100 Watt DIY flashlight

Powerful, ultra-bright LED light sources have now become popular and available. Advantages LEDs the fact is that their service life is much longer - up to 20,000 hours, and not 1000 hours like conventional incandescent lamps. Also, LED modules consume much less electricity and shine several times brighter than conventional lamps. Buy these LEDs available in specialized stores. We bought a 100W LED module and decided to make a powerful flashlight for walking on dark winter evenings.

We will need

-A small piece of sewer pipe with a socket, diameter 110 mm. and approximately 250 mm long. as well as a plug for the socket.
-Lithium Ion batteries (Can be taken from old laptop or phone batteries).
-Cooling radiator with fan (can be taken from the processor from the computer).
-Controller for lithium-ion batteries YH11047A.
-Boost converter from 10-32V to 12-35V.
-Lens for focusing the light flux.
-100W LED LED module.
-Voltmeter with sound signal.
-Switches, buttons, etc...

Making a powerful 100 Watt flashlight

Let's start with the LED module. Apply thermoplastic to Light-emitting diode.

We install it on a cooling radiator, I use cooling from an old video card. We fasten the module on 4 sides with screws (if you don’t have holes, you can easily drill them and screw the screws, they will make the thread themselves).

We cut off part of the plug from the socket of the same size as the cooling radiator. This will give us the opportunity to install a radiator with an LED in the pipe socket and tightly close the lid.

We make holes in the cover for the lens and mounting screws, as well as ventilation holes.

We install the lens in its place and fasten it with screws and rubber washers.

To make it easier to hold the lantern, we screw on the handle from an old cabinet.

The electrical part of the flashlight consists of modules. The main module YH11047A monitors the state of charge on the batteries; you can also use any other BMS on 4S instead. The voltage from the controller is supplied to a powerful 150W. boost converter. For convenience, so that you can adjust the brightness LED, we replace the built-in construction potentiometer with a large one to secure it to the body. We connect an LED module to the output of the converter. To monitor the voltage on the batteries, we will use a voltmeter with a sound signal that will beep when the voltage on the battery is low.

We took batteries from old iPhone 5, 24 pcs. which were connected in 6 pieces. in parallel to increase the capacitance and in series with each other to increase the voltage, the result was a 4s6p assembly. Batteries can also be taken from old laptop batteries.

We make holes in the case for control buttons: indicators, switches...

We assemble the electrical modules into one unit so that it is convenient to install everything in the housing.We isolate the modules and make sure that there is no short circuit anywhere.

Everything is assembled on an old iPhone 6+ case, at the corners of which we screwed the modules to the main pipe with the corners. We also install control buttons and glue the connector for charging the flashlight with hot glue.

We install a fan in the back and secure it with ties. The air will cool the electrical modules and the radiator LED, passing through the entire pipe. If possible, we install protection on the fan blades...

For better mounting of the LED, we screw the radiator to the body on the sides.

Conclusion

In the process of testing the flashlight, we got 2 glow modes: the first, as we planned with the lens, the beam of light shines far and brightly and easily illuminates the edges of trees, it also illuminates the ground from the 9th floor, the beam of light is more than 30m. When we turned on the flashlight without a lens, the entire area around us was illuminated with diffused light, like daylight, but in this case it shines not far away, about 10m. You also need to be careful not to blind anyone.