ElektroLumens
Flashlight Enthusiast
Luxeon Star Two \'D\' cell Flashlight Mod
Hello everyone,
I have been trying to find a way to mount a Luxeon Star in a 'D' cell flashlight for some time. I would like to use 'D' cells because of battery life considerations. Size is not important. I finally found a flashlight that works, a Rayovac Industrial 3 'D' cell flashlight.
I designed and built a DC/DC step up power regulator using the Linear Technology LT1302 chip. The board is 1" X 2". This is a variable voltage step up, with 85% efficency. I put the board in a plastic film container, and it is used in place of one of the batteries. The 2 'D' cells follow behind it. I set the voltage to 3.2 volts. The shutdown of this circuitry is kind of high, at 1.8 volts, but is acceptable to me. The 3.2 volts is maintained until the battery voltage drops to 1.9, and then quickly dims and goes out at about 1.7 volts.
The heat sink is 2 aluminum plates, about 1 7/8 diameter, separated with a copper plate. The aluminum plates have been cut to have fins, for heat dissipation. They seem to do the job, although I might add one more plate.
The Luxeon Stare is mounted to the heat sink, and two small bolts mount this assembly to the head of the flashlight bulb housing, making a very firm conection. The clear plastic cover is then screwed on.
I just finished assembling this flashlight last night. Works great! I am not sure how long the batteries will last. Any input will be appreciated here. I have heard that a 'D' alkaline has 14 amp hours. Is this true? At 85% efficiency, and bearing in mind the cut off is at 1.8 volts, any idea calculation wise how long the batteries will last?
Any input or comments on my design, or improvement ideas are welcome.
Is there plans to continue to produce the Luxeon Star with the optics ? Or is only the versions without the optics going to be available in the future. Will I need to design the light with this in mind? I haven't heard anything concerning this.
I have also reserved a Arc LS, and am awaiting it's availability. I couldn't wait, and decided to make my own. I am not an electrical engineer, but a computer programmer. I had to figure out the schematics of the power supplies in order to build my power supply.
Wayne
Hello everyone,
I have been trying to find a way to mount a Luxeon Star in a 'D' cell flashlight for some time. I would like to use 'D' cells because of battery life considerations. Size is not important. I finally found a flashlight that works, a Rayovac Industrial 3 'D' cell flashlight.
I designed and built a DC/DC step up power regulator using the Linear Technology LT1302 chip. The board is 1" X 2". This is a variable voltage step up, with 85% efficency. I put the board in a plastic film container, and it is used in place of one of the batteries. The 2 'D' cells follow behind it. I set the voltage to 3.2 volts. The shutdown of this circuitry is kind of high, at 1.8 volts, but is acceptable to me. The 3.2 volts is maintained until the battery voltage drops to 1.9, and then quickly dims and goes out at about 1.7 volts.
The heat sink is 2 aluminum plates, about 1 7/8 diameter, separated with a copper plate. The aluminum plates have been cut to have fins, for heat dissipation. They seem to do the job, although I might add one more plate.
The Luxeon Stare is mounted to the heat sink, and two small bolts mount this assembly to the head of the flashlight bulb housing, making a very firm conection. The clear plastic cover is then screwed on.
I just finished assembling this flashlight last night. Works great! I am not sure how long the batteries will last. Any input will be appreciated here. I have heard that a 'D' alkaline has 14 amp hours. Is this true? At 85% efficiency, and bearing in mind the cut off is at 1.8 volts, any idea calculation wise how long the batteries will last?
Any input or comments on my design, or improvement ideas are welcome.
Is there plans to continue to produce the Luxeon Star with the optics ? Or is only the versions without the optics going to be available in the future. Will I need to design the light with this in mind? I haven't heard anything concerning this.
I have also reserved a Arc LS, and am awaiting it's availability. I couldn't wait, and decided to make my own. I am not an electrical engineer, but a computer programmer. I had to figure out the schematics of the power supplies in order to build my power supply.
Wayne