BLF Interest List: EX3 High Current Beryllium Copper Silver Plated springs - Still selling my springs :)

External spring bypass. Somehow or other, that is a spring bypass sorry to say.

By the same principle, a solid copper conductor spring could be designed to couple with a proper elastic material spring like steel. Somehow or other again, for this to work practically the coils would need to be soldered or spot welded at the base and the top somehow.

Cheers :-)

The copper spring could also be on the inside, and so the more resilient steel would protect it from damage.

In my experience doing inner coiled wire spring bypasses, which is more elegant but also more tricky than outer, when properly done they're long-lasting. By the same principle an inner copper spring head connected to an outer steel spring would work fine. Pretty sure.

Is it possible to design a steel spring and a copper spring/coil to be used together as a set in a way that would protect the copper coil from plastic deformation? Also, for me anyway, if it will compete with a large/small pair of BeCu springs, then the steel spring must be coated some way to make it easier to solder. And, with the added complexity, would it be significantly cheaper than a set of BeCu springs?

Modded Q8 with inner coiled copper (~ .040” / 1 mm) and outer nickel steel spring. Capped with brass terminal lugs. Soldered beneath the caps and puddled at base.
Gave very satisfactory results.
Tedious work and if done again, would counter coil the inner part (not to bind in compression state).

Much easier and cleaner w/ BeCu. Also, my experience with silver, excellent solderability.

Yeah DavidEF came and explained better my prototype idea, but as BlueSwordM says it would probably only work well with a multistrand wire conductive spring.

In my experience with multi-strand coiled copper wire the plastic deformation once set it doesn't gets any worse. I also do not think a spring coiled single conductor copper wire would break, but it would make such a sorry nag of a spring in terms of stiffness that the steel spring would certainly have a hard time pulling it.

So well, better keep devising properly elastic conductive alloys. O:)

Dude! The idea works!

O:)

@ Blue;

Just checked my Q8 and the springs are just as stiff and resilient.
The copper is pushed back by the steel spring as they are held together via the brass cap.

As I had said, much work involved. BeCu with silver coating much easier (and excellent solderability).
And I’m just a tinkerer…

It does not beat nor have the science as your endeavor.

At the time, the only option was an ugly multi strand by-pass.

I had done one such with pure silver stranded wire - what a mess as silver has a creep with the solder (think soldering wick, but much more capillary).

Wait, pure silver wire?

That’s expensive.

And does it pose the same problem as a copper wire bypass?

Well it isn’t gold! (mine is in leaf form - not convenient at conducting).

Have a few odds and ends in the shop. Had some platinum once - used it as a heater.

As for the copper coils, they do get compressed. What did you imply by “lower and lower” ?

Besides, my rudimentary set-up for tailcap measurement gave 17 amps with the stock XPL-2 and Q30s in the lamp. I may try out your springs to see the gain.

My idea is the copper is the primary conductor, the nickel steel spring to sustain the mechanical load.
Visually, the tailcap looks very much as I had made some year ago.
I could take it apart and compare to my original posting, but I rather wait til I have your gen 3 springs as I may try them.
The trick may lay in the soldered cap, this retains the copper coil. These coils were just wound around some mandrel, I believe some 5 turns and had the ends loop flat. The caps were presoldered and the nickel steel spring was fluxed with an acid (something laying in my soldering pastes drawer). The base is completely puddled in solder. A very good mechanical connection.

Some have posted 20 and some amps on a Q8 (to be taken with a grain of salt). But with my phone’s lux meter and a conversion factor that I derived from a known flashlight, I got some 5700 lumens (on turn on). I’m happy with the results.

Anybody can still enter the BeCu spring GB BTW.
It’s not nearly done yet.

People can still enter for the best spring design yet.

We are at:
571 Large BeCu Silver+Copper plated springs
507 small BeCu Silver+Copper plated springs

That’s pretty much what I meant.

Copper doesn’t need to hold the strength on its own, when they are joined together at the top and at the bottom steel should push it up.
And no, double BeCu won’t be nearly as conductive as that.
1 mm copper wire (AWG18) has 50% better conductivity than 0.8 + 1 mm BeCu (w/out extra coating). Furthermore removing coils should reduce the conductor length. And…without tight coils I think that conductor could be thicker.

OK guys.

I’m going to ask the manufacturer if this is actually a good idea or not, and we’ll see what they say.

I already know the answer, but might as well ask someone which perhaps has more practical experience than us.

If they say it’s good, then I’ll just not order the large spring, and use this steel+copper spring array.

If not, well…

Just seems like you guys are getting closer and closer to something like this:

We are at:
596 large BeCu springs
532 small BeCu springs

We are at:
621 large BeCu springs
557 small BeCu springs

Preliminary specifications:

Spring upper diameter: 6,25mm
Spring base diameter: 9mm
Spring thickness: 1,0mm
Spring height: 12mm
Total number of coils: 5
Plating: Copper(25um) + Silver electroplating

Small spring:
Spring upper diameter: 4,25mm
Spring base diameter: 5,70mm
Spring thickness: 0,8mm
Spring height: 10,5mm
Total number of coils: 5
Plating: Copper(20um)+ Silver electroplating

We are at:
621 large BeCu springs
557 small BeCu springs

Source: https://giphy.com/gifs/southparkgifs-3o6Zt4gdNsj11l7Eje

Just had an hypoglycemia, saw BlueSwordM's location and T & P came out in my mind. Fully naive joke. O:)

Out of topic again if you don't mind, but now that I'm in let me say I also find this pretty funny:

Source: https://www.mallorcadiario.com/supremacismo-blanco-no-piadosos-nazarenos

The Semana Santa is just a religious tradition, but certain foreigners seem to look at it in a different way.

Mmmkay, enough with the off topic.

:-)