High power light-emitting diode package and methods for making same

In a light-emitting diode package made in accordance with the present invention, a light-emitting diode assembly is positioned above a spacer assembly. In the light-emitting diode assembly, a die containing a light-emitting diode is positioned above a substrate. During operation, both the combination of at least one conductive plate adjacent to the die and a plurality of castellated side holes positioned on sides of the substrate, and a substrate thermal via positioned beneath the die, conduct thermal energy from the die to a light-emitting diode assembly pad on which the substrate is mounted. The light-emitting diode assembly pad conducts thermal energy to a top pad of the spacer assembly. A plurality of castellated side holes formed in sides of a spacer of the spacer assembly and a plurality of thermal vias positioned within the spacer conduct thermal energy from the top pad of the spacer assembly to a base pad of the spacer assembly.

TECHNICAL FIELD

These teachings generally concern light-emitting diodes packages, and more particularly concern light-emitting diode package designs that have improved thermal dissipation properties and thus allow light-emitting diodes to operate at higher power loadings.

BACKGROUND

Light-emitting diodes (“LEDs”) are semiconductor devices that emit light when a voltage or current are applied to their terminals. LEDs have found widespread application in consumer electronics. It is well-known to those skilled in the art to use LEDs in alphanumeric displays; control panels; remote controls and many other applications.

As with many electronic circuit devices, there are often particular applications which require relatively high-power operating conditions for LEDs. In such situations, LEDs create significant thermal energy during operation. In addition, current LED architectures are incapable of handling increased power loads without the possibility of failure.

Thus, those skilled in the art desire improved LED package designs that are capable of handling significantly-increased power loads without failure. In particular, LED packages with improved capability to dissipate thermal energy during operation are desired.

SUMMARY OF THE PREFERRED EMBODIMENTS

The foregoing and other problems are overcome, and other advantages are realized, in accordance with the presently preferred embodiments of these teachings.

A first alternate embodiment of the present invention comprises a light-emitting diode package comprising: a spacer assembly comprising: a base pad made from conductive material; a spacer made from insulating material positioned atop the base pad, where a first plurality of castellated side holes are formed in sides of the spacer, the first plurality of castellated side holes formed at least in part from conductive material, the conductive material of the first plurality of castellated side holes in contact with the conductive material of the base pad, the spacer further comprising a plurality of internal cavities in contact with, and extending away from, the base pad; a top pad made from conductive material positioned above the spacer, the top pad in contact with the first plurality of castellated side holes of the spacer and the plurality of internal cavities of the spacer; a thermal via formed in each of the plurality of internal cavities in the spacer, the thermal vias made from conductive material and serving to conduct thermal energy from the top pad to the base pad; a light-emitting diode assembly positioned above the spacer assembly and affixed to the top pad of the spacer assembly, the light-emitting diode assembly comprising: a light-emitting diode assembly base pad made from conductive material; a substrate made from insulating material positioned atop the light-emitting diode assembly base pad, where a second plurality of castellated side holes are fabricated in sides of the substrate, the second plurality of castellated side holes formed at least in part from conductive material, the conductive material of the second plurality of castellated side holes in contact with the conductive material of the light-emitting diode assembly base pad; a die containing a light-emitting diode positioned atop the substrate; at least one plate made from conducting material positioned atop the substrate extending from the die to sides of the substrate, the at least one plate serving to conduct thermal energy away from the die containing the light-emitting diode to the second plurality of castellated side holes in the substrate; and a substrate thermal via positioned within a cavity of the substrate, the substrate thermal via extending from the die to the light-emitting diode assembly base pad, the substrate thermal via made from conducting material and serving to conduct thermal energy from the die to the light-emitting diode assembly base pad; and whereby during operation thermal energy is first conducted away from the light-emitting diode to the light-emitting diode assembly base pad by the substrate thermal via and the combination of the at least one plate and the second plurality of castellated side holes, and then conducted from the light-emitting diode assembly base pad to the base pad of the spacer assembly by the top pad, the first plurality of castellated side holes and the plurality of thermal vias positioned within the spacer.

A second alternate embodiment of the present invention comprises a light-emitting diode package comprising: a base pad made from conductive material; a substrate made from insulating material positioned atop the base pad, where a plurality of castellated side holes are formed in sides of the substrate, the plurality of castellated side holes formed at least in part from conductive material, the conductive material of the plurality of castellated side holes in contact with the conductive material of the base pad; a die containing a light-emitting diode positioned atop the substrate; at least one plate made from conducting material positioned atop the substrate and extending from the die to sides of the substrate, the at least one plate serving to conduct thermal energy away from the die containing the light-emitting diode to the castellated side holes of the substrate; and a substrate thermal via positioned within a cavity of the substrate, the substrate thermal via extending from the die to the base pad, the substrate thermal via made from conductive material and serving to conduct thermal energy from the die containing the light-emitting diode to the base pad; and whereby during operation thermal energy is conducted away from the die containing the light-emitting diode to the base pad by the substrate thermal via and the combination of the at least one plate and the plurality of castellated side holes.

A third alternate embodiment of the present invention comprises a light-emitting diode package comprising: a spacer assembly comprising: a base pad made from conductive material; a spacer made from insulating material positioned atop the base pad, where a first plurality of castellated side holes are formed in sides of the spacer, the first plurality of castellated side holes formed at least in part from conductive material, the conductive material of the first plurality of castellated side holes in contact with the conductive material of the base pad, the spacer further comprising a plurality of internal cavities in contact with, and extending away from, the base pad; a top pad made from conductive material positioned above the spacer, the top pad in contact with the first plurality of castellated side holes of the spacer and the plurality of internal cavities of the spacer; a thermal via formed in each of the plurality of internal cavities in the spacer, the thermal vias made from conductive material and serving to conduct thermal energy from the top pad to the base pad; a light-emitting diode assembly positioned above the spacer assembly and affixed to the top pad of the spacer assembly, the light-emitting diode assembly comprising: a light-emitting diode assembly base pad made from conductive material; a substrate made from insulating material positioned atop the light-emitting diode assembly base pad, where a second plurality of castellated side holes are fabricated in sides of the substrate, the second plurality of castellated side holes formed at least in part from conductive material, the conductive material of the second plurality of castellated side holes in contact with the conductive material of the light-emitting diode assembly base pad; a die containing a light-emitting diode positioned atop the substrate; at least one plate made from conducting material positioned atop the substrate extending from the die to sides of the substrate, the at least one plate serving to conduct thermal energy away from the die containing the light-emitting diode to the second plurality of castellated side holes in the substrate; and whereby during operation thermal energy is first conducted away from the light-emitting diode to the light-emitting diode assembly base pad by the at least one plate and the second plurality of castellated side holes, and then conducted from the light-emitting diode assembly base pad to the base pad of the spacer assembly by the top pad, the first plurality of castellated side holes and the plurality of thermal vias positioned within the spacer.

A fourth alternate embodiment of the present invention comprises a light-emitting diode package comprising: a spacer assembly comprising: a base pad made from conductive material; a spacer made from insulating material positioned atop the base pad, where a first plurality of castellated side holes are formed in sides of the spacer, the first plurality of castellated side holes formed at least in part from conductive material, the conductive material of the first plurality of castellated side holes in contact with the conductive material of the base pad; a top pad made from conductive material positioned above the spacer, the top pad in contact with the first plurality of castellated side holes of the spacer; a light-emitting diode assembly positioned above the spacer assembly and affixed to the top pad of the spacer assembly, the light-emitting diode assembly comprising: a light-emitting diode assembly base pad made from conductive material; a substrate made from insulating material positioned atop the light-emitting diode assembly base pad, where a second plurality of castellated side holes are fabricated in sides of the substrate, the second plurality of castellated side holes formed at least in part from conductive material, the conductive material of the second plurality of castellated side holes in contact with the conductive material of the light-emitting diode assembly base pad; a die containing a light-emitting diode positioned atop the substrate; at least one plate made from conducting material positioned atop the substrate extending from the die to sides of the substrate, the at least one plate serving to conduct thermal energy away from the die containing the light-emitting diode to the second plurality of castellated side holes in the substrate; and a substrate thermal via positioned within a cavity of the substrate, the substrate thermal via extending from the die to the light-emitting diode assembly base pad, the substrate thermal via made from conducting material and serving to conduct thermal energy from the die to the light-emitting diode assembly base pad; and whereby during operation thermal energy is first conducted away from the light-emitting diode to the light-emitting diode assembly base pad by the substrate thermal via and the combination of the at least one plate and the second plurality of castellated side holes, and then conducted from the light-emitting diode assembly base pad to the base pad of the spacer assembly by the top pad and the first plurality of castellated side holes.

A fifth alternate embodiment of the present invention comprises a method for making a light-emitting diode package comprising: forming a spacer assembly, wherein forming a spacer assembly comprises: forming a spacer assembly base pad from conductive material; forming a spacer made from insulating material atop the spacer assembly base pad; forming a first plurality of castellated side holes on sides of the spacer, the first plurality of castellated side holes formed at least in part from conductive material, the conductive material in contact with the conductive material of the spacer assembly base pad; forming a plurality of internal cavities in the spacer, the internal cavities contacting the spacer assembly base pad, and extending upwards away from the spacer assembly base pad; forming a plurality of thermal vias in the plurality of internal cavities of the spacer from conductive material; forming a spacer assembly top pad atop the spacer, the spacer assembly top pad made from conductive material, the conductive material of the spacer assembly top pad in contact with the conductive material of the thermal vias and the first plurality of castellated side holes; forming a light-emitting diode assembly, wherein forming a light-emitting diode assembly comprises: forming a light-emitting diode assembly base pad from conductive material; forming a substrate from insulating material above the light-emitting diode assembly base pad; forming a cavity in the substrate, the cavity contacting the light-emitting diode assembly base pad and extending upward away from the light-emitting diode assembly base pad; forming a substrate thermal via in the cavity of the substrate; forming a second plurality of castellated side holes on sides of the substrate, the second plurality of castellated side holes formed at least in part from conductive material, the conductive material of the second plurality of castellated side holes in contact with the conductive material of the light-emitting diode assembly base pad; forming at least one plate atop the substrate from conductive material, the plate extending from a position where a die containing a light-emitting diode is to be positioned on the substrate to the sides of the substrate, the conductive material of the at least one plate contacting the conductive material of the second plurality of castellated side holes; and placing the die containing the light-emitting diode on the substrate above the substrate thermal via and adjacent to the at least one plate; and affixing the light-emitting diode assembly base pad to the top pad of the spacer assembly.

Thus it is seen that the foregoing alternate embodiments of the present invention overcome the limitations of the prior art. In particular, the high-power infrared light-emitting diode package of the present invention provides improved thermal dissipation capabilities over packages made in accordance with the prior art. Infrared light-emitting diodes incorporated in packages made in accordance with the present invention can operate at significantly higher power levels without experiencing an undue decrease in the mean time between failure, as in the case of infrared light-emitting diodes incorporated in packages made in accordance with the prior art.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An infrared (“IR”) LED package100made in accordance with the prior art is depicted inFIGS. 1A–Band comprises a spacer assembly110affixed to a light-emitting diode assembly150. The spacer assembly110comprises a spacer114made from insulating material positioned between a base pad112and a top pad130both made from conductive material (for example, copper). Formed in sides116of the spacer114are a first plurality of castellated side holes118made in part from conducting material. The conducting material of the first plurality of castellated side holes118is in contact with the conductive material of the base pad112and the top pad130.

Positioned atop the spacer assembly110is the light-emitting diode assembly150comprising a light-emitting diode assembly base pad152made from conductive material. Positioned above the light-emitting diode assembly base pad152is a substrate154made from insulating material for supporting a die170. Formed in sides156of the substrate154is a second plurality of castellated side holes158made in part from conductive material. The conductive material of the second plurality of castellated side holes158is in contact with the light-emitting diode assembly base pad152. Conductive plates160,162are positioned adjacent to, and are in contact with, die170containing the light-emitting diode. In the embodiment depicted inFIG. 1A–B, conductive plate160extends beneath die170. The conductive plates160,162serve to conduct thermal energy away from the die170to the second plurality of castellated side holes158.

Positioned above the light-emitting diode assembly150is a lens180.

As is apparent from an examination ofFIGS. 1A–B, the die170containing the light-emitting diode is surrounded for the most part by insulating material in the form of the substrate154and spacer114. This situation significantly limits the ability of the package100to dissipate thermal energy generated by the light-emitting diode during operation, and thereby limits the ability of the light-emitting diode to operate at higher power loadings. Accordingly, those skilled in the art desired an improved high power IR light-emitting diode package design with substantially improved thermal energy dissipation capability.

An improved high power IR light-emitting diode package200made in accordance with the present invention and overcoming the limitations of the prior art is depicted inFIGS. 2A–B. In the improved light-emitting diode package200of the present invention, a spacer assembly210is affixed by, for example, solder248, to a light-emitting diode assembly250. The spacer assembly210comprises a spacer214made from insulating material positioned between a base pad212and a top pad230both made from conductive material. Formed in sides216of the spacer214are a first plurality of castellated side holes218made in part from conducting material. The conducting material of the first plurality of castellated side holes218is in contact with the conductive material of the base pad212and top pad230, and during operation serves to conduct thermal energy from the top pad230to the base pad212.

An improvement of the present invention is apparent in the spacer assembly210. Formed in the spacer214is a plurality of internal cavities220in contact with, and extending away from, the base pad212. Formed within the internal cavities220is a plurality of thermal vias222. The thermal vias222can be fabricated in many ways; for example, they can be created by plating the internal cavities220with thermally conductive material (for example, copper or copper compounds), or the cavities can be filled in their entirety with conductive material. The plurality of thermal vias222are in contact with, and serve to conduct thermal energy away from, the top pad230positioned atop the spacer214.

Positioned atop the spacer assembly210is a light-emitting diode assembly250comprising a substrate254positioned above a light-emitting diode assembly base pad252. The light-emitting diode assembly base pad252is made from conductive material, and the substrate254from insulating material. Positioned above the substrate254is a die270containing the light-emitting diode.

Another improvement of the present invention is apparent from examination ofFIGS. 2A–B. In contrast to the prior art light-emitting diode package100, a second plurality of castellated side holes258are arrayed on all sides256of the substrate. Further in contrast to the light-emitting diode package100of the prior art, in the light-emitting diode package of the present invention, at least one conductive plate260fans outward from the die270and contacts ones of the second plurality of castellated side holes258positioned on at least two sides256of the substrate254(in the embodiment ofFIGS. 2A–B, conductive plate260contacts castellated side holes on three sides of the substrate). The increased dimensions and improved arrangement of the conductive plate260and the castellated side holes of the second plurality258provide improved thermal dissipation properties for the light-emitting diode200of the present invention in comparison to those of the prior art. Plate262also conducts thermal energy to castellated side holes located on another side of the substrate254.

In alternate embodiments of the present invention, the substrate254may have three or more vertical sides256, or may be circular or oval in configuration. In such embodiments, individual ones of the second plurality of castellated side holes258would be positioned on each of the sides of the substrate or, in embodiments having a cylindrical substrate, about the circumference of the substrate. In such embodiments, at least one conductive plate would fan outward from the270to contact castellated side holes from the second plurality on at least two sides, or about the periphery, of the substrate254.

An additional improvement of the light-emitting diode package200of the present invention over that of the prior art is apparent in the substrate254of the light-emitting diode assembly250. Positioned beneath the die270in a cavity264of the substrate is a base thermal via266. The base thermal via266positioned beneath the die270serves to conduct thermal energy away from the die270to the light-emitting diode assembly pad252.

Further improvements apparent in the light-emitting diode package200cooperate with the preceding improvements to further increase the thermal dissipation properties of the package200over those of the prior art. For example, the base pad212is enlarged over that of the prior art light-emitting diode package100extending to a position where it is beneath die270and cooperating with the plurality of thermal vias222in the spacer. The light-emitting diode assembly pad252of the light-emitting diode package200is similarly enlarged and also cooperates with the base thermal via262to improve the thermal dissipation properties of the package200. Notably, there is a direct thermal path from die270through the thermal vias266and222to the spacer base pad212.

Thus, taken together, the improvements incorporated in the light-emitting diode package200made in accordance with the present invention serve to provide additional thermal conduits to conduct thermal energy away from the light-emitting diode during operation. One of ordinary skill in the art will also understand that the thermal conduits can serve a dual purpose by also establishing electrical contacts for the light emitting diode with power sources external to the light-emitting diode package. Alternatively, separate electrical contacts may be used.

The improved thermal dissipation properties of light-emitting diode packages incorporating the improvements of the present invention provide high-power infrared (“IR”) light-emitting diode packages with the ability to operate at higher power loadings. The improvements of the present invention are also applicable to light-emitting diodes operating at different frequencies where improved thermal dissipation properties are likewise desired.

In alternate embodiments of the present invention, the improvements depicted inFIGS. 2A–Bcan be used alone or in combination. In addition, a spacer element need not be used.

FIGS. 3A–Bdepict another embodiment having a spacer. The light-emitting diode package300comprises a light-emitting diode assembly350positioned atop, and affixed by a solder layer348to, a spacer assembly310using a solder joint348. The spacer assembly310comprises a spacer314made from insulating material positioned between a base pad312and a top pad330both made from conductive material. Formed in sides316of the spacer314are a first plurality of castellated side holes318made in part from conducting material. The conducting material of the first plurality of castellated side holes318is in contact with the conductive material of the base pad312and top pad330, and during operation serves to conduct thermal energy from the top pad330to the base pad312.

Incorporated in the spacer assembly is one of the improvements of the present invention previously depicted in, and described with respect to,FIGS. 2A–B. Formed in the spacer314is a plurality of internal cavities320in contact with, and extending away from, the base pad312. Formed within the internal cavities320is a plurality of thermal vias322. As described with respect toFIGS. 2A–B, the thermal vias322can be fabricated in many ways; for example, they can be created by plating the internal cavities320with thermally conductive material (for example, copper or copper compounds), or the cavities can be filled in their entirety with conductive material. The plurality of thermal vias322are in contact with, and serve to conduct thermal energy away from, the top pad330located above the spacer314.

A light-emitting diode assembly350is affixed by solder joint348to, and positioned above, the spacer assembly310. The light-emitting diode assembly350comprises at least in part a substrate354positioned above a light-emitting diode assembly base pad352. The light-emitting diode assembly base pad is made from conductive material, and the substrate354from insulating material. A die370containing a light-emitting diode is located above the substrate354.

The light-emitting diode package300depicted inFIGS. 3A–Bincorporates another improvement depicted in, and described with respect to,FIGS. 2A–B. In this improvement, a second plurality of castellated side holes358is arrayed on all sides356of the substrate. Two conductive plates360,362extend outward from the die370and contact ones of the second plurality of castellated sideholes358positioned on the sides356of the substrate. In particular, conductive plate360fans outward from the die370and contacts ones of the second plurality of castellated side holes358on three sides356of the substrate354. The increased dimensions and improved arrangement of the conductive plate360and the castellated side holes358of the second plurality provide improved thermal dissipation properties for the light-emitting diode package300of the present invention in comparison to those of the prior art.

A lens380is positioned above die370.

In combination, the improvements of the light-emitting diode package300of the present invention serve to improve the thermal dissipation properties of the package300. During operation, thermal energy is conducted away from the die370first by the combination of the plates360,362and the second plurality of castellated side holes358. This combination conducts thermal energy to the light-emitting diode assembly base pad352. From the light-emitting diode assembly base pad352, thermal energy is then conducted to the spacer assembly base pad312by the combination of the top pad330, the first plurality of castellated side holes318and the plurality of thermal vias322.

A further embodiment of the present invention having a different combination of improvements over prior-art light-emitting diode packages is depicted inFIGS. 4A–B. In the improved light-emitting diode package400of the further embodiment of the present invention, a spacer assembly410is affixed to a light-emitting diode assembly450by a solder joint448. In the spacer assembly410, a spacer414made from insulating material is positioned between a base pad412and a top pad430both made from conductive material. Formed in sides416of the spacer414are a first plurality of castellated side holes418made in part from conductive material. The conductive material of the first plurality of castellated side holes418is in contact with the conductive material of the base pad412and top pad430, and during operation serves to conduct thermal energy away from the top pad430to the base pad412.

The light-emitting diode assembly450is affixed by any known method familiar to those skilled in the art, for example, soldering, to the spacer assembly410. The light-emitting diode assembly comprises a substrate454positioned above a light-emitting diode assembly base pad. The light-emitting assembly base pad452is made from conductive material, and the substrate454from insulating material. Positioned above the substrate454is a die470containing the light-emitting diode. A lens480is positioned above the die470.

An improvement incorporated in a preceding embodiment is likewise included in the further embodiment of the present invention and comprises a second plurality of castellated side holes arrayed on all sides of the substrate. At least one conductive plate460fans outward from the die470and contacts ones of the second plurality of castellated side holes458positioned on three sides of the substrate. The increased dimensions of the conductive plate460and the castellated side holes of the second plurality458provide improved thermal dissipation properties for the light-emitting diode package400of the present invention.

The further embodiment depicted inFIGS. 4A–Balso incorporates a substrate thermal via466positioned beneath the conductive plate460and die470. In operation, the combination of the conductive plates460,462nd second plurality of castellated side holes458, and the substrate thermal via466conduct thermal energy away from the die470containing the light-emitting diode to the light-emitting diode assembly base pad452. The top pad430and first plurality of castellated side holes418in turn serve to conduct thermal energy away from the light-emitting diode assembly base pad452to the spacer assembly410base pad412.

As indicated previously, the improvements of the present invention can be incorporated in a light-emitting diode package not having a space assembly.FIGS. 5A–Bdepict a light-emitting diode package500made in accordance with the prior art. The light-emitting diode package500comprises a substrate514positioned above a base pad512. Positioned on two sides516of the substrate is a plurality of castellated side holes518made in part from conductive material. Positioned above the substrate are two conductive plates520,522. Positioned above the conductive plate520and substrate514is a die530containing alight-emitting diode. A lens580is positioned above the die530. As in the case of the light-emitting diode package100having a spacer assembly110made in accordance with the prior art depicted inFIGS. 1A–B, the light-emitting diode package500has limited thermal dissipation capabilities. In the first instance, the die is positioned above a substrate514that has limited thermal dissipation capabilities. Further, the limited surface area and small size of the conductive plates520,522and plurality of castellated side holes further limits the thermal dissipation properties of the light-emitting diode package500.

A light-emitting diode package600made in accordance with the present invention which overcomes the limitations of the light-emitting diode package500of the prior art is depicted inFIGS. 6A–B. As is apparent, the light-emitting diode package600made in accordance with the present invention lacks a spacer assembly, illustrating that the teachings of the present invention can be applied to a light-emitting diode package not having a spacer assembly.

The light-emitting diode package600of the present invention depicted inFIGS. 6A–Bcomprises a substrate614positioned above a base pad612. Located on at least three sides of the substrate514is a plurality of castellated side holes620cooperating with conductive plate622which fans outward from a die630containing a light-emitting diode. The conductive plate is of enlarged dimension and contacts ones of the plurality of castellated side holes on three sides of the spacer. In addition, there is a substrate thermal via640positioned beneath the die630containing the light-emitting diode.

The present invention further comprises methods for constructing a light-emitting diode package having improved thermal dissipation properties. One such method is depicted inFIGS. 7A–Band comprises a step710of creating a spacer assembly by first forming a spacer assembly base pad from conductive material at step712. Then, at step714a spacer made from insulating material is affixed to the spacer assembly base pad. Next, at step716a first plurality of castellated side holes is formed on sides of the spacer. The first plurality of castellated side holes may comprise, for example, semi-circular indentations extending vertically up and down sides of the spacer. The first plurality of castellated side holes are plated with conductive material which is in contact with the spacer assembly base pad. Then, at step718, a plurality of internal cavities is formed in the spacer by drilling the spacer. The internal cavities contact the spacer assembly base pad on one end and extend upward away from the spacer assembly base pad. In alternate embodiments of the method, the spacer may be formed by a casting or molding process. In such processes, the first plurality of castellated side holes and internal cavities can be cast or molded into the spacer. Next, at step720, thermal vias are formed in each of the internal cavities by, for example, plating the walls of the internal cavities with conductive material, or by filling the cavities with conductive material. Then, at step722a spacer assembly top pad is affixed to the top of the spacer. The spacer assembly top pad can be used as a solder pad to affix a light emitting diode assembly to the spacer assembly. The spacer assembly top pad is made from conductive material which is in contact with the conductive material of the thermal vias and the first plurality of castellated side holes.

The second part of the method is depicted inFIG. 7Band comprises at step724creating a light emitting diode assembly by first creating a light emitting diode assembly base pad from conductive material at step726. Then, at step728a substrate comprising insulating material is formed atop the light-emitting diode assembly base pad. Next, at step730a cavity is formed in the substrate by, for example, drilling. The cavity contacts the light-emitting diode assembly and extends upward away from the light emitting diode assembly base pad. Then, at step732a substrate thermal via is formed in the cavity by plating the sides of the cavity with conductive material, or by filling the cavity with conductive material. Next, at step734a second plurality of castellated side holes are formed in sides of the substrate. The second plurality of castellated side holes comprise semi-circular indentations that extend vertically up and down the sides of the substrate, although other cross-sections can be adopted, for example, square or rectangular. The surfaces of the castellated side holes are plated with conductive material which is in contact with the conductive material of the light-emitting diode assembly base pad. Then, at step736at least one plate is formed above the substrate; the plate is made from conductive material and extends from a position where a die containing a light-emitting diode is to be positioned on the substrate to the sides of the substrate. The conductive material of the at least one plate contacts the conductive material of the second plurality of castellated side holes. Next, at step738, the die containing the light-emitting diode is placed on the substrate above the substrate thermal via and adjacent to the at least one plate. Then at step740, the light-emitting diode assembly base pad is affixed to the top pad of the spacer assembly.

One of ordinary skill in the art will understand that one or more additional steps may need to be performed to establish electrical contacts for the light emitting diode. In other embodiments, the conductive elements of the present invention may serve a dual purpose by both establishing electrical contacts with the light emitting diode and conducting thermal energy away from the light emitting diode.

In addition, one of ordinary skill in the art will understand that one or more steps of the method of the present invention may be deleted where it is desired that an improved light-emitting diode package be constructed that does not incorporate all of the improvements of the present invention. Such methods are still within the scope of the present invention. For example, in one alternate method, the steps having to do with creation of a spacer assembly may be deleted where a spacer assembly is not desired. In other alternate methods of the present invention, a spacer assembly may be created which lacks internal cavities for accommodating thermal vias. The light-emitting diode packages made with these alternate methods will, nonetheless, incorporate one or more improvements of the preset invention.

The foregoing description has provided by way of exemplary and non-limiting examples a full and informative description of the best method and apparatus presently contemplated by the inventors for carrying out the invention. However, various modifications and adaptations may become apparent to those skilled in the relevant arts in view of the foregoing description, when read in conjunction with the accompanying drawings and the appended claims. As but some examples, the use of other similar or equivalent high power infrared light-emitting diode packages may be attempted by those skilled in the art. However, all such and similar modifications of the teachings of this invention will still fall within the scope of this invention.

Thus it is seen that an high-power infrared light-emitting diode package and methods for making same are provided by the present invention. One skilled in the art will appreciate that the various embodiments described herein can be practiced individually; in combination with one or more other embodiments described herein; or in combination with IR LED package designs differing from those described herein. Further, one skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments; that these described embodiments are presented for the purposes of illustration and not of limitation; and that the present invention is therefore limited only by the claims which follow.