Patent ID: 7710045

Claim:
An illumination assembly, comprising: a substrate comprising a first and second electrically conductive layer separated by an electrically insulating layer, the insulating layer comprising a polymer material loaded with thermally conductive particles, wherein at least a portion of the thermally conductive particles simultaneously contact both the first and second electrically conductive layers and extend partially into at least one of the first and second electrically conductive layers, wherein the thermally conductive particles are not deformed and at least one of the first and second electrically conductive layers are deformed by the thermally conductive particles sufficiently to eliminate an interface of the polymer material between the thermally conductive particles and the at least one of the first and second electrically conductive layers into which the portion of the thermally conductive particles extend, and wherein the thermally conductive particles penetrate the at least one of the first and second electrically conductive layers beyond the eliminated interface; and a plurality of light sources disposed on the first conductive layer.