Old 06-27-2013, 07:29 PM #1
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Default DIY 1.2 Watt Output 365nm Led Torch

Hey all

I have seen a few threads show up on UV 365nm leds and after taking the dive I have ordered the parts to build my own UV 635nm Torch .

The Led that I plan to use is a LedEngine 11 Watt 365nm MCPCB mounted led , the led consists of 4 300mW dies and they are all wired in series for a running voltage of 16.8 Volts @ 700 mA drive current .

The Driver is a "puckdrive" 700mA constant current , dimmable driver with 4 - 32 Volts input range .

The power source is a 6 cell Lipo pack that I am putting together suing 350mA 20C cells , in this case they will be run at 2C , the fully charged voltage is 25 Volts and when the cells drop to 3.7 volts , around 22.2 Volts . The Cells measure 30mm x21mm x 7mm each .

I did plan to use a 5 cell setup , but at 3.7 cell voltage the pack would be 18.5 and the led driver requires Vin to be 2.5 Volts + led Vf and I wanted to be abit above that even when batteries are nearly at 80% empty

Cooling is a heatsink setup with a ultraflat aluminium/acetone heat pipe that is 20mm Wide x 1mm thick and 200mm long , I do have a 30mm wide x 1.6mm thick version aswell if the first one dosent work , but for a heat load of 10 watts max there should be no problem .

The idea is to have the led at the front of the housing with it bolted to a square pice of aluminium with the heatpipe sandwiched in-between , then the heatpipe bends 90 degree round to the side where the 120mm long x 40mm heatsink will be mounted by the side of the battery compartment .

It may not end up working the way I planed , But ill soon find out , the led does like to be run fairly cool so hopefully the heatpipe setup will work , plus I will have forced air cooling on the heatsinks .

Pics will follow as I build it and when I find my camer cable :P

Twirly .


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Old 06-28-2013, 01:57 AM #2
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Default Re: DIY 1.2 Watt Output 365nm Led Torch

Awesome, keep us posted on the progress!
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Old 06-28-2013, 06:21 PM #3
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Default Re: DIY 1.2 Watt Output 365nm Led Torch

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Originally Posted by Sigurthr View Post
Awesome, keep us posted on the progress!
Thanks

Will do , The led and cells will arrive Tuesday and the heat pipes arrived today .

Only thing with using the heatpipe idea is that you wouldn't be able to tilt the torch front up , otherwise it doesn't function as a heatpipe :P
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Old 07-01-2013, 05:35 PM #4
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Default Re: DIY 1.2 Watt Output 365nm Led Torch

You might could look at the specs on your heatpipe. Depending on what kind you bought, it very well may be able to operate in any orientation, so long as one side is cool and the other hot, and matching the specs of the phase change liquid inside.
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Old 07-01-2013, 08:17 PM #5
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Default Re: DIY 1.2 Watt Output 365nm Led Torch

Quote:
Originally Posted by BShanahan14rulz View Post
You might could look at the specs on your heatpipe. Depending on what kind you bought, it very well may be able to operate in any orientation, so long as one side is cool and the other hot, and matching the specs of the phase change liquid inside.
Thanks , But I ended up changing my mind and I used a intel stock aluminium heatsink for the led , works really well and a 80mm fan fits behind it perfectly

My Plan has changed to now the flashlight will be a Acrylic box with a handle on the back so it will still be fully portable and have a run time of about 20 minuets on full power
So Update , I got the led and driver and .... im in love , this is by far the coolest most expensive led I have purchased to date .

The led cost £71 and the driver was £13.99

Pics ! ! , its tiny but puts out some 365nm xD , Just need a reflector for it next .


IMG_0493 by TwirlyWhirly555, on Flickr

IMG_0497 by TwirlyWhirly555, on Flickr

IMG_0499 by TwirlyWhirly555, on Flickr

IMG_0501 by TwirlyWhirly555, on Flickr

IMG_0502 by TwirlyWhirly555, on Flickr

IMG_0503 by TwirlyWhirly555, on Flickr

IMG_0504 by TwirlyWhirly555, on Flickr

IMG_0505 by TwirlyWhirly555, on Flickr

More updates soon
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Old 07-01-2013, 08:31 PM #6
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Default Re: DIY 1.2 Watt Output 365nm Led Torch

What a beauty! Wonder where they get their chips...
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Old 07-02-2013, 02:04 AM #7
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Default Re: DIY 1.2 Watt Output 365nm Led Torch

Man that is sweet! Though if that heatsink is what you're going to be using I can't help but wonder how huge the torch is going to be, haha.
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Old 07-06-2013, 02:29 PM #8
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Default Re: DIY 1.2 Watt Output 365nm Led Torch

Quote:
Originally Posted by BShanahan14rulz View Post
What a beauty! Wonder where they get their chips...
Thanks I be interested to know , May get the 40 Watt version ... But £180 Price tag

Quote:
Originally Posted by Sigurthr View Post
Man that is sweet! Though if that heatsink is what you're going to be using I can't help but wonder how huge the torch is going to be, haha.
Thanks , It wont be "that" big :P , the battery pack is small so shouldn't take up much space .


Update - The Cells arrived and I made the pack , was abit nervous making then pack but soldering the tabs on the cells went well , just used a tiny bit of flux on each tab and it was straight forward , just need to keep soldering time as fast a possible . Pack is a 6S 350mA 20C pack around 25 Volts fully charged ,

Nearly there


IMG_0524 by TwirlyWhirly555, on Flickr

IMG_0526 by TwirlyWhirly555, on Flickr

IMG_0527 by TwirlyWhirly555, on Flickr

IMG_0530 by TwirlyWhirly555, on Flickr

IMG_0528 by TwirlyWhirly555, on Flickr

Just need to make the mini case for it all , and heatshrink warp the Lipo Pack and that .
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Old 07-07-2013, 03:18 PM #9
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Default Re: DIY 1.2 Watt Output 365nm Led Torch

Something like this would be lovely in a Polarion PH-40 host
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Old 07-07-2013, 08:35 PM #10
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Default Re: DIY 1.2 Watt Output 365nm Led Torch

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Originally Posted by Smeerworst View Post
Something like this would be lovely in a Polarion PH-40 host
It would ,

Ive desided to get a copper host made for this led and will make a LiFeO4 pack for it and I may get the 40 Watt 365nm led and make a 16 cell pack and get a host made for that aswell .


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