Thermal block assembly, LED arrangement with the same, and method of manufacturing said thermal assembly

A method of manufacturing a thermal block assembly, which method comprises the steps of

• providing first thermally and electrically conductive block part for connection to an anode pad of a light-emitting diode and dimensioned to provide an essentially complete thermal path for heat originating at the anode pad;
• providing a second thermally and electrically conductive block part realised for connection to a cathode pad of a light-emitting diode and dimensioned to provide an essentially complete thermal path for heat originating at the cathode pad;
• wherein at least one of the first block part and the second block part comprises a number of cooling fins, and wherein the height of at least one of the first block part and the second block part is greater than its width;
• arranging at least one of the first block part and the second block part on either side of an air-gap;
• and
• applying a bonding layer comprising a dielectric layer arranged to adhere to at least one of the first block part or the second block part, the bonding layer to at least one of the first block parts and the second block parts to fix the positions of at least one of the first block parts and the second block parts, which the bonding layer is applied to lie over two co-planar outside surfaces of the first and second block parts, bridging the intervening air-gap but not extending into the air-gap and arranged to lie essentially completely outside the thermal path.