Patent ID: 7670872

Claim:
A method for forming an LED package from a panel, the method comprising: forming a top body layer of the panel; forming an intermediate body layer of the panel; forming a cavity through a portion of the top body layer and the intermediate body layer corresponding to the center of the LED package; forming a thermally conducting ceramic layer of the panel, the thermally conducting ceramic layer having a top surface and a bottom surface; bonding a metallization pattern including a thermal bonding pad to the top surface of the thermally conducting ceramic layer, the thermal bonding pad configured to thermally bond the top surface of the conducting ceramic layer to an LED; bonding a substantially continuous central pad without a corner on the bottom surface of the thermally conducting ceramic layer, the central pad having a continuously curved periphery and configured to provide a thermal path from the bottom surface of the thermally conducting ceramic layer to a substrate; bonding the intermediate body layer between the top body layer and thermally conducting ceramic layer such that the panel includes the top layer, the intermediate body layer, and the thermally conducting ceramic layer; creating a grid of LED packages in the panel, the grid defined by one or more grooves on a top surface and a bottom surface of the panel; and separating the LED package from the grid of LED packages in the panel by breaking the panel along the one or more grooves of the grid.