Patent ID: 7795051

Claim:
A method for assembling LED components, comprising; mounting an LED die on a submount; applying a first solder between a bottom mating surface of the submount and a raised top mating surface of a heat sink, wherein at least the bottom mating surface and the raised top mating surface are solder wettable and have substantially the same shape and area; reflowing the first solder, whereby the submount and the heat sink are aligned and bonded together during reflowing, wherein the first solder aligns perimeters of the bottom mating surface and the raised top mating surface with an accuracy of at least 20 microns; applying a second solder between a raised bottom mating surface of the heat sink and a top mating surface of a substrate wherein at least the raised bottom mating surface and the top mating surface are solder wettable and have substantially the same shape and area; and reflowing the second solder, whereby the heat sink and the substrate are aligned and bonded together during reflowing.