We will present methods we used to further improve the slow axis BPP without efficiency penalty. Results of performance for multi-KW direct diode laser system application with this technology will be presented as well.
IntroductionFor high brightness direct diode laser systems it is of fundamental importance to improve the slow axis beam quality of the incorporated laser diodes regardless what beam combining technology is applied. The beam quality is predominantly determined by the build in index step in combination with the thermal lens effect. According to device analysis and related simulations, with increasing operation current, the self-heating nature of the waveguide causes an increase in the thermal gradient between the waveguide and surrounding materials. Consequently, higher order modes reach their thresholds, yielding larger lateral far fields. In order to reduce the underlying thermal lens effect in broad area laser diodes, humping pillars of plated gold [1] and copper pedestals under emitters [2, 3] have been used as thermal path to minimize the thermal gradient across the slow axis direction. Control of slow axis mode behavior with phase structures in broad area lasers [4,5], mode filters [6] and current path structuring [7] have also been reported. Unfortunately, most of these publications report methods for beam quality improvements of semiconductor broad area diode lasers that sacrifice device efficiency and reliable output power. To improve beam quality as well as increase efficiency and reliable output power, we investigated methods of reducing local heat generation, thermal gradient across the slow axis direction and discriminating high order modes. We have already reported results of lateral waveguide design based on the control of lateral index difference and the discrimination of high order modes [8]. Based on our findings from experiments, we have combined these different methods in our new device design. Subsequently, the beam parameter product (BPP) of laser diode bars with 10% fill factor has improved by approximately 30% at the ~7W/emitter operation power without efficiency penalty. The same technology has also been applied on various fiber coupled high brightness multi-kilowatt direct diode laser products. In this paper, we will elaborate on methods we used as well as test results our new products yielded.