[ QUOTE ]
Lurker said:
Doug, in that example, since the resistor is consuming some power and heating up, would it make sense to replace it with a load that would produce light, such as another LED (or multiple LEDs) in series? Would that work to keep current down to safe levels and produce more total light over the battery life than the single LED with a resistor? What would be the drawback to that besides the monetary cost of additional LEDs?
Or maybe some combination of LEDs in parallel? Or reducing the cells from 4 to 3?
[/ QUOTE ]
Spot on, you've broken the code. Congratulations.
This is just the sort of thing the DD advocates are looking at. The rub comes from the real world (as it so often does), in this case what happens as the battery voltage changes. Remember, alkalines are down to 1.2 Volts per cell at the *half used* point, the maker considers end of life .8 Volts! Such a DD light would be out of light with 90% of the battery capacity unused. To avoid this, DD designs must seriously overdrive with fresh cells (so they at least put out some light with weak ones) with all the attendant trade offs. Adding extra resistance helps here, notice that in the calculation we just did, at the 'half used' point, 1.2 Volts we still had over half the original light out. Even when the cells are flat, we have four times .8 Volts, 3.2. Two tenths of a volt across the 100 ohms is 2 mA, still a useful level for some uses (it will of course, be fading fast).
Fewer cells makes this tougher. 3, while more efficient overall, will still stop with more useful energy left per cell.
Other batteries are worth consideration. For instance NiMH (and NiCd) cells have very stable voltages as they age (and generally lower and more stable internal resistance) at about 1.2 Volts per. So a pack of 3 gives us 3.6 Volts (and a bit more typically) through 90% or more of the usable life.
The next step is probably a low drop out regulator (a simple sort of DC/DC converter), sort of a 'smart resistor' if you will that adjusts the effective total resistance to set the current to exactly what we want and keep it there as the battery ages and the rest changes as it will (within the limits of available energy of course). Such a circuit can be as simple as a single transistor, a current regulator IC with 3 leads, 3 resistors and a small capacitor, totaling less than $2 and presenting few 'challenges' WRT building (no PCBs, bitty parts, etc.). Using 3 NiMH cells and such circuits I typically get 50 solid continuous hours of uniform light at 30 mA from 1700 mAH cells (nearly full capacity) at *over 90% efficiency*. The key is 'low headroom' (close match between the battery voltage and the requirement of the LED) and 'low drop out' (the ability of the regulator to work with very little voltage drop, under .1 Volt in this case). Funny bit is, when it shuts down regulation at the end of the battery, it's essentially a Direct Drive set up......
BTW, I think simple resistored lights are so popular because they're cheap and simple. IMO, not always good qualties......in flashlights or women.....
Doug Owen