Patent ID: 7087463

Claim:
The method comprising: attaching a plurality of light emitting chips on a sub-mount wafer; encapsulating the attached light emitting chips including disposing encapsulant material on the sub-mount in areas between light emitting chips; laser-cutting fracture-initiating trenches into the sub-mount wafer between the attached light emitting chips using a laser, the laser-cutting including: performing one or more first passes of the laser to remove the encapsulant disposed between the light emitting chips, the performing of one or more first passes including selecting one or more operating parameters of the laser such that the laser produces a selected encapsulant sidewall geometry along the fracture-initiating trenches, and performing one or more subsequent passes of the laser to form a trench in the sub-mount wafer; and fracturing the sub-mount wafer along the fracture-initiating trenches.