1. A method for determining a temperature of at least one light emitting diode (LED) in a circuit which includes (i) a power supply for powering the LED and (ii) a thermistor electrically connected in parallel with the LED, the thermistor having an effective resistance range that is lower than a reverse bias resistance of the LED and that is higher than a forward voltage resistance of the LED, where the LED is operable to generate light, the method comprising:
providing an operating current and an operating voltage to the LED;
superimposing a current pulse on the operating current, superimposition of the current pulse causing a relatively larger amount of the current pulse to flow through the thermistor and a relatively smaller amount of the current pulse to flow through the LED;
determining a temperature of the thermistor based on the amount of the current pulse flowing therethrough;
sensing a magnitude of a voltage pulse across the LED resulting from the applied current pulse superimposed on the operating current; and
determining an operating temperature of the LED at the provided operating current based on a magnitude of the amount of the current pulse caused to flow through the LED and the magnitude of the voltage pulse.
2. The method according to claim 1, further comprising:
before providing the operating current, providing an initial operating current and initial operating voltage at a known initial temperature of the LED;
determining at least one LED parameter based on the initial operating current, initial operating voltage, and initial temperature, the operating temperature being determined based in part on the LED parameter.
3. The method according to claim 2 wherein the initial operating current and initial operating voltage are provided at a time when the LED has reached a resting temperature that is essentially the same as an ambient temperature around the LED.
4. The method according to claim 3 wherein determining the operating temperature includes using the LED parameter in the ideal diode equation
I
=
I
o
\u2062
exp
\u2061
V
–
E
g
AkT
,
where I is the operating current, Io is a constant, V is the voltage applied across a diode junction of the LED, Eg is the effective optical band gap of the semiconductor at the diode junction, A is the diode factor, k is Boltzmann’s constant, and T is the operating temperature in degrees Kelvin.
5. The method according to claim 4 wherein the LED parameter is related to the effective optical band gap of the LED.
6. The method according to claim 4 wherein the LED parameter is used to determine a current to voltage curve for at least one temperature.
7. The method according to claim 1 wherein superimposing includes selecting a power supply that exhibits a ripple current and using the ripple current as the current pulse.
8. The method according to claim 1 wherein the circuit including the LED and the power supply is part of a device to at least provide illumination to assist visual perception of humans, and where the superimposition of the current pulse on the operating current produces a temporary change in the light level from the LED that is less than an interval having a duration imperceptible to humans.
9. The method according to claim 1, wherein the LED is operable at a temperature less than a maximum temperature and is subject to thermal damage at a damage temperature exceeding the maximum temperature, the method further comprising:
comparing the operating temperature with the maximum temperature; and
reducing the operating current responsive to the operating temperature exceeding the maximum temperature.
10. The method according to claim 1 wherein the superimposed current pulse lowers the magnitude of the operating current to a value that is less than another value of the operating current that would otherwise be present without the superimposed current pulse.
11. The method according to claim 1 further comprising using the thermistor temperature in a calibration procedure to increase an accuracy of the determination of the operating temperature of the LED.
12. The method according to claim 1 further comprising:
receiving with a ballast a utility power in the form of a utility alternating current and a utility alternating voltage, the alternating voltage having a root-mean-square voltage over 100 Volts, and wherein providing the operating current to the LED includes converting the utility alternating current into the operating current using the ballast, the ballast having a size smaller than a volume envelope of a conventional single gang junction box.
13. The method according to claim 1 further comprising:
determining multiple operating temperatures at multiple different times and saving values of the temperatures and times at which the temperatures were determined to determine an overall operable lifetime of the LED.
14. The method according to claim 1 further comprising:
determining the overall operable lifetime of the LED based at least in part on the multiple operating temperatures and the multiple times at temperature.
15. The method according to claim 14 further comprising:
indicating the overall operable lifetime of the LED to a user.
16. The method according to claim 14 further comprising: providing the determined overall operable lifetime of the LED to a system that monitors power usage.
17. The method according to claim 14, wherein the operation lifetime increases when the LED is operated with the operating temperature below a maximum operating temperature, the method further comprising:
comparing the operating temperature with the maximum temperature; and
reducing the operating current to reduce the operating temperature below the maximum operating temperature.
18. The method according to claim 1 wherein there are at least two LEDs in the circuit and wherein the superimposed current pulse includes a frequency component at a predetermined frequency, the method further comprising: passing the current pulse to a first LED while blocking the current pulse to the second LED based on the frequency component and wherein the determined operating temperature is the operating temperature of the first LED.
19. The method according to claim 1 wherein the determined operating temperature is a first operating temperature which occurs at a first time and further comprising determining a second, different operating temperature at a second, different time.
20. The method according to claim 1 wherein the provided operating voltage is between 1.5 Volts and 2.5 Volts DC.
21. The method according to claim 1 wherein the superimposed current pulse is a current ramp having a plurality of current magnitudes and the sensed voltage pulse is a voltage ramp having a plurality of voltage magnitudes corresponding to the current magnitudes such that the operating temperature is determined based on a curve relating a log of a plurality of the currents against a corresponding plurality of voltages.
22. The method according to claim 1 wherein superimposing the current pulse, sensing the voltage pulse, and determining the operating temperature are performed periodically.
23. The method according to claim 1 wherein the superimposed current pulse is a first current pulse and the voltage pulse is a first voltage pulse, and further comprising:
superimposing at least a second, different current pulse on the operating current which results in a second, different voltage pulse that is superimposed on the operating voltage;
deriving an operating temperature curve from a logarithm of a magnitude of the current pulses against a magnitude of the voltage pulses;
determining a slope of the operating temperature curve; and
determining the operating temperature of the LED based on the determined slope of the operating temperature curve.
24. The method according to claim 23 wherein the operating temperature is determined by comparing the slope of the operating temperature curve to predetermined slope values that correspond to different LED temperatures.
25. A control system for determining a temperature of at least one light emitting diode (LED) (i) receiving an operating current and an operating voltage and (ii) electrically connected in parallel to a thermistor having an effective resistance range that is lower than a reverse bias resistance of the LED and that is higher than a forward voltage resistance of the LED, the LED being operable at an operating temperature, the control system comprising:
a power supply for providing the operating current and operating voltage to the LED, the power supply superimposing at least one current pulse on the operating current to the LED resulting in (i) a voltage pulse superimposed on the operating voltage and (ii) a relatively larger amount of the current pulse flowing through the thermistor and a relatively smaller amount of the current pulse flowing through the LED;
a voltage sensor for determining a voltage magnitude of the voltage pulse;
a current sensor for determining a current magnitude of the current pulse; and
a controller for determining (i) the operating temperature of the LED at the provided operating current based on the current magnitude of the amount of the current pulse flowing through the LED and the voltage magnitude of the voltage pulse and (ii) a temperature of the thermistor based on the amount of the current pulse flowing therethrough.
26. The control system according to claim 25, wherein the controller is configured to utilize the thermistor temperature to increase an accuracy of the determination of the operating temperature of the LED.
27. The control system according to claim 25, wherein the controller is configured to control the power supply to provide an initial operating current and initial operating voltage at a known initial temperature of the LED before providing the operating current, the controller is configured to use the measured values of the initial operating current, initial operating voltage and initial temperature to determine at least one LED parameter of the LED, and the controller is configured to determine the operating temperature using the determined LED parameter.
28. The control system according to claim 27 wherein the controller is configured to control the power supply to provide the initial operating current and initial operating voltage at a time when the LED has reached a resting temperature that is essentially the same as an ambient temperature around the LED.
29. The control system according to claim 27 wherein the controller is configured to determine the operating temperature using the LED parameter in the ideal diode equation
I
=
I
o
\u2062
exp
\u2061
V
–
E
g
AkT
,
where I is the operating current, Io is a constant, V is the voltage applied across a diode junction of the LED, Eg is the effective optical band gap of the semiconductor at the diode junction, A is the diode factor, k is Boltzmann’s constant, and T is the operating temperature in degrees Kelvin.
30. The control system according to claim 29 wherein the LED parameter is related to the effective optical band gap of the LED.
31. The control system according to claim 29 wherein the LED parameter is used to determine a current to voltage curve for at least one temperature.
32. The control system according to claim 25 wherein the superimposed current pulse is a first current pulse and the voltage pulse is a first voltage pulse, and wherein the controller is configured to control the power supply to superimpose at least a second, different current pulse on the operating current which results in a second, different voltage pulse that is superimposed on the operating voltage, and wherein the controller is configured to derive an operating temperature curve from a logarithm of a magnitude of the current pulses against a magnitude of the voltage pulses and to determine a slope of the operating temperature curve, and to determine the operating temperature of the LED based on the determined slope of the operating temperature curve.
33. The control system according to claim 32 wherein the controller is configured to determine the operating temperature by comparing the slope of the operating temperature curve to predetermined slope values that correspond to different LED temperatures.
34. The control system according to claim 25 wherein the current pulse comprises a ripple current of the power supply.
35. The control system according to claim 25 wherein the power supply superimposes the current pulse on the operating current to produce a temporary change in the light level from the LED that has a duration imperceptible to humans.
36. The control system according to claim 25, wherein the LED is operable at a temperature less than a maximum temperature and is subject to thermal damage at a damage temperature exceeding the maximum temperature, and wherein the controller is configured to compare the operating temperature with the maximum temperature and reduce the operating current in response to the operating temperature exceeding the maximum temperature.
37. The control system according to claim 25 wherein the power supply superimposes the current pulse resulting in lowering the magnitude of the operating current to a value that is less than another value of the operating current that would otherwise be present without the superimposed current pulse.
38. The control system according to claim 25 further comprising:
a ballast for receiving a utility power in the form of a utility alternating current and a utility alternating voltage, the alternating voltage having a root-mean-square voltage over 100 Volts, wherein the ballast is configured to convert the utility alternating current into the operating current and configured to provide the operating current to the LED and control system, wherein the ballast has a size smaller than a volume envelope of a conventional single gang junction box.
39. The control system according to claim 25 wherein the controller is configured to determine multiple operating temperatures at multiple different times, and further comprising:
a clock for determining times; and
a memory for saving values of the temperatures and times at which the temperatures were determined to facilitate determining an overall operable lifetime of the LED.
40. The control system according to claim 39 wherein the controller is configured to determine the overall operable lifetime of the LED based at least in part on the multiple operating temperatures and the multiple times at temperature.
41. The control system according to claim 40 further comprising a display for indicating the overall operable lifetime of the LED to a user.
42. The control system according to claim 39 further comprising an interface for providing the determined overall operable lifetime of the LED to a separate, different system that monitors power usage.
43. The control system according to claim 39 wherein the overall operable lifetime increases when the LED is operated with the operating temperature below a maximum operating temperature, the controller being configured to compare the operating temperature to the maximum temperature and to reduce the operating current to reduce the operating temperature below the maximum operating temperature.
44. The control system according to claim 25 wherein the LED is a first LED electrically connected to a second LED, and wherein the power supply superimposes the current pulse with a frequency component at a predetermined frequency, and further comprising:
a first frequency filter positioned for passing the current pulse to the first LED and a second frequency filter positioned for blocking the current pulse to the second LED based on the frequency component.
45. The control system according to claim 25 wherein the controller is configured to determine a plurality of operating temperatures at a plurality of different times.
46. The control system according to claim 25 wherein the power supply is configured to provide the operating voltage at 1.5 Volts to 2.5 Volts DC.
47. The control system according to claim 25 wherein the power supply is configured to superimpose the current pulse in the form of a current ramp having a plurality of current magnitudes and the sensed voltage pulse is a voltage ramp having a plurality of voltage magnitudes corresponding to the current magnitudes, the controller being configured to determine the operating temperature based on a curve relating logarithms of a plurality of the currents against the corresponding plurality of voltages.
48. The control system according to claim 25 wherein the control system is configured to superimpose the current pulse, sense the voltage pulse, determine the current magnitude, and determine the operating temperature periodically.
49. The control system according to claim 25 wherein at least a portion of the control system is integrated into a chip.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A method for making a power inductor comprising:
providing a first magnetic core comprising a ferrite bead core material;
cutting a first cavity and a first air gap in said first magnetic core; and
attaching a second magnetic core to said first magnetic core at least one of in and adjacent to said air gap.
2. The method of claim 1 further comprising polishing at least one of said first and second magnetic cores prior to said attaching step.
3. The method of claim 1 wherein said attaching step includes bonding said first and second magnetic cores together.
4. The method of claim 1 wherein said second magnetic core comprises a soft magnetic metal.
5. The method of claim 4 wherein said soft magnetic material comprises powdered metal.
6. The method of claim 1 further comprising forming distributed gaps in said second magnetic core to lower a permeability of said second magnetic core.
7. The method of claim 6 wherein said second magnetic core includes ferrite bead core material and said distribute gaps comprise distributed air gaps.
8. The method of claim 1 wherein said providing step comprises molding and baking said first magnetic core.
9. The method of claim 1 wherein said providing step comprises cutting said first magnetic core from a block of said ferrite bead core material.
10. The method of claim 1 further comprising attaching said first and second magnetic cores together using at least one of adhesive and a strap.
11. A method for making a power inductor comprising:
molding a ferrite bead core material into a desired shape;
baking said ferrite bead core material to provide a first magnetic core; and
arranging a second magnetic core relative to said first magnetic core to provide a magnetic path that flows through both said first and second magnetic cores.
12. The method of claim 11 wherein said first magnetic core includes a cavity and an air gap and wherein said second magnetic core is located at least one of in and adjacent to said air gap.
13. The method of claim 12 further comprising cutting said cavity and said air gap in said first magnetic core.
14. The method of claim 11 further comprising polishing at least one of said first and second magnetic cores prior to said attaching step.
15. The method of claim 11 wherein said attaching step includes bonding said first and second magnetic cores together.
16. The method of claim 11 wherein said second magnetic core comprises a soft magnetic metal.
17. The method of claim 16 wherein said soft magnetic material comprises powdered metal.
18. The method of claim 11 further comprising forming distributed gaps in said second magnetic core to lower a permeability of said second magnetic core.
19. The method of claim 18 wherein second magnetic core material includes ferrite bead core material and said distribute gaps comprise distributed air gaps.
20. The method of claim 11 further comprising attaching said first and second magnetic cores together using at least one of adhesive and a strap.