 116, wherein a separation distance corresponding to the distance between each of said plurality of stepped mounting surfaces of said cooling block and said inclined cooling block bottom surface is the same for each of said plurality of stepped mounting surfaces.

118. Adiode laser assembly comprising: a cooling block comprised of a plurality of stepped mounting surfaces of increasing height relative to a plane corresponding to a lowermost portion of a cooling block bottom surface; a plurality of diode laser subassemblies, wherein each of said diode laser subassemblies is comprised of: a mounting block, wherein said mounting block does not include integral coolant passages; a diode laser submount mounted to said mounting block; a diode laser mounted to said diode laser submount; a first beam conditioning lens mounted to said mounting block, wherein an output beam from said diode laser passes through said first beam conditioning lens; and a second beam conditioning lens mounted to said mounting block, wherein a second output beam from a different diode laser subassembly of said plurality of diode laser subassemblies passes through said second beam conditioning lens; and means for mounting said plurality of diode laser subassemblies onto said plurality of stepped mounting surfaces of said cooling block, wherein each output beam from said plurality of diode laser subassemblies is displaced relative to an adjacent output beam.

119. A diode laser assembly comprising: a cooling block comprised of a de laser subassembly of said plurality of diode laser subassemblies passes through said second beam conditioning lens; and means for mounting said plurality of diode laser subassemblies onto said plurality of stepped mounting surfaces of said cooling block, wherein each output beam from said plurality of diode laser subassemblies is displaced relative to an adjacent output beam.