Light efficient LED assembly including a shaped reflective cavity and method for making same

Abstract

A method for making an efficient light emitting diode (LED) assembly by providing a thermally conductive base having a surface cavity, disposing a reflective paste in the surface cavity, and shaping the reflective paste to form a reflective cavity. The reflective cavity is shaped such that there is a mounting region and at least one reflective side wall at least partially surrounding the mounting region. Once shaped, the reflective paste is fired to set the reflective cavity in its shaped form. Next, one or more LED die may be mounted on the mounting region of the reflective cavity such that the emitted light is reflected by the side walls, thus increasing the light output of the LED assembly.