AU2013100326B4 - High Efficiency LED Flashlight - Google Patents

High Efficiency LED Flashlight

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AU2013100326B4
AU2013100326B4 AU2013100326A AU2013100326A AU2013100326B4 AU 2013100326 B4 AU2013100326 B4 AU 2013100326B4 AU 2013100326 A AU2013100326 A AU 2013100326A AU 2013100326 A AU2013100326 A AU 2013100326A AU 2013100326 B4 AU2013100326 B4 AU 2013100326B4
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polar
flashlight
hehb
low
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Laurence Faget
Michael Snowden
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Abstract

The disclosed High Efficiency LED Flashlight is a compact, portable, hand-held, and high efficiency Flashlight design for indoor and or outdoor use. It utilizes an LED(s) with reduced polarization effect to provide a significant increase in energy density of light output. Through the use of an LED(s) with reduced polarization effect in the emitter(s), the Flashlight is kept compact in physical size as well as power requirements. The "reduced polarization effect LED(s)" allow for a reduced power consumption and or minimized thermal problems, and improved optical efficiency.

Description

AUSTRALIA Patents Act 1990 Complete Specification Innovation Patent Portable Hand-held High Efficiency LED Flashlight The following statement is a full description of this Invention, including the best method of performing it known to us: 1 References Australian Patent documents 2008100630 9/7/2008 Improved High Intensity Underwater LED Flashlight, Jankowski I., Snowden M., Wallek E. 2008100631 9/7/2008 Improved High Intensity Flashlight, Jankowski I., Snowden M., Wallek E. Foreign Patent documents RU 2006103270 6/2006 Abramov et al. Other publications (1) Park S.H. and Chuang S.L, "Crystal orientation effects on piezoelectric field and electronic properties of strained wurtzite semiconductors", Phys. Rev. B, vol. 59, pp. 4725-4737, (1999). (2) Waltereit P, Brandt 0, Trampert A, Grahn A.T, Menniger J, Ramsteiner M, Reiche M, and Ploog K.H, "Nitride semiconductors free of electrostatic fields for efficient white light-emitting diodes", Nature 406, 865 (2000). Brief description of the drawings/attachments Fig 1 is a collection of earlier type (Non-High Brightness) LEDs in the common sizes of 5 mm, T1.3/4, 3 mm and T1 packages. (The third LED from the right is a Tri-colour LED). Fig 2 is a Cree white XM-L2 HB LED emitter (single die emitter). Fig 3 is a 4 dice (2 series-2 parallel) emitter mounted on a star shaped metal cored pcb. Fig 4 is an example of a common Tactical type portable hand-held LED Flashlight utilizing a white high brightness LED. Fig 5 is an example of a high output portable hand-held LED Flashlight utilizing a single white high brightness Luminus Products SST-90 LED. 2 Fig 6 is an example of a prior art halogen diving portable hand-held Flashlight with remote battery pack. Fig 7 is an artist's impression of how two conventional HB LED modules on PCBs 7, 9, using conventional HB LED Chips compare with similar light output Low-Polar HEHB LED modules on PCBs 8,10. Fig 8 is an example of a parabolic reflector with a point source of sample light rays emitting forwards, but only showing those light rays bouncing off the reflector. Fig 9 is an example of a parabolic reflector with a point source of sample light rays emitting forwards, showing those light rays bouncing off the reflector as well as those rays that emerge from the reflector without bouncing off the reflector's surface. Fig 10 is an example of a parabolic reflector with a medium width source of sample light rays emitting forwards, but only showing those light rays bouncing off the reflector. Fig 11 is an example of a parabolic reflector with a medium width source of sample light rays emitting forwards, showing those light rays bouncing off the reflector as well as those rays that emerge from the reflector without bouncing off the reflector's surface. Fig 12 is an example of a parabolic reflector with a wide width source of sample light rays emitting forwards, but only showing those light rays bouncing off the reflector. Fig 13 is an example of a parabolic reflector with a wide width source of sample light rays emitting forwards, showing those light rays bouncing off the reflector as well as those rays that emerge from the reflector without bouncing off the reflector's surface. Fig 14 shows an example representation of the Gallium Nitride crystal structure with a C-axis growth direction 21, C-plane 22, A-plane 24, M-plane 25 and R-plane 23. Fig 15 shows a diagrammatical (not to scale) representation of a prior art HB LED die. Fig 16 is an example of a Buck type solution for the electronic driver circuit using a Texas Instruments' TPS92510 Buck switching regulator. 3 Fig 17 is an example of a Buck type solution for the electronic driver circuit using a Texas Instruments' LM3402 Buck switching regulator. Background During the past 15 years (1998 to 2012) there have been improvements in high performance portable hand-held Flashlights (Torches). Early prior art portable hand held Flashlights used plain Incandescent, Krypton, Fluorescent, Xenon, or Halogen miniature incandescent globes as their light source. In the late 1990's the first white LED based portable hand-held Flashlights appeared, mostly based upon one or more white 3mm or 5mm diameter LEDs of low-power (usually less than 1 watt and mostly with a current requirement of 20-50ma). To move to significantly higher power output light sources it is necessary to minimize the LED's heat in order to maintain the reliability of the LED(s), so the "packages" of the new High Brightness LEDs (HB LEDs) have become more complex, and adapted for heat dissipation. Packages for late model prior art high power LEDs bear little resemblance to early LEDs; see for example fig 1 for pictures of early low power LEDs similar to those used in early prior art portable hand-held LED Flashlights. Fig 2 shows a Cree XM-L2 late model single die HB LED emitter, and fig 3 shows a late model multi-die HB LED 1 mounted on a metal cored printed circuit board (pcb) which assists in draining the heat away from the LED emitter. Examples of common prior art portable hand-held Flashlights are: Fig 4, a common Tactical type aluminium bodied portable hand-held LED Flashlight utilizing a single white HB LED; fig 5 a high output (-2500 lumens, Luminus Products SST-90) 2 aluminium bodied portable hand-held LED Flashlight with large heat sink ribs 3; and fig 6 showing an example of one of the Applicants' prior art halogen diving (underwater) portable hand-held Flashlights with remote battery pack 4 connected by a cable 5 to a light head 6. Up until the late 1990's, most high performance portable hand-held Flashlights used Krypton, Xenon, or Quartz Halogen globes as a source of white light illumination. About the year 2001, Welch Allyn Corporation (USA) released compact low voltage metal halide (MH) ballast/lamp assemblies, which were taken up firstly by underwater Flashlight manufacturers to bring a new level of higher performance in underwater 4 lighting for scuba divers. Compact MH lighting provided a big boost in the efficiency and output of light, which lessened the need for scuba divers to carry bulky battery packs. Following on from the scuba diving field, compact MH lights were also adapted for bicycle use, finding a market especially in off-road mountain bike type applications. Whilst compact MH lighting was a big step forward there were problems with the fragility of the MH lamps and the associated ballasts. Other manufacturers have produced compact MH assemblies since, but a more reliable, robust and efficient solution has been found by the use of white HB LEDs, which can have lifetimes of up to 50,000 hours. In recent years 2006-2012 manufacturers of white HB LED's have been able to substantially increase the reliability and output power of these white HB LED's, so that white HB LED's consuming about 2-10 watts of power and producing output light levels of about 200 to 1100 lumens have been made available. Further development led to Cree Inc. USA introducing in 2008, HB LED's with emitters that have multiple dice that are individually addressable electrically and which can have different colours of light output from each of the individual dice of an emitter. This is the current stage of the prior art in the efficacy (light) of HB LED's used in Flashlights and is described in Australian Innovation patents 2008100630 Jankowski et al., and 2008100631 Jankowski, et al., which are hereby included in their entirety by way of reference. Research in the field of LED design and manufacture over the past 15 years has also been towards producing High Efficiency (HE) "Non-Polar" and HE "Semi-Polar" LED's, which can have a reduced or nil polarization effect in their HB LED emitter's die(ce), which can lead to increased lumen density, better heat resistance, and easier optical design (due to smaller emitter die size). Various Research papers and Laboratory results; eg: Park and Chuang (1), Waltereit et al. (2); have described versions and/or theoretical results of these Non-Polar and Semi Polar HB LED die, and a portable hand-held Flashlight utilising at least one of either or both of these types of high efficiency LED die(ce) in their Non Laser versions would be a significant Innovation in the field of LED Flashlight design. 5 We define and collectively refer to from now on, these types of "HE Non-Laser Non Polar and HE Non-Laser Semi-Polar, HB LED" die(ce) used in the Invention as being "Low-Polar HEHB LED die(ce)". By way of definition we limit the Invention to those Flashlights that are portable and hand-held, with a weight limit of 25kgs for the complete Flashlight with its power source. A Flashlight that is attached to a power supply, that together cannot be carried (eg: attached to a battery in an automobile) is not considered to be a Flashlight of the Invention. The disclosed portable hand-held HE LED Flashlight of the Invention is a significant improvement on prior art portable hand-held LED Flashlights. Low-Polar HEHB LEDs will be the preferred light source for portable hand-held LED Flashlights and do not suffer many of the internal in-efficiencies of prior art "polar" HB LEDs. The portable hand-held HE LED Flashlight of the Invention uses a Low-Polar HEHB LED(s) which contain at least one Low-Polar HEHB LED die(ce). The Invention teaches those skilled in the art how to produce a more efficient portable hand-held LED Flashlight. Benefits of the Invention As LED technology is rapidly gaining momentum as the "Green" and preferable lighting source for today and the future, this technology is the most preferred for its Green Credentials. A more efficient Flashlight requires less and smaller disposable or rechargeable batteries. A Low-Polar HEHB LED can produce over 400% more light for the same LED die size as a prior art conventional HB LED, and so there are benefits that are recognised. The use of State of the Art Low-Polar HEHB LEDs Technology has a multi-pronged advantage over the use of prior art light source technologies. 6 Firstly, Flashlights with large reflectors can be considerably reduced in size as the smaller Low-Polar HEHB LED die size allows for much reduced optics size to obtain a similar optical efficiency. A parabolically shaped reflector is often used in Flashlights. A simple general Cartesian equation of a parabola can be expressed as y=a *x2, with the height being expressed as y, and the width as x. Because of the squared relationship between y and x, reducing the LED die horizontal cross-section by 0.5 (by use of a Low Polar HEHB LED) gives a 0.52=0.25 of the original height- ie: reflector height is only 25% of original, and diameter is 50% of the original. Thus, a portable hand-held HE LED Flashlight's reflector diameter can be halved and its height reduced by %, for the same output of light as a prior art portable hand-held LED Flashlight, resulting in a considerable saving in aluminium and machining in a portable hand-held LED Flashlight. Secondly, when a Low-Polar HEHB LED has a higher lumen output density over prior art LEDs of similar size, then designs associated with that Low-Polar HEHB LED may lead to reduced thermal design challenges. Low-Polar HEHB LED die(ce) of the same brightness as prior art HB LED die(ce) often require a smaller heat sink design which reduces thermal design criteria when used in the Portable hand-held HE LED Flashlight. Often there are also the benefits of lower heat management requirements. Thirdly, the Invention allows for a much higher brightness than ever before for the same size LED light source, whereby this gain is achieved without normally increasing the physical size of the LED, the Portable hand-held HE LED Flashlight, and/or the optical components, but rather by increasing the light density output of the light source, in this case using the Low-Polar HEHB LEDs of the Invention. Fourthly, the reduced size of a Low-Polar HEHB LED Chip when compared to a similar brightness prior art conventional HB LED Chip allows for a relatively more compact LED Module size if needed. The more efficient Low-Polar HEHB LED die(ce) can replace multiple prior art single die HB LED die(ce). The following examples demonstrate the significant improvement that may be gained by the use of the Low-Polar HEHB LED Chip(s). Fig 7 depicts an artist's impression of how two conventional HB LED modules 7, 9, using conventional HB LED Chips compare with similar light output Low-Polar HEHB LED modules 8, 10 respectively, using Low-Polar HEHB LED Chips. This representation (not to scale) gives an example of what reduction there may be in the required number of LED chips using Low-Polar HEHB LED die(ce) required for the 7 similar light outputs. 8 can replace 7, and 10 replaces 9. The examples shown are used for comparison only. In the field of portable hand-held Flashlights as of February 2013, no Flashlight utilizing one or more Low-Polar HEHB LED's with reduced polarization die(ce) in an LED emitter(s) is known to the Inventors. The flexibility of optical design from the increased light density of Low-Polar HEHB LEDs can decrease the power requirements of a portable hand-held LED Flashlight and assists the manufacturer in reducing physical size, heat sinking requirements and high current electronic pcb circuit design. As an example, Police Forces require their field Operational Police personnel to be equipped with a considerable amount of equipment resulting in a significant weight for a Police Officer to carry on their belt/vests. By utilising a portable hand-held HE LED Flashlight incorporating Low-Polar HEHB LED(s), a Police Officer can reduce the physical size and weight of a portable hand-held Flashlight considerably and still keep the same brightness and run-time configuration as previously with a prior art portable hand-held Flashlight. Detailed description and preferred embodiments The disclosed Invention uses a Low-Polar HEHB LED die(ce) as a source of Illumination. Elaboration of the Invention's Low-Polar HEHB LEDs and their use is necessary to appreciate the fundamentals of the Invention and their relation to the prior art. Low-Polar HEHB LEDs have been shown to have brightness increases of over 400% over current technology conventional HB LEDs of similar size. That is, a similar light output is emitted from a Low-Polar HEHB LED die that is over four times smaller than the conventional HB LED die. A HB LED die(ce) emitting area reduced in the order of 75+%, results in a die(ce) width reduction of about 50+%. Such a reduction in a HB LED's die(ce) size makes for very 8 significant reductions in optics size, as well as increased efficiencies in light beam output and control. Referring to figs 8-13, we show the sample parabola's optical paths in 2-D view with a reduced number of light rays, whereby light is only projected forward from the source (simulating a real life use of a HB LED), being a point 11 in fig 8 and fig 9, a semi-wide light source 15 in fig 10 and fig 11, and a wide light source 18 in fig 12 and fig 13. The edge of the reflector 12 is the delineating point on the reflector's diameter/length that determines the limit of where light rays either bounce off the reflector or emerge directly without hitting the reflector's surface. To show the affects of HB LED widths, we show in fig 8, fig 10, and fig 12 only the light rays emitting from the HB LED surface that bounce off the reflector and then emerge 13, 16, and 19, and in fig 9, fig 11 and fig 13 we show all rays, that is, rays coming from the HB LED surface and bouncing off the reflector 13, 16, and 19 as well as light rays that emerge directly from the HB LED surface and emerge without hitting the reflector's surface 14, 17, 20. As can be seen from fig 8 and fig 9 the theoretical point source of light 11 at the parabola's focus is the best "behaved" when used in a parabolic reflector, that is, the light emerging from the parabola's focus 11 and hitting the reflector will always project straight forward as mathematically defined. As the light source becomes wider 15 and wider 18 the light beam outputs become more and more complex and unfocussed, leading to extremely difficult optical design problems and/or significant loss of efficiency in light beam output. A similar and often more complex problem exists when lense optics are used, and in general the larger the reflector(s) and/or the lense(s) optics relative to the dimensions of the light emitting area, the tighter the beam output and the more efficient is the output. The use of Low-Polar HEHB LEDs as the light source in the Invention's portable hand held HE LED Flashlight allows for the optical problems to be significantly reduced or virtually eliminated by the inherent nature of the smaller Low-Polar HEHB LED die'(s) physical widths relative to prior art HB LEDs, resulting in increased light efficacy (lumens), higher quality light beam spread, and reduced optics sizes. 9 As of February 2013, commercially available Non Laser LEDs are of a "Polarized effect" design. The Polarized effect LED can be summarised best by referring to fig 14, and noting the atomic structure of the Gallium Nitride (GaN) crystal lattice which is the main constituent of the light generating layer in most common LEDs. The LED chip die(s) are produced on wafers in a semiconductor production facility. Referring to fig 14, there are various Planes indicated. The "C" plane 22 is the normal and easiest plane orientation for a LED manufacturer to make and slice off the individual LED wafer/dies from, as it is the normal direction 21 of crystal growth. However, C-axis plane sliced wafers exhibit a high polarization effect on the resulting LED die(s). This high polarization effect has to date, reduced the efficiency and increased the thermal problems of current LEDs. Worldwide research over the past 15 years or so, (eg: Park and Chuang (1), Waltereit et al. (2)) has proven that LED wafers/die(s) sliced in a Semi-Polar direction (eg: R-plane 23), or Non-Polar direction ("M" 25 or "A" 24 planes)(at 90 deg to the C-plane) see fig 14, dramatically reduce or nearly eliminate the polarizing effect and can result in efficiency increases in LEDs of 400 to 1000%. The field of semi-conductor fabrication and crystal growth in LED substrates is very complex in the science of physics and chemistry and is on-going in development, and so a brief description follows as those knowledgeable in the art will appreciate the performance in efficiency improvements in reduced polarization Low-Polar HEHB LEDs, the improvements therein, and their basis in epitaxial LED wafer production. Fundamentally, prior art HB LED die(ce) suffer from in-efficiencies in light production due to internal inefficiencies, defects and dislocations within the HB LED die's active light producing region(s). One cause of the inefficiencies is the "piezoelectric induced and intrinsic polarization" (Polar) effects in type III-nitride-based (eg: Gallium Nitride (GaN)) crystal structures which have typically been grown on a C-plane type substrate which creates "Polar" electric field effects within the resulting structure. The typical growth process of creating prior art HB LED die(ce) using a C-plane type substrate (eg: Silicon Carbide, Sapphire) structure can create strong intrinsic and induced electric fields (piezoelectric) within the die structures (including the light emitting active regions), and reduces the ability to produce light emission from the die's active region(s), i.e. by the Quantum Confined Stark Effect (QCSE) within quantum wells. One way that these "Polar" effects can be greatly reduced, along with a significant reduction of many dislocations and defects, is by growing the devices on Non-Polar 10 planes of a type Ill-nitride-based structure (eg: A Non-Polar plane of GaN type crystal structure) instead of the more commonly used Polar C-plane crystal structure. For example, in a Non-Polar plane of GaN type structure which contains equal numbers of Ga and N atoms the plane is "charge-neutral", or "without polarity". Further Non-Polar layers that are laid down epitaxially are the same to one another, so the crystal(s) are not polarized along these growth directions. To the Inventors' best knowledge, as of late 2012, there are two such known groups of symmetry-equivalent Non-Polar planes in type Ill-nitride-based (eg: GaN type) structures. They are the {11-20} group, the "A planes", and the {1-100} group, the "M-planes". Another way to reduce or even eliminate the polarization effects in type Ill-nitride-based (eg: GaN type) structures is to grow the structures on Semi-Polar planes of type III nitride-based (eg: GaN type) structures. The term Semi-Polar planes in the context of the Invention refers to planes within a (eg: GaN type) hexagonal type crystal structure(s) where such planes possess two nonzero "A", ";" or "" Miller indices, and a nonzero "I" Miller index. The more often referred to Semi-Polar planes include the {1 1-22} (R Plane), {10-11}, and {10-13} planes. A Semi-Polar plane's electric field vector lies at an oblique angle to the plane's surface normal, hence reducing any full Polar effect within the plane. Non-Laser LED die structures epitaxially grown from Non-Polar or Semi-Polar type III nitride-based structure base-substrate crystals, in general produce high efficiency LED die(ce) with very little or no "Polar" affected light producing active regions. These LED dice can be used to produce Low-Polar HEHB LED Chips and are referred to as Non Laser Non-Polar or Non-Laser Semi-Polar, HEHB LED Chips as appropriate. These Non-Polar or Semi-Polar, Non-Laser HEHB LED Chips have a much higher light density output (eg: 400+ % increase) than "Polar" type HB LED Chips because of the higher efficiencies in the active regions of these LED Chip's dice. We describe Low-Polar HEHB LEDs' typical physical structures by first describing a typical prior art Non-Laser HB LED. A typical prior art Non-Laser white light output HB LED die as depicted in fig 15, is usually comprised of at least one die which in turn is manufactured from several substrate layers. The light producing Active Layer 30 is normally a layer containing Gallium Nitride (GaN) (and/or AIGaN, InGaN) with various substrate layers above 26, 27, 28, 29 and below 33, 34, 35 this layer 30. 11 Electrical connection to the die is normally via an Anode fine gold wire to the p-electrode 26 and a Cathode fine gold wire to the n-electrode 31. Electrical current through these connections results in electron flow producing photons (light) from the GaN type light producing layer 30. The bonding layers of Indium Tin Oxide (ITO) 27, 32 allow the electrode layers 26, 31 respectively to be electrically bonded to the structure(s). In the GaN light-producing layer of standard prior art GaN fig 14 with crystal growth starting with for example, a Sapphire (A1 2
O
3 ) substrate 35 in the C-plane 22 crystal growth direction 21, (the 3 most commonly used Polar substrates are Sapphire and Silicon carbide, and most recently Silicon), quantum wells grown along this axis 21 exhibit high piezoelectric fields due to the hexagonal lattice symmetry without a centre of inversion. This results in electrons and holes being pulled to the opposite sides in quantum wells resulting in greatly reduced efficiency eg: QCSE. Additionally, lack of purity, dislocations, defect concentrations, droop, and colour shift contribute to a reduced luminous efficacy of most prior art light HB LEDs to be limited to the range of 90-110 lumens/watt maximum. Low-Polar HEHB LED dice significantly reduce or eliminate these problems, and the "Low-Polar" terminology naming comes from the description of the arrangement of the crystal planes in the Type Ill-nitride based light emitting crystal structures and how they are fabricated/manufactured/cut/used in a Low-Polar HEHB LED die. To keep the description brief we concentrate on the aforementioned common planes, as those skilled in the art of GaN A3N epitaxial heterostructure optoelectronic research, design, and manufacture will recognize they are a good representation of the field of research and design. We define, in a crystallographic sense, the definition of Low-Polar Planes to be those planes in GaN crystals to be the fully Non-Polar, and including the Semi-Polar, and whereby the Low-Polar plane(s) in a Low-Polar HEHB LED die may be cut/produced at an angle up to +0.0/- 1.5 degrees, for one or more of the three principal axes (X, Y, Z). The principal axes X, Y, Z are analogous to the principal planes as follows: C-axis @ Z axis, M-axis @ Y-axis, A-axis @ X-axis. 12 Referring to fig 14, the most commonly referred to GaN type crystal planes are shown namely the standard polar(ized) C-plane {0001} 22, the A-plane {1 1-20} 24 and M-plane {1-100} 25 non-polar planes, and the R-plane {1 1-22} 23 semi-polar plane. There are other semi-polar planes eg: {10-11}, {10-1-1}, {10-1-3}, {10-13} as well, but the C, A, M, and R are the most commonly referred to crystallographic planes in GaN type crystal structures, and by our definition above, the A, M, and R planes are Low-Polar. Waltereit et al. (2) in the year 2000 were the first researchers to demonstrate an absence of a piezoelectric field in GaN/AIGaN in the non-polar M plane. Park and Chuang (1) noted in the year 1999 that certain semi-polar planes can eliminate or nearly eliminate the piezoelectric field. Research in the past few years has shown solutions to the problems of manufacturing Low-Polar GaN LED dice, and one example is: Abramov et al. (Foreign patent RU 2006103270) who teach the use of Langasite that is a natural Non-polar crystal that can be used as a substrate base for producing Non-polar GaN. By utilizing a low-polar type III-nitride based (eg: GaN) light producing layer ("active layer"), the polarization and piezoelectric effect is minimized or not present, resulting in increased lumen efficacy, greater lumen density in the range of 400%+, minimal droop at high temperatures and currents, increased heat resistance and minimal colour shift. It is noted that a portable hand-held HE LED Flashlight's light source may use a coloured output non-white light emitting HB LED that uses other chemistry mixes, including alloys of Gallium. Eg: Infrared LEDs may use Gallium arsenide (GaAs) or Aluminium Gallium arsenide (AIGaAs); or where a UV emitting HB LED may use Aluminium Gallium Indium Nitride (AIGaInN), a yellow HB LED may use Aluminium Gallium Indium Phosphide (AIGaInP) in its active layer(s). The most common "colours" are infrared, red, orange, yellow, green, blue, violet, and ultra violet (UV). To keep the descriptions brief we will refer to typical structure types and alloys/mixes where Gallium is used, as GaN "type" structures. There are many other type Ill-nitride chemistries, including alloys of Gallium, that may be used to produce different coloured light emissions, as well as the combined use of multiple LED die(ce) of different output colours that may be individually powered to produce a variable coloured light as desired. The descriptions and examples given should not limit the scope of the Invention in any way. 13 There are generally two basic types of configurations of portable hand-held Flashlights: those that are self contained with the housing, lamp, switch(es), electronics and batteries, all in the one case (eg: fig 4 and fig 5); and less commonly, those with remote attached battery packs (eg: fig 6), where the Lamp head contains a housing with or without associated electronics and switch(es), a cable attaching the Lamp head to the battery pack, and the battery pack containing the batteries and maybe electronics/switch(es), and often an additional/alternative input power means. The main purpose of the remote type system is to enable additional/larger battery capacities to be conveniently carried to provide a lightweight Lamp head, and to attach the remote battery pack around the users waist or to be attached to the users equipment. A remote battery pack can provide very long running times of 10 or more hours. A typical example is a Miner's Light which generally has a Head-piece "Lamp" housing mounted frontally on the Miner's Helmet, and a remote battery pack attached to a waist belt, with the two parts being connected by a flexible heavy duty power cable. Once the choice of using Low-Polar HEHB LED(s) in a portable hand-held HE LED Flashlight is made, the method of electrically driving the Low-Polar HEHB LED(s) needs to be considered. A Flashlight is fundamentally powered by electricity. This electricity is usually pre stored in a non-rechargeable battery such as an Alkaline cell, often referred to as a "Primary cell", or in a rechargeable format. The most common rechargeable formats ("Secondary cells") are sealed lead acid, nickel cadmium, nickel metal hydride, or lithium chemistry types. Various other methods of storing or generating the required electricity are available such as: Super Capacitors, Solar cells, miniature Fuel cells, Spring wound hand generators that use the energy stored in a spring to drive an electrical generating means to provide electricity, "Shake" Flashlights that utilise the shaking effect of a user of the Flashlight to generate electricity by passing a ferrite core magnet repeatedly to-and-fro through a coil to generate and store electricity in a capacitor or battery, and so on. The examples given are not to be seen as limiting the scope of the Invention The German language commonly refers to rechargeable batteries as "Akkus". Lending from the German language and for simplicity from now on we will refer to all Primary 14 and Secondary cells, and all other electrical storage means as "ACCUs": essentially accumulation and or storage of electrical power. There are at least 4 ways to electrically drive a Low-Polar HEHB LED(s), with the most common being: 1 By direct voltage, with or without a "dropping resistor", from an ACCU(s). 2 By boosting the voltage from an ACCU source that is lower than that required by the Low-Polar HEHB LED configuration. ("Boost" configuration) 3 By reducing the voltage from an ACCU source that is higher than the Low-Polar HEHB LED operating voltage range. ("Buck" configuration) 4 By a combination of reducing and boosting the voltage when the ACCU source is initially higher than the Low-Polar HEHB LED operating voltage range, but perhaps lower later on when the ACCU voltage drops through discharge use. (Eg: "Buck-Boost", "SEPIC", "Flyback", "Inverting", or other variations). Preferably, the electrical drive current should be limited to that recommended for the particular Low-Polar HEHB LED(s) being used, and predominantly regulated at a Constant Current to maintain even brightness during the run time and maintain the expected lifetime of the Low-Polar HEHB LED(s). In method 1 above, it is difficult to achieve this and can result in efficiency losses and either lower than optimum output of light, or damage and shortened life expectancy to the emitter. A variation of the Buck circuit (a Switched mode type circuit) is to use a non-Switched mode simple Linear Voltage Regulator circuit arranged to produce a constant current, however this is less than optimal as it often wastes/burns off the excess voltage as extra heat which then has to be dispersed away. Even if a Low Drop Out Voltage Regulator is used to more closely match the voltage of the HEHB LED, this can still present problems as most batteries will drop in voltage during use and this will affect the output of the light. An alternative is to use a Linear (non-switch mode) LED driver design and this is a more dedicated design for an LED circuit but still has large energy losses that reduce efficiency in the driver circuit and generate a large amount of wasted heat from the Linear Driver. This type of circuit is less efficient in general than the normal Buck Switching type circuit, or the Boost, Buck-Boost, SEPIC, etc., switch mode type circuits. 15 A single prior art White LED die in a portable hand-held LED Flashlight usually needs about 3.0-3.6v dc for running, and a Boost circuit utilizing a voltage less than say 3.6v dc, would normally only be built with 1-3 alkaline or nickel cadmium(Nicd)/ nickel metal hydride (Nimh) battery cells of at least AA, or more preferably sub-C, C or D size. A typical D size Nimh cell has about 9ah capacity resulting in a 3-cell pack (3.6v dc) providing a run time for a prior art 10-watt HB LED (using 1 Cree MC-E multi-die HB LED and producing approximately 1000 lumens of light output giving an efficiency of 100 lumens/watt) of about 3 hours after allowing for circuit inefficiencies. However a portable hand-held HE LED Flashlight with a battery pack of 3.6v dc as just mentioned, when powering a single Low-Polar HEHB LED die of an output of 500 lumens might only require 5 watts of input power to power the Low-Polar HEHB LED die in the portable hand-held HE LED Flashlight because of Optical Efficiency, resulting in a 2-fold increase in run-time for the same battery set. Significantly, for a portable hand held LED Flashlight of this size, the thermal heatsink problems in a prior art 10 watt portable hand-held HB LED Flashlight are greatly reduced in a 5 watt portable hand held HE LED Flashlight, thus simplifying design and manufacturing difficulties and costs greatly. Preferably a voltage higher than 3.6v would be used (or that voltage higher than the Low-Polar HEHB LED die) so that a switched mode Buck circuit configuration could be implemented, which is in general more efficient and simpler in design than Boost, Boost-Buck, SEPIC, or other boosting type circuits. A voltage maximum of 12 volts dc from the ACCU source is a useful and safe limit for general purposes, however higher dc (and ac) voltages and/or ampere hour capacities can be used if the requirement is for very long running time or if the higher voltage is more readily available. Suitable ACCU configurations when batteries are used in a single HE LED die portable hand-held HE LED Flashlight, would be four or more Alkaline disposable cells of C or D size; four or more AA to F size nickel cadmium or nickel metal hydride cells; or preferably at least two Lithium Ion cells of "18650 size" and 2400mah minimum capacity arranged in series (or series-parallel and four or more cells) for a minimum output voltage that is in general at least 0.5v dc higher than the dice of the emitter require. It should also be remembered that it is good design practice to allow for the lower part of 16 the batteries voltage cycle when calculating the voltage requirements. Thus, it is normal to consider the low voltage cut-off point of 0.9v dc per cell when designing with nickel metal hydride batteries so that the batteries are protected from damage before being drained below 0.9v/cell towards the end of a run. Similarly, with Lithium type chemistry cells, which normally should be equipped with a safety protection pcb(s), it is a preferred design to allow for about 0.25v dc above the protection circuit's lower cut-off voltage. The first preferred embodiment for a portable hand-held HE LED Flashlight would have a single White Low-Polar HEHB LED dice, would use 4 pieces of AA disposable alkaline cell batteries contained within the portable hand-held HE LED Flashlight body itself, and a Buck type LED electronic driver circuit to regulate a constant current to the Low Polar HEHB LED. The portable hand-held HE LED Flashlight would have multiple power settings (eg: 100%, 50%, 10%, 5%) as well as strobe, and/or variable pulse signals. The second preferred embodiment for a portable hand-held HE Led Flashlight would have a four White Low-Polar HEHB LED dice, use a remote attached battery pack containing a set of approximately 4-12 Lithium-ion-cobalt type 18650 cells (each 3.6v dc. 2400ma nominal) wired in series/parallel/ or series-parallel, with the usual inbuilt safety protection circuit(s) for Lithium Ion battery cells, and a Buck type LED electronic driver circuit to regulate a constant current to the Low Polar HEHB LED dice. Additionally the remote battery pack and the light head would have means for alternative power source inputs. The portable hand-held HE LED Flashlight with remote attached battery pack, would have multiple power settings (eg: 100%, 50%, 10%, 5%) as well as strobe, and/or variable pulse signals. Referring to fig 6 as an example of a prior art Remote battery pack type portable hand held Flashlight, substitution of the halogen lamp head 6 depicted (50 watt power consumption and approximately 900 lumens output), with a similar sized aluminium lamp head with White Low-Polar HEHB LED(s) results in virtually no change in overall size of the unit, but the running time for the portable hand-held HE LED Flashlight increases about 800%+ from 50 minutes to about 400+ minutes with similar but higher quality light output. For the first preferred embodiment, an example of a Buck type circuit utilizing a Texas Instruments' TPS92510 LED drive converter chip is shown in fig 16. In fig 16 the circuit 17 is configured to provide the drive power for a Low-Polar HEHB LED single dice emitter (The LED emitter is shown in the schematic of fig 16 schematically as "Output Block"). The battery supply voltage is in the range 3.5-7.Ov dc, representing the range of voltage of a fresh set of four alkaline battery cells in series between the usable almost exhausted voltage (3.5v dc) and the new fresh voltage 7.Ov dc, whereby the constant current to the Low Polar HEHB LED die is 700ma at full power, and the voltage nominally 3.Ov dc. The actual component values of the schematic of fig 16 are calculated when the exact values of Forward voltage and LED resistance of the Low Polar HEHB LED die are known. For the second preferred embodiment, an example of a Buck type circuit utilizing a Texas Instruments' LM3402 LED drive converter chip is shown in fig 17. In fig 17 the circuit is configured to provide the drive power for a Low-Polar HEHB LED quad dice emitter with the four dice connected serially electrically, (The LED emitter is shown in the schematic of fig 17 schematically as "Output Block" showing multiple LED's but in this case representing a quad LED die). The battery supply voltage is in the range 16.2 21.6v dc, representing the range of voltage of a set of six Lithium-ion-cobalt rechargeable battery cells in series, between the battery protection circuits low voltage cut-off of 16.2v (ie: 6 x 2.7v dc = 16.2v dc) and the nominal charged voltage 21.6v dc. The fully charged voltage when the battery pack is removed from charging would be 25.2v dc, but this quickly falls to 21.6v dc during use and/or storage). The constant current to the Low Polar HEHB LED quad dice emitter is 700ma at full power, and the voltage nominally 12.Ov dc (Quad dice, 4 x 3.Ov dc = 12.0 v dc nominal). The actual component values of the schematic of fig 17 are calculated when the exact values of Forward voltage and LED resistance of the Low Polar LED are known. For both the first and second preferred embodiments, those skilled in the art would see that the circuit components could be adjusted for different voltage input/output ranges and different current outputs, as well as utilizing other Buck, Boost, Buck-Boost, SEPIC, etc., type switching regulators, or power regulating means. It is also considered to be feasible to use no electrical regulating means and simply rely on the ACCU's dynamic electrical range to stay within acceptable limits for the Low Polar HEHB LED die(ce) arrangement being used.. 18 Additionally, instead of, or in addition to the switch arrangements mentioned previously, a series of magnetic reed/Hall Effect switches could be arranged on the driver printed circuit board, positioned to be operated via a rotary ring and magnet assembly around the portable hand-held HE LED Flashlight. Upon rotating/sliding the rotary ring to a selective position, each magnetic reed/Hall effect switch is activated in turn selectively activating the signal for the particular colour/action needed. A further embodiment of the Invention would use a Remote Switching means, solely or in addition to any switching means in the Flashlight body itself. Such a Remote type switch could take the form of a "Tape" type pressure switch with a connecting lead to the Flashlight, and this is often used on guns or rifles where the user simply applies finger pressure to the Tape switch to activate the switch. Other types of Remote switching could be via a connecting electrical cable with a switch at the distal end of the cable, and the Flashlight connected at the proximal end of the cable. Also, the switching means does not necessarily have to be directly connected in all its parts and operation to the Flashlight. For example the switching means could operate wirelessly, such as by an infrared signal that could be sent from a Remote switching means and then be received by a sensor on the Flashlight to operate the various function(s) of the Flashlight. The switching means could be operated remotely such as via a signal on the Electromagnetic Spectrum (eg: Radio Frequency signal), or maybe by optical light means signal (eg: Infra-red signalling). It is recognised by those skilled in the art that the switching means could be more than one switching means and that there could be more than one switching transmission/receiving means at either or both the Flashlight and the Remote switch(s), and there could be 2-way communication between the Remote switching means and the Flashlight. One of the main problems associated with using prior art HB LEDs in portable hand held LED Flashlights is that they produce a lot of heat that must be carried away from the HB LED emitter very quickly, otherwise damage will occur to the HB LED reducing its lifetime and light quality dramatically. A heat sink is normally used for this purpose, and construction of the portable hand-held HE LED Flashlight out of a predominantly metal casing such as aluminium, along with mounting the HB LED(s) with a silicon or similar heat sink mounting paste (eg: "Artic Silver"), helps considerably in removing the heat from the heat sink/LED arrangement. Occasionally a user may use the portable hand-held HE LED Flashlight in excessively warm conditions and the heat sink will not 19 function as well as normal. Use of a thermistor or temperature sensor electronically integrated in circuit can provide a feedback arrangement to the electronic driver circuit to reduce the input power to the HB LED and the resultant heat generated and thus protects the HB LED from damage. The thermistor can be directly connected to the appropriate driver pin (if present) of the LED driver IC chip to provide a feedback from the temperature of the HB LED emitter and to respond by reducing the drive current and hence the temperature of the emitter to prevent damage to the emitter. Alternatively, or in addition, a cpu microprocessor such as a PIC16F28A-I-ML could receive the feedback signal from a thermistor and adjust the drive current via control of the led driver IC, or alternatively by generating an appropriate Pulse Width Modulation (PWM) signal to vary the light output of the HB LEDs and hence the current consumption (ie: heat generated). It should be noted that some available off-the-shelf HB LED driver IC's have an inbuilt PWM function which can simplify the design process of reducing the current consumption proportionately to the heat generated and thus keep the emitter temperature within a safe range. An arrangement of "fins" on the outside of the preferably aluminium portable hand-held HE LED Flashlight casing will provide an enhanced high efficiency heat drain from the prior art HB LED(s) emitter, and thus the portable hand-held HE LED Flashlight described will run at full capacity and full battery capability and with reduced tendency to overheat which would require reducing the light output of the portable hand-held HE LED Flashlight. Conversely, with the use of Low-Polar HEHB LED(s), the aforementioned heat sink problems are greatly reduced in a portable hand-held HE LED Flashlight of the Invention's design. A portable hand-held HE LED Flashlight of 5 watts power consumption equalling a best prior art power consumption of 10 watts can virtually almost be made of plastic with an aluminium insert for the higher temperature areas, thus significantly improving the manufacturing design, processes and costs. The disclosed description of the Invention reveals the advantages and methods of how to produce a reliable, portable hand-held HE LED Flashlight utilizing a Low-Polar HEHB LED(s). 20 The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the Inventors to make use of the Invention. Nothing in this specification should be considered as limiting the scope of the present Invention. All examples presented are representative and non-limiting. The above-described embodiments of the Invention may be modified or varied, without departing from the Invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the Invention may be practiced otherwise than as specifically described. 21
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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110031739A1 (en) * 2009-08-06 2011-02-10 Nitta Corporation Connection-state check tool used for assembling a pipe coupling
US8299473B1 (en) * 2009-04-07 2012-10-30 Soraa, Inc. Polarized white light devices using non-polar or semipolar gallium containing materials and transparent phosphors

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8299473B1 (en) * 2009-04-07 2012-10-30 Soraa, Inc. Polarized white light devices using non-polar or semipolar gallium containing materials and transparent phosphors
US20110031739A1 (en) * 2009-08-06 2011-02-10 Nitta Corporation Connection-state check tool used for assembling a pipe coupling

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