Patent ID: 7687810

Claim:
A method for fabricating a light emitting device comprising: providing a flip-chip light emitting diode (LED) die on a substrate, wherein the LED is mounted on a submount such that the LED die is between the submount and the substrate, the substrate being wider and longer than the LED die so that edges of the substrate extend over edges of the LED die; providing an insulating underfill between the LED die and the submount and around edges of the LED die and substrate; removing the substrate from the LED die, wherein walls are formed around the LED die by portions of the underfill that were around the edges of the substrate, inner boundaries of the walls being laterally separated from the edges of the LED die; and placing an optical element over an exposed surface of the LED die after the substrate has been removed, at least portions of edges of the optical element being within the walls of the underfill, the optical element having a preformed shape prior to being placed over the exposed surface of the LED die, the optical element having length and width outer dimensions, wherein the length dimension of the optical element is less than a length dimension of the inner boundaries of the walls, and wherein the width dimension of the optical element is less than a width dimension of the inner boundaries of the walls, so that there is a relaxed tolerance when placing the optical element flush over the exposed surface of the LED die, and wherein all edges of the preformed optical element overhang edges of the LED die.