LED multi-chip lighting units and related methods

• US 20090080185A1
• Filed: 09/25/2007
• Published: 03/26/2009
• Est. Priority Date: 09/25/2007
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: McMillan, Michael
• Granted Patent: US 7,802,901 B2
• Time in Patent Office: Days
• US Class Current: 362/231
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21L 4/027 the light sources being a LED
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/48471 the other connecting portion not on the bonding area being a ball bond, i.e. wedge-to-ball, reverse stitch
• CPC Class Codes: H01L 2224/49175 Parallel arrangements
• CPC Class Codes: H01L 2224/73265 Layer and wire connectors
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/10253 Silicon [Si]
• CPC Class Codes: H01L 2924/181 Encapsulation

Abstract

Light emitting device multi-chip lighting units and related methods are disclosed. According to one aspect, a white LED chip, a red LED chip, a blue LED chip, and a green LED chip are operably configured to a semiconductor substrate positioned within a lighting unit housing. The lighting unit can therefore provide a white light beam, a red light beam, a green light beam, and a blue light beam. The LED chips can be configured on the substrate such that the emitted light beams can overlap. Thus, in addition to the white LED chip providing a white light beam, the red LED chip, the blue LED chip, and the green LED chip can be actuated simultaneously with the white LED chip to combine and emit a more powerful and intense white light beam. Additionally, the red LED chip, the blue LED chip and the green LED chip can be actuated simultaneously to emit an intermediary intensity white light beam from the lighting unit.

Claims

1. A portable LED lighting unit for providing a plurality of individually selectable colored beams, the lighting unit comprising:

a housing;

a power supply source carried by the housing; and

a multi-chip lamp source assembly operably configured to the power supply source, the multi-chip lamp source assembly comprising;

a semiconductor substrate;

at least one white light emitting diode (LED) chip operably configured to the semiconductor substrate to emit a substantially white light beam;

at least one red LED chip operably configured to the semiconductor substrate to emit a substantially red light beam;

at least one blue LED chip operably configured to the semiconductor substrate to emit a substantially blue light beam; and

at least one green LED chip operably configured to the semiconductor substrate to emit a substantially green light beam; and

wherein the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip, and the least one green LED are configured to be actuatable to create at least two white light beams of different intensities.

2. The portable LED lighting unit of claim 1, wherein the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip are centered symmetrically on the substrate.

3. The portable LED lighting unit of claim 1, wherein the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip are configured to be actuated individually and the at least one white LED chip can be individually actuated to provide a substantially white light beam having a first intensity.

4. The portable LED lighting unit of claim 3, wherein the at least one white LED chip is configured to emit light simultaneously with the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip to provide a substantially white light beam having a second intensity.

5. The portable LED lighting unit of claim 4, wherein the second intensity is greater than the first intensity, thereby providing multi-output brightness.

6. The portable LED lighting unit of claim 1, wherein the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip are configured to emit light simultaneously that overlaps to provide a substantially white light beam having a third intensity.

7. The portable LED lighting unit of claim 1, further comprising a control chip operably configured to the semiconductor substrate, the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip.

8. The portable LED lighting unit of claim 7, wherein the control chip is configured to regulate thermal output and power consumption.

9. The portable LED lighting unit of claim 7, wherein the control chip is configured to control the intensity of the light emitted by the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip.

10. The portable LED lighting unit of claim 7, wherein the portable LED lighting unit comprises a flashlight.

11. A portable LED lighting unit for providing a plurality of individually selectable colored beams without the use of filters, the lighting unit comprising:

a housing;

a power supply source attached to the housing; and

a multi-chip lamp source assembly operably configured to the power source, the multi-chip lamp source assembly comprising;

a semiconductor substrate having a first side;

at least one white light emitting diode (LED) chip operably configured to the first side of the semiconductor substrate to provide a substantially white light beam;

at least one red LED chip operably configured to the first side of the semiconductor substrate to emit a substantially red light beam;

at least one blue LED chip operably configured to the first side of the semiconductor substrate to emit a substantially blue light beam;

at least one green LED chip operably configured to the first side of the semiconductor substrate to emit a substantially green light beam; and

a lens positioned over the first side of the semiconductor substrate and the lens positioned above the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip to thereby encase each chip therewithin; and

wherein the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip, and the least one green LED are configured to be actuatable to create at least two white light beams of different intensities.

12. The portable LED lighting unit of claim 11, wherein the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip are configured to be actuated individually and said at least one white LED chip can be individually actuated to provide a substantially white light beam having a first intensity.

13. The portable LED lighting unit of claim 12, wherein the at least one white LED chip is configured to emit light simultaneously with the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip to provide a white light beam having a second intensity.

14. The portable LED lighting unit of claim 13, wherein the second intensity is greater than the first intensity, thereby providing multi-output brightness.

15. The portable LED lighting unit of claim 11, wherein the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip are configured to emit light simultaneously that overlaps to provide a white light beam having a third intensity.

16. The portable LED lighting unit of claim 11, wherein the lamp is configured to provide the light emission source of a flashlight.

17. The portable LED lighting unit of claim 16, wherein a control chip is used to control the actuation of individual chips and sets of chips.

18. The portable LED lighting unit of claim 11, further comprising a control chip operably configured to the semiconductor substrate, the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip.

19. The portable LED lighting unit of claim 18, wherein the control chip is configured to regulate thermal output and power consumption.

20. The portable LED lighting unit of claim 18, wherein the control chip is configured to control the intensity of the light emitted by the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip.

21. The portable LED lighting unit of claim 18, wherein the portable LED lighting unit comprises a flashlight.

22. A method of forming a portable LED lighting unit for providing a plurality of individually selectable colored beams without the use of filters, the method comprising:

providing a housing;

providing a power supply source that is carried by the housing; and

configuring a multi-chip lamp source assembly operably to the power source, the multi-chip lamp source assembly comprising;

a semiconductor substrate;

at least one white light emitting diode (LED) chip configured to the semiconductor substrate such that the at least one white LED chip is configured to emit a substantially white light;

at least one red LED chip configured to the semiconductor substrate, the at least one red LED chip configured to emit a substantially red light beam;

at least one blue LED chip configured to the semiconductor substrate, the at least one blue LED chip configured to emit a substantially blue light beam; and

at least one green LED chip configured to the semiconductor substrate, the at least one green LED chip configured to emit a substantially green light beam; and

wherein the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip, and the least one green LED are configured to be actuatable to create at least two white light beams of different intensities.

23. The method of claim 22, wherein the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip are attached in a centered and symmetrical configuration on the semiconductor substrate.

24. The method of claim 22, further comprising the step of attaching a control chip to the substrate for regulating thermal output and power consumption.

25. The method of claim 22, further comprising the step of operably configuring a control chip to the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip and the at least one green LED chip for actuating individual chips and sets of chips in order to selectively provide one of a substantially red light beam, a substantially blue light beam, a substantially green light beam, a first intensity white light beam, a second intensity white light beam, and a third intensity white light beam.

26. A portable LED lighting unit for providing a plurality of individually selectable colored beams, the lighting unit comprising:

a housing;

a power supply source carried by the housing; and

a multi-chip lamp source assembly operably configured to the power supply source, the multi-chip lamp source assembly comprising;

a semiconductor substrate having a center;

at least one white light emitting diode (LED) chip operably configured to the semiconductor substrate to emit a substantially white light beam;

at least one red LED chip operably configured to the semiconductor substrate to emit a substantially red light beam;

at least one blue LED chip operably configured to the semiconductor substrate to emit a substantially blue light beam; and

at least one green LED chip operably configured to the semiconductor substrate to emit a substantially green light beam; and

wherein the at least one red LED chip, the at least one blue LED chip, and the least one green LED are configured to be equidistant from the center of the substrate.

27. The portable LED lighting unit of claim 26, wherein the at least one white LED chip, the at least one red LED chip, the at least one blue LED chip, and the least one green LED are configured in a centered and symmetrical configuration on the substrate.

28. A portable handheld LED lighting device comprising:

a housing configured to be portable and to be sized to permit a user to carry the device in the hand of the user;

a power supply source carried by the housing; and

a multi-chip lamp source assembly operably configured to the power supply source, the multi-chip lamp source assembly comprising;

a semiconductor substrate;

at least two light emitting diode (LED) chips operably configured to the semiconductor substrate to form a single LED package, the LED chips comprising at least two different colored LED chips, and being configured to be actuatable either individually or together to provide selectable colored light beams.

29. The portable handheld LED lighting device of claim 28, wherein the at least two LED chips are selected from a group consisting of a white LED chip, a red LED chip, a blue LED chip and a green LED chip.

30. The portable handheld LED lighting device of claim 29, wherein the at least two LED chips comprise at least one white LED chip, at least one red LED chip, at least one blue LED chip and at least one green LED chip are configured in a centered and symmetrical configuration the substrate.

31. The portable handheld LED lighting device of claim 28, wherein the at least two LED chips are configured to be actuatable to create at least two white light beams of different intensities.