Custom small flashlights

e_utopia

e_utopia

Joined
Feb 7, 2000
Messages
3,221
Since this forum seems pretty flashlight-oriented, here goes: what would you like to see in a custom-made flashlight along the lines of the Photon and Saphire lights? If there's enough interest, I might just start my own business.

Right now, I'm thinking of something that uses two AAA batteries next to each other, ot make it wider rather than longer (I hate these weird-sized, expensive batteries). LED color would be pretty open (they make almost any color, and they are in certain standard sizes, so they become very interchangeable). The case would be metal (probably Aluminum, for cost and weight, but I might consider Ti if there was enough interest). Definitely watertight. Metal would be far more rugged than plastic, as well.

I'm thinking somewhere in the $30-$40 range, but that's just an estimate. Even if I can't make the numbers crunch at a cheaper cost, remember that that would be for a metal-body light (more durable) which uses standard batteries (cheaper in the long run).

So, if you're interested, post here. If you have any suggestions, comments, etc., post here. After I get a sense of what most people would want, I'll do up a CAD design and try and post some specifications and pictures.

--JB

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e_utopia@hotmail.com
 
I'm not sure I could conceive of something radically better than what is already out there. BUT, I was just thinking about this the other day.

What I would like to have is a LED light driven by an integrated circut, further the IC (PAL? PLC ?) could be programmable by the end user. The user has a standard set of subroutines for timing, addressing each LED, button push processing, brightness, etc.

Ok, that's probably not to realistic.

DaveH
 
It's been a little while since this link has been psoted so maybe it's time to do it again:
http://www.hdssystems.com/ActionLight.htm

In a few months the all-in-one light is supposed to get the new controller with "over-drive" and 5 power settings. If I have
any money by then, I'll get one.

Anyway, I'd like to see something like the all in one, with a more "flashlight like" configuration. That would be perfect, Oh and in Ti.
biggrin.gif


Exceeding the price target - DaveH
 
If you made it with lithium batteries you would eliminate most of the corrosion increase shelf life. And what about silver or PL contacts would that help in power dist. Squeeze focus would be easier to adjust that the standard turning the lens area. Mi2sents
 
Okay, I guess I should refine this a little more. I'm looking at making something small, as close to the mere size of hte batteries and LED as possible. I would use two AAA batteries to get 3V, so no circuitry would be needed. There would be no lens or reflector, just the exposed LED (which has a lens built into it, and I could offer different shapes as options). The batteries would be user-serviceable, so even if I didn't sell it with lithium (I probably would, though, since lithium batteries are good enough that they easily are worth the minor increase in cost), you could change them out.

A programable IC would be nice (although I'd go with a ooPic, since it would be easier for a lay-person to program), but would add to the cost, size, and complexity, and kill the battery life. I want to keep this as simple as possible, so it should just be a case (okay, that's two pieces), a gasket, two batteries, an LED (maybe have a model with two), a switch, a spring contact (probably gold-plated copper), a switch, and a couple of screws.

If enough are interested, I might go with 3 batteries in a cylinder like the light Brock posted a link to, but that would make it bigger. Also, how many would be willing to pay extra for Ti? Finally (for now), what do you think about 1 LED vs 2 LEDs; is the added brightness worth the reduction in battery life?

--JB

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e_utopia@hotmail.com
 
e_utopia,

I've had a UKE 2AAA Mini-Pocket for a year now. More or less. I've wanted to try the red LED lamp but forgot to order it when I ordered the light. When Clay posted the UKE 2L special I ordered that and the LED lamp also. I'll let you know what it is like when I get it. It sounds like what you're looking for but in plastic.

For your custom aluminum and Ti versions I suggest you include catalysts to deal with battery gasses. I don't like watertight flashlights without them. When I open them up you can smell the gasses emitted from the batteries. My 6P and Tekna Splashlights are the worst examples. I always wonder if a spark would set them off.

Here's another idea. Take a Tekna Splashlight that uses a single DL123A battery and convert it to a white LED. Or something similar in aluminum. Or maybe one that uses 2 N cell batteries. I'd be interested with whatever you come up with.

And speaking of customs, have you seen a 3C cell divelight that uses the UKE 4C lamp?

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"A knifeless man is a lifeless man"
-Nordic proverb
 
If you are going to try to drive a white LED you will need between 4v to 5v to get any real light out of it. Thats why most LED flashlights lights take 3 cells. I bet though that a 123A would have enough power to drive white ones at an ok level. So the Tekna Splashlight body might work, or a similar size.

I personally would put 2 or maybe even 3 led's in it. Actually if you put 3 white ones at 3v (2 AAA cells) you would probably draw about the same or less power as a single led on 4.5v and also get about the same light output.

What about the UKE "mini pocket light" at http://www.tannersstorefront.com/underwater_kinetics.htm it has the side by side 2 AAA battery configuration and would easily hold 2 leds.

I have the red led for the 2 AAA light and it is really dim. I would say it could only be used after yours eyes have completly adjusted, or as a marker light.

You know what it sounds like we are talking about, the infinity, except in a AAA version. That would be my favorite light.

Brock - http://www.uwgb.edu/nevermab/led.htm
 
How about something shaped like a Zippo lighter? Polished with rounded corners? That's roughly 2 AAA's side by side. Could also act as a signal mirror if you're lost somewhere and the batteries die
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Thanks, tma, that's pretty much exactly what I was thinking. Maybe not the signal mirror part, since I'm partial to anodizing, but either the customer could do it, or it could be an option.

Brock, I don't think white LEDs can be driven at only 3V, or that they would draw a lot of power and kil the batteries if you did. I'm not an EE, so I might be wrong. If I can, I'd like to have no more than two LEDs, since each one is another place to waterproof.

--JB

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e_utopia@hotmail.com
 
Have ya'll seen these at Triple Aught Designs?

  • *Over 700 hours from one set of AA alkaline batteries!
    *That's over 30days of continuous light from regular AA alkalines.
    *Double or more light output time with lithium batteries.
    *4 cool white LED lamps.
    *Timer mode - automatically turns unit off if left on accidentally.
    *On/Dim mode - allows for variable power output.
    *Flasher mode - high visibility blinking mode with variable rate.
    *Strobe mode - short exposure for stop-action effects.
    *Dazzle mode - great for attention getting needs like sales presentations or product promotions.
    *S.O.S. mode - emergency distress mode sends the Morse code S.O.S. international distress call continuously.
    *Momentary mode - allows user to send code and signals.
    *Waterproof to 100 feet!
    *Alkaline AA batteries included.
ergoangle.jpg
 
Hi JB, I can say for sure that the lower voltage driving an LED the less light it will put out and less power it will use. Most LED's are rated to run in the range of 15ma to 25ma draw. The voltage is more dependant on color. But for the most part the lower voltage you give them the more efficient it is. So a white LED driven at say 2.8v at 5ma will be very efficient. Most LED flashlights will drive the same LED at 4.3v at 40ma. It makes a lot more light that way, but also uses a lot more power.

Last night I tried driving the white LED from a Photon, Nichia white 5600mcd 5mm, using 2 AAA batteries and it lit, but was a lot dimmer. I didn't meter it but I bet it was about 5ma. The good thing about this is it would last a really long time on a set of batteries.

So using 2 AAA you would get about 1/3 the light for about 1/8 the power.

Brock - http://www.uwgb.edu/nevermab/led.htm
 
I have the red led for the 2 AAA light and it is really dim. I would say it could only be used after yours eyes have completly adjusted, or as a marker light.

-Brock
Click to expand...
You're right. I just got the red LED today for the Mini-Pocket and it's dim. I have a red Photon I and that is brighter with old batteries in it. I think it is still usable though. I can't think of anything right now. The advantages are common batteries, easy to replace and very watertight.

I gave it to my daughter to play with. She loves it.

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"A knifeless man is a lifeless man"
-Nordic proverb

[This message has been edited by David Williams (edited 06-26-2000).]
 
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