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Old 01-29-2012, 04:01 AM #1
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Default The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

The "IRON 4D" driver:
(The "I've Run Out of Names for Drivers" driver)

I designed this driver almost exclusively for the purpose of unlocking really tiny AAA host 635nm builds. Long story short, it adds zero bulk to the diode itself, and in fact those leads you see coming out the other side of the driver, are the diode's own leads, with wires attached directly to them.



This driver will run a Mitsubishi 635 at 1A from a single lithium ion cell from fully charged to the lowest a lithium-ion can safely go. It creates almost no heat. Even with a fully charged cell, the AMC ICs will only dissipate about 300mW of heat each, and even then, the driver design allows for them to be thermally epoxied straight up against the Aixiz module.

There's also a solder pad on the rear of the driver. You can snip off the diode leads, add a spring for the battery (+) feed, and take the battery (-) from the host via the Aixiz module's case.

Attached Thumbnails
The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver-635nm-module.jpg   The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver-635nm-module-2.jpg  


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Last edited by rhd; 01-29-2012 at 04:02 AM.
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Old 01-29-2012, 04:03 AM #2
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

wow thats nice and tiny.
you could build a micro laser with that just make the bottom side a pad and case ground the thing.

Question got a pic of it on a scope?
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Old 01-29-2012, 04:13 AM #3
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

Quote:
Originally Posted by kiyoukan View Post
wow thats nice and tiny.
you could build a micro laser with that just make the bottom side a pad and case ground the thing.

Question got a pic of it on a scope?
Once I get some time to learn my DSD Nano, I could snap a screenshot of that, if that counts

But it should be solid. I know a lot of AMC-based drivers skip this, but I actually include input and output caps on all of mine (even this small one).
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Old 01-29-2012, 04:27 AM #4
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

I don't know how you managed to fit all 3 of those on there, including caps, on one side. What is the diameter of the boards?

I like the name! Lol
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Old 01-29-2012, 04:34 AM #5
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

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Originally Posted by benmwv View Post
I don't know how you managed to fit all 3 of those on there, including caps, on one side. What is the diameter of the boards?

I like the name! Lol
11mm. You have to violate board edge rules, but in practice everything actually fits when you put it all together (mostly because the SOT-89 packages in Eagle are generous with their outline dimensions).

We're also given some leeway by the fact that the outward facing tab of the SOT-89 ICs happens to be the GND feed that you'd be getting from the case wall anyway - so if they happened to touch the inner edge of the heatsink (which they don't when the drivers are reflowed properly), there is still no issue with shorts.

It's a very very compact driver layout, but it all fits.
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Old 01-29-2012, 04:57 AM #6
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

That's awesome! I'm sure you are fine on stability too, I have a 635 running from two amcs on a similar board but with no caps and it does fine.

I always violate the board edge rules

I have noticed that the eagle sot-89 packages have a much larger pad for the tab than needed.
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Old 01-29-2012, 06:13 AM #7
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Smile Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

Love.
I'm such a sucker for tiny builds. Don't be shy if you stumble upon more pics.

Quote:
Originally Posted by rhd View Post
But it should be solid. I know a lot of AMC-based drivers skip this, but I actually include input and output caps on all of mine (even this small one).
Will you be selling these little guys?
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Old 01-29-2012, 06:55 AM #8
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

Nice driver, and name!

I actually think thermally connecting the driver to your aixiz module will ADD heat to the AMC chip. There is going to be more heat coming from the diode than the AMC chips.
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Old 01-29-2012, 08:44 AM #9
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

The name is EPIC
Very good job man, you help
the forum a lot !

Jim
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Old 01-29-2012, 09:21 AM #10
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

great driver )) If you can and (want) take a photo of it
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Old 01-29-2012, 07:20 PM #11
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

Quote:
Originally Posted by HaloBlu View Post
Will you be selling these little guys?
A few people have offered to sell my drivers at various points. It really depends on whether I could find someone (or a few people) interested in grabbing maybe like a total of 100 of them. That way I could order some boards, and then components in bulk(ish), and spend a day reflowing efficiently.

I'm not setup for efficiently selling 1 or 2 small items at a time. So for that time being, no. But maybe that will change
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Old 03-21-2012, 02:09 AM #12
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

We can make a button cell burner too.. If we find some cells!!!!!!
man this driver is like ..epic! wish that i could buy 100 of them i would take one day off your life rhd..
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Old 03-21-2012, 02:55 AM #13
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

Hello Rhd you done it again great work,how much do you figure it would cost to make 100 boards .With all the components to assemble it.

Postive rep if i can.

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Last edited by Dave934; 03-21-2012 at 02:57 AM. Reason: missed a word
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Old 03-21-2012, 03:24 AM #14
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Default Re: The "IRON 4D" Driver - Ultra Low Profile 1A Red Driver

Quote:
Originally Posted by Dave934 View Post
Hello Rhd you done it again great work,how much do you figure it would cost to make 100 boards .With all the components to assemble it.

Postive rep if i can.

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That really depends a lot on who is putting them together, and how much they value their time at. These are more labor intensive than they are part cost intensive. You've got to be very *perfect* in your positioning of the components because everything is truly spaced right at the 6 mil limit from adjacent components. Getting these as small as they are took a number of revisions, and they take a heck of a lot of reflowing patience.
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