The Juggernaut "RED Edition"

I am starting another "Juggernaut" Maglite build
This one will be using a 500mW 635 Mitsubishi diode











I am expecting 1.2W+ out of this guy
Not to mention this build might actually be close to 635nm (Chilled Diode)
True 635 is quite a bit birghter per mw than 445

The 2 part heasink was custom made by Eudaimonium
Same one used in my 445 Juggernaut

Focus adapter was made by Flamingpyro.

Using 2 X-Drives a 1.8A for the TEC and a 1.5A for the Diode.
First time using an X-drive, so far they have been great. Very easy to work with, and efficient too.

I'm using a Custom Thermoelectic peltier to cool the diode,
This TEC will be running at 1.8A
Diode will be running at 1.5A

WARNING MATH BELOW...

(1.8A * 6.3V) = 11.5W being output by the TEC
(1.5A * 2.5V ) - 1.2W = 2.5W being output by the Diode
[(1.5A * 2.5V )+(1.8A * 5.5V)]*.07 = 1W being output by Drivers

This time total heat is only 15W about 1/2 the heat of my original Juggernaut



The Heat differential between the Hot side and Cold side will be 45C!
The hot side will be something like 35c
so -10c on the cold side

To avoid condensation, the inside of the maglite head will be dehumidified

Stunning build. I like the TEC sandwiched between the two massive sinks. It will surely keep the diode cool. The color of the laser dot must be beautiful !

Are the drivers connected to the sink end of the TEC?

Nice fancy build using a TEC... :gj:

I just can't see the logic in putting a TEC between 2 heat sinks
since after the TEC transfers the heat from the front thermal
mass to the rear mass the rear thermal mass seems to have
no active cooling (ie. fan/water cooling etc.).

You would get the same or better heat transfer using one single
solid heat sink of the same total length and would save the power
required to run the TEC.... IMO


Jerry

You can contact us at any time on our Website: J.BAUER Electronics

Thanks, Blord

jander6442 said:

Are the drivers connected to the sink end of the TEC?

Click to expand...

Yes, they are on the hot side.

lasersbee said:

Nice fancy build using a TEC... :gj:

I just can't see the logic in putting a TEC between 2 heat sinks
since after the TEC transfers the heat from the front thermal
mass to the rear mass the rear thermal mass seems to have
no active cooling (ie. fan/water cooling etc.).

Click to expand...

The Cold side is as small as possible,
while still covering the tec and holding the aixiz module

A fan is a good idea in theory,
But not very practical in a real handheld.

I know Jayrob tried something like this with a fan,
and he made it sound like the his setup didnt acomplish much

lasersbee said:

You would get the same or better heat transfer using one single
solid heat sink of the same total length and would save the power
required to run the TEC.... IMO

Click to expand...

Wait do you mean without a tec?

Yeah... without the TEC.

The TEC eats a lot of energy from the batteries.
Without some kind of active cooling I can't see the TEC
helping in your build. It is just tranferring heat from the
front heatsink to the rear heatsink using energy to do
so.

It's like disconnecting the cooling fan in an air conditioner.
The pump (TEC) is still taking the warm air from the
inside (Laser) and transferring it to the outside radiator
(rear heatsink) but it can't get rid of the heat because
the active cooling fan is disconnected. No way to get
rid of the built up heat.


Jerry

You can contact us at any time on our Website: J.BAUER Electronics

And an airconditioner could put out 10 KW of heat, 1000 times more than my laser,
You could replace an Air conditioners fan with a Chunk of aluminum 1000 times larger than a maglite,
and the air conditioner would work fine for quite some time.

The duty cycle of this build will be over 5 mins

This design is already proven to work:
Here's an LMP shot of a build that has the same heatsink, same tec, but a power hungry 9mm diode
How many high power, portable lasers have you seen that can output over 95% power at 5mins?

I'm not comparing your Laser's heat generation to a
10KW Air conditioner. I'm simply demonstrating my
logic (as I see it) in using a TEC in your build.

Well.... I guess I'm wrong and you are right....:beer:


Jerry

You can contact us at any time on our Website: J.BAUER Electronics

I usually do not criticize builds.... here it goes, justin I hope you take this as just my being weird, but man with that nice sink you got there it looks like u could have centered those sweet xdrives a little better.

Also could you give your source for that peltier the size and voltage. I have an idea, but sometimes those are hard to source.

jander6442 said:

I usually do not criticize builds.... here it goes, justin I hope you take this as just my being weird, but man with that nice sink you got there it looks like u could have centered those sweet xdrives a little better.

Click to expand...

Lol, Ya I guess.
Considering once I assemble it, you will never see them again, I wasn't to woried about it.

But centering the the cold side sink was very imporant,
Because my lens is held my the maglite head,
and any misalignment could mess with my beam shape

(Not that a mitsubishi multimode has a good shape to begin with :crackup

jander6442 said:

Also could you give your source for that peltier the size and voltage. I have an idea, but sometimes those are hard to source.

Click to expand...

Custom thermoelectric has a good range of decent TEC's that dont cost a fortune.
This one is 2.5A 8.4v, 14w qmax

lasersbee said:

I'm not comparing your Laser's heat generation to a
10KW Air conditioner. I'm simply demonstrating my
logic (as I see it) in using a TEC in your build.

Click to expand...

I know what you mean,
I was actually suprized at how well the 445 build worked out

at the 5 min mark, the body of the maglite was hot to the point it was uncomfortable to hold,
but the cold side was just below ambiant

some beamshots would be great :yh:

Ill get some beam shots asap,
but Im still waiting on my Molecular Sieve Desicant to arive,

With out it the build would get condensation, which would be bad...

justinjja said:

Ill get some beam shots asap,
but Im still waiting on my Molecular Sieve Desicant to arive,

With out it the build would get condensation, which would be bad...

Click to expand...

Very nice build and really impressive run time with the 9 mm 445!

Just thought Id mention it, but you know you need to heat the molecular sieves in an oven to dry them and then hermetically seal them inside your build? If you dont and air can get in they will suck up all the moisture and then stop working, until you remove, reheat and reactivate them...:beer:

Very cool build, I like the TEC setup. How much longer do you think you'd be able to increase the runtime by upgrading to copper? Also, we should halo sometime. :yh: