Now made an update. removed copper and made a mix with thermal pads and grease. Where the gaps bigger I used silicone and at smaller or almost no gaps I used grease.
When removed yesterday’s work I saw that pads worked well but on the side colse to driver pcb I did not manage to tuck them deep enough.
Now made a better shaped thermal pad.
And for driver and side contact I used thermal grease.
Stuff needed:
And after assembly I also tucked in thermal pad slices to the side as many I could to heatsink the hell out of it:
And first run with 35 click ramp max setup (1367 lumens) Head temp was topped at 46°C and stayed within 1-2°C moving. You see the step down but the flashlight was tailstanding in a half open drawer in my desk so absolutely no air movement around it. In colder enviroment it can hold longer the output.
You can see there is absolutely no drop at start just a little stepping down caused by heating up for around 7-8 minutes. After that it stepped down because of the complete light was very warm. At end of test the light blinked out 48°C (Temp reading calibrated at home so it is pretty accurate.)
So you need to make sure you use enough thermal transfer materials and I suggest using 0,5-1mm silicone thermal pads cutted shape on the 7135 top.
With factory ramp max setting which is above 2400 lumens you still have the drop.
I think you can’t do much more for this issue. Only one I can think of that removing one 7135 which is exactly the opposite side on the driver as MCU but that may cause a bump when ramping. I usually set ramp max to a level what a flashlight can hold for at least 5-6 minutes so I am ok with around 1300-1400 lumen setting where it works great. That output is plenty enough for daily use.
Played with Ramp max config. at 27 clicks ramp max you have no drop but at 25 clicks you have. I setted it to 35 clicks because 1360-70 lumens is enough for most tasks and it can handle for 7-8 minutes steady. If I ramp down a bit from ramp max I can use it for longer time.
Well tests from my site are done so far, don’t know if ZozzV6 will do any further tests, I thought he will do a video review for the MF01 mini on his Youtube channel with the mod mentioned. Although I thinks it should be clear how this mod/heatsink work, or are there some questions?
The production is still on going, but had a little delay. The Supplier confirmed that the full Batch will be ready after Christmas days, end of next Week. I had previously hoped for an earlier completion date, but that’s how it is around Christmas.
I will send PMs to all on the first list with payment information as soon as I have the completed notification from the supplier.
I will also update post # 1 with the current status.
A video would be nice on putting the grease/paste/pads on. I’m not a very technical person and at least for me, there are gaps in going from point A to B. Maybe one will be created. Thanks for figuring this out.
