Torch/Bikelight
Started 1y. Edited 10moStarted almost 2 years ago. Last edit 11 months ago
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researchproductinjectionPP
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1
The concept
Published 1yPublished over 1 year ago
The basics of this torch is to combine 4 basic components into a plastic housing to create a torch.
These 4 basic components are:
- LED and Lens
- 18650 Rechargeable Cell
- USB recharging interface
- On/off Switch
2
Looking Inside A Normal Torch
Published 1yPublished over 1 year ago
To understand a little bit more about torches, we dissected a cheap and common torch style to understand the exact layout and specification of these components, what can be easily sourced, and what can be improved upon.
As predicted the components are pretty simple and should be easily obtained.
3
Purchasing Parts & Design Decisions
Published 1yPublished over 1 year ago
After a little bit of waiting and much research, we have sourced a series of components that will make the basis of the torch.
Lens:https://www.aliexpress.com/item/1005007014068880.html
LED: https://www.aliexpress.com/item/32863732033.html
USB Charging Module: https://www.aliexpress.com/item/1005005037876729.htm
On/Off Button: https://www.aliexpress.com/item/1005007581031292.html
However, one variable remains. While waiting for these components, we started looking at waste battery sources. Originally the battery was going to be an 18650 Cell. As these are easily found and readily available. However, we recently started tearing apart other waste items and came across a smaller and potentially more suitable 550mAh battery used in Vapes. These batteries are currently being wasted, with limited recycling but are potentially valuable.
Since these batteries are so small and actually more in scale with the rest of the parts. It may be easier to create an injection moulded housing for the smaller battery rather than the larger battery.
Either way, the next step is to model some layouts of the parts and test battery life on the small battery.
4
We Have A Problem: Overheating
Published 1yPublished over 1 year ago
As with any research project, you are likely to encounter issues. Unfortunately, due to the focus on trying to develop the brightest/most useful torch, we have encountered an overheating issue.
As you can see in the image below, when testing the circuit, the LED (with Heatsink) rose rapidly (within 30 seconds) to 132c before the test was stopped. As a result, we are now seeking slightly lower powered LED setups that may not be as bright, but hopefully more suitable for a torch with a recycled plastic housing.
On the upside. We successfully charged and discharged to recycled battery from disposable vapes using a 1amp USB C charger. So we wont be changing these parts any time soon.
Stay tuned for updates on the new parts.
5
Fixing Bugs
Published 1y. Edited 1yPublished over 1 year ago. Last edit over 1 year ago
Since the last update we have been working on both the over heating problem and finding a nice compact form factor for the components to sit in.
We have made this 3D printed prototype to see how all the components and wires fit, and we are pretty pleased with it, the dimensions end up being around 94mm x 30mm.
To combat the overheating issues, we have swapped to using a small 3W LED instead of the 10W we were using before. Currently, this LED is just wired straight up to the battery, however we are exploring having a small LED control board to regulate the amperage (Hopefully leading to a longer lasting LED). As you can see, this LED is quite impressive for its size and has the added benefit of being a nice push fit into the lens.
We are working on making a finalised design for the housing while stress testing the current electronics set-up.
Stay tuned!
6
Over heating now fixed
Published 1y. Edited 1yPublished about 1 year ago. Last edit about 1 year ago
After the previous update, we began stress-testing the electronics. What we really wanted to learn from this was if the overheating problem still occurs and find out any other interesting issues that may arise.
We set up the torch and turned it on for 2 hours, during this time we regularly checked the temperature of the LED and the other components inside the torch housing and thankfully there was no significant temperature change, The components all stayed room temperature. During the 2 hour test, we noticed how quickly the LED would start to dim when running low on charge so we swapped the LED out for a LED which has a built-in amp regulator. This seemed to have helped with the issue and kept the LED running brighter for longer. The only issue with this is that the new LED module reached temperatures of 90 degrees. We then ran this torch again, this time for 2 and a half hours, with no issues with it in our current PLA housing.
We also monitored the components while charging the torch to check for temperature changes, we noticed that the chip on the USB charging module shot up to 87degc which was worrying at first however it plateaued and seemed to cause no issues. The components do seem to heat up a fair bit, however, they neither get hot enough or stay hot enough for long enough to do any damage to the plastic housing or components themselves.
Another benefit to these tests is understanding the battery life of the torch. With the current battery we have in it, this torch will last for about 2 hours on a full charge before starting to dim.
The next steps will be for us to finalise the design of the touch housing and then complete the mould.
7
Mould Design
Published 1y. Edited 1yPublished about 1 year ago. Last edit about 1 year ago
Since our last update, we have been working on designing the mould!
In working on this design, we wanted to make sure that we are considering a few points;
- The weight of the torch
- The material usage
- The final finish of the torch
- Weather proofing the torch
- Easy removal from the mould
We decided to make the torch as thin as possible while still keeping its strength, much like a store bought injection moulded torch. We have made the torch around 2mm thick, while that may sound fairly thin, we have added multiple ribs on the inside of the housing to hold the components while also adding strength to the overall torch.
You may have noticed that the torch housing is now rounded instead of hexagonal. We always intended for the torch to be rounded (it was hexagonal to make prototyping quicker!). This will not only feel nicer in the users hands but also makes it easy to use as a bike light with a cheap part like this (https://www.aliexpress.com/item/1005007301096377.html?spm=a2g0o.productlist.main.1.1e7151cbj192I5&algo_pvid=1b7d76f7-2dc0-43f2-abe0-62efb7a0a373&algo_exp_id=1b7d76f7-2dc0-43f2-abe0-62efb7a0a373-0&pdp_ext_f=%7B)
For this torch to be considered weatherproof, we need it to be fairly waterproof. To save on cost and extra supplies, we are incorporating a lip into the housing to act as a barrier, hopefully making it more waterproof.
The next steps are getting the mould fabricated and testing the design.
8
Sourcing and awaiting final components
Published 11moPublished 12 months ago
Now that the mould design is done, and we are working on getting it fabricated, Our attention had turned to getting all the parts we will need ordered.
Alongside the injection moulded body, the torch consists of;
- A 3W LED Module (https://www.aliexpress.com/item/32984506965.html)
- A 12mm Waterproof locking push button (https://www.aliexpress.com/item/1005008683268470.html)
- A 22mm 45° Lens (https://www.aliexpress.com/item/1005004118671017.html)
- A USB-C Battery charging circuit (https://www.aliexpress.com/item/1005005037876729.html)
- A 13400 Battery (We have sourced ours from an old vape, but these can also be purchased online)
- 4 M2x6mm Countersink Self tapping screws (https://www.aliexpress.com/item/32809898654.html)
Our next update will consist of testing the mould and assembling the torch for the first time. Once we have confirmed that everything is okay, we will upload the mould. This update will likely be done for the 15th of June, this is due to the fabrication time and getting all the parts and aluminium in house.
Stay Tuned!
9
Project link
Published 10moPublished 11 months ago
For more information and files, check out the project here:
https://community.preciousplastic.com/library/make-a-torch--bikelight--mould
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