Another thing to note when using the 7135 chip is that it is the chip that is limited to 6 volt, not the supply voltage for the circuit. This is used in some clever circuits that runs at higher voltage but uses a 7135 chip.
HKJ I’m not at all doubting any info you post but I have a light (pukelight v1) that uses 2 parallel strings of 4s NiMH and it runs at 5.3v fresh off the charger, dead they’re around 5.1v, why the difference?
That sound like the charger is undercharging the batteries or maybe they rest a long time before you measure them.
I assume you measure the final voltage without any load on the batteries, that will be higher than loaded voltage.
You might not see that they overheat, it is very difficult to see if the brightness drops 30% and when you add a ammeter you add some extra resistance, i.e. the voltage to the 7135 will be lower with less risk of overheating.
The risk of overheating depends on the number of 7135 places close to each other and their contact to a heatsink (I.e. flashlight body).
what i would like to know is the difficulty in creating a single li-ion boost driver for single high Vf emitters (xp-g2, xm-l2 etc). i know the discussions with lightmalls fell through. what could have been the technical causes? large drop out, low efficiency?
thanks hkj. i know buck-boosts like this are available. of course i mean i would like to know the inherent problems of a boost driver for to meet Vf at high current (>4A). i see your reviewed driver regulated well at 1A, and that boost mode was more inefficient than buck mode.
It is no problem to make a boost or buck driver, but combining to a buck/boost is a problem. There exist only a few chips that can do it.
The problem is that you basically need two switchers sharing one inductor, this requires multiple transistors. As long as all the transistors are in a chip it is fine, but a led driver does not have place for external transistors for higher power.
a mass market driver with boost should be buck+boost, and i can understand the complexities of such drivers. good explanation also! but the driver in dicussion with lightmalls would have been boost only (DD at Vin>Vf). in other words, a specialised driver for lights which can withstand DDing an emitter (i.e. 5A+).
at high current would a boost driver never reach the required efficiency to work from a single li-ion? or something else, like lack of commercial ics? i can’t even find any mass produced step-up voltage converters for this range and output.
Buck-Boost drivers are also less efficient than just a Buck.
If he wants to drive a XM-L2 at 4A or more he should consider having two Li-Ion cells in series to get 7.4V and using a buck converter… However it will be bulky to be able to withstand 4A.
Again, as long as the input voltage is below 6V even with fully charged cells, the driver won’t fail. But it will be wasteful and run hot.
Let’s do some maths:
Your 4*AA are at about 5V during discharge.
The LED needs about 3.3V
that means that the driver needs to lower the voltage of 1.7V!
3.3/5=66% efficiency! That’s not really good… And that means that 37% of the power is lost in the driver and heats it up.
Use a dummy cell and efficiency will go up, reducing the heat in the driver and you’ll still have the same brightness.
i see in tests of some high discharge cells that outputs of 10A @ >3V are sustainable, so i assumed in theory a boost driver could continue to regulate on a single cell. if the loss is primarily ohmic then i presume it is linear. the size constraints make it difficult i guess.