Demonstration of a Saturated Liquid Refrigerant Spray Cooling System for Laser Diode Arrays

"Next-generation laser diode arrays and solid-state lasers being developed for a variety of military and commercial applications, are rapidly becoming limited by their cooling systems. Improved high heat flux capabilities of the thermal management systemcan significantly improve device output power, reliability, size, and mass. Researchers have demonstrated the potential of spray cooling laser diode modules, but were limited by small surface areas, below ambient spray pressures, and high temperatures.Mainstream, a world leader in spray cooling of electronics devices, will demonstrate the advantages of a saturated liquid refrigerant spray cooling array and its application to large laser diode arrays. In Phase I, Mainstream will demonstrate both highheat flux capability at low wall superheat and uniform high heat flux capability over large surface areas. The advantages of this thermal system will be demonstrated on an actual laser diode array. Phase II will demonstrate laser performance and lifeimprovements of an integrated diode array / high heat flux thermal management system. The worldwide market for diode lasers reached $6.59 billion in 2000. With a growth rate of 108% there is an urgent need to develop high heat flux cooling techniques thatcan be implemented into the thermal packaging of the next-generation military, aerospace, and commercial lasers. Mainstream has already demonstrated saturated liquid spray cooling systems f