BLF Interest list for Very High Current Beryllium Copper springs Pt1(ENDED)

718 posts / 0 new
Last post
teacher
teacher's picture
Offline
Last seen: 30 min 9 sec ago
Joined: 02/23/2016 - 19:04
Posts: 6807
Location: NE & SW Alabama

50 Large
30 Small
.

Thank you!! Thumbs Up

      You never know how a horse will pull until you hook him up to a heavy load. / Paul "Bear" Bryant ~/~\~ "Slow is Smooth, Smooth is Fast"

       Texas Lumens Flashlights  <>   M4D M4X Deals : sign up - save $$$$    ||||

         Rudeness Level /\ mΩ /\ {width:70%} /\ LightWiki /\ LED Tint Chart /\ LED Tint Picture /\ Xlamp size chart /\ BatteryU                   Flashaholic? Need Professional Help???   wink   /\ TheOriginal /\ TAB /\ LightSearch /\ BatterySearch /\ 14500's /\ DiCal                                                       

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

Updated.

@Barkuti again, thank you. I will add the Fasttech Carobronze spring info on the OP.

Edit: I have also added the small springs measurements.

Edit 2: Spreadsheet has been updated.

We are at 812 big springs at 257 small springs.

I will ask the manufacturer if it is possible to make 1000 big springs, and 500 small springs. So we can get all of our springs at the same time LOL

Well, this is what I am probably going to do once I receive my testing samples and test the voltage drop at 6A.

skinny_tie
Offline
Last seen: 2 hours 51 min ago
Joined: 09/23/2017 - 03:14
Posts: 262
Location: Australia

I’m interested in 20 large springs and 20 small springs. Thanks BlueSwordM!

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

You’re welcome skinny_tie.

I do wonder though.

Why did Hank not make a bigger beryllium copper spring? He must know about the demand, no? Or does he think the spring would not sell well?

Or maybe it is just because that at the time the small beryllium copper spring was introduced, there were almost no lights which could take advanatge of their very low resistance except for the Noctigon Meteor?

Or maybe he did just think there was no market for a bigger spring.

Edit: There are a total of 841 big springs and 277 small springs.

If the small springs reach 500-600 springs, I will ping the manufacturer to make a batch of 1000 springs.

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

The group buy will continue for 3 weeks.

Is there something you guys think I should change about the big spring?

Would you prefer a gold plating instead, and a 1.1-1.2mm wire for even better conductivity? Or a smaller top?

Let me know.

Barkuti
Barkuti's picture
Offline
Last seen: 31 min 43 sec ago
Joined: 02/19/2014 - 14:46
Posts: 3151
Location: Alhama de Murcia, Spain

BlueSwordM wrote:

Would you prefer a gold plating instead, and a 1.1-1.2mm wire for even better conductivity? Or a smaller top?

Let me know.

Gold plating will make it corrosion resistant but, how much is that? Is it worth it?

1.2mm (≈1.131mm²) wire diameter will make it a little bit better conductor than AWG21 copper wire. Thumbs Up

 

Cheers Smile

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

Yeah I don’t think it is worth it for the additional cost

I will ask if it is possible to use 1.2mm wire for the same cost or not. I don’t think it is going to cost more, if it will cost more at all.

At 1.2mm diameter though, that is going to be one tough spring.

leroycp
Offline
Last seen: 1 hour 31 min ago
Joined: 12/27/2015 - 19:24
Posts: 703
Location: Stewart TN

40 + 20

contactcr
Online
Last seen: 13 min 2 sec ago
Joined: 05/19/2017 - 18:52
Posts: 824
Location: US

When i have done a bypass on thick springs sometimes its too hard to press after bypass. Not a huge deal i guess but i would still end up bypassing some of these unless it was just as good as 22g wire bypass.

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

With a 1mm wire diameter, it is better than a 23AWG wire, and a bit less than 22AWG wire.

With a 1.1mm wire diameter though, it is about as good as 22AWG wire.

With a 1.2mm wire diameter, almost as good as 21AWG wire.

So no need for a bypass for once with these springs.

I personally don’t like doing spring bypasses on steel springs. They just suck too much solder, and tend to fail if you don’t have enough experience.

contactcr
Online
Last seen: 13 min 2 sec ago
Joined: 05/19/2017 - 18:52
Posts: 824
Location: US

If a bypass is truly not needed even with this length spring maybe thicker is better. Idk. Will be interested to see what the others think

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

Thicker is always better when resistance is concerned at such high currents we do(10A+).

However, there are design limitations in the case of a compression spring for a battery, mostly memory elasticity.

From the info I have gathered, 1,3mm is probably the limit, but a bit thinner for more room for elasticity is needed. So 1.2mm will probably be what I pick if there is a small cost difference, if any since I’m ordering more than a 1000pcs.

Barkuti
Barkuti's picture
Offline
Last seen: 31 min 43 sec ago
Joined: 02/19/2014 - 14:46
Posts: 3151
Location: Alhama de Murcia, Spain

BlueSwordM wrote:

With a 1.1mm wire diameter though, it is about as good as 22AWG wire.

With a 1.2mm wire diameter, almost as good as 21AWG wire.

So no need for a bypass for once with these springs.


∅1.2mm wire has π(½(1.2mm))² = 1.131mm², with 38% IACS that equals almost 0.43mm² of copper wire.

My Electrodroid app lists 0.41mm² for AWG21 wire, thus it should be a little bit better.

 

Cheers Smile

pscal
Offline
Last seen: 12 hours 2 min ago
Joined: 01/06/2015 - 11:34
Posts: 109
Location: Arkansas USA

I’m in for 20 big, 20 small. Thank you!

contactcr
Online
Last seen: 13 min 2 sec ago
Joined: 05/19/2017 - 18:52
Posts: 824
Location: US
Barkuti wrote:

BlueSwordM wrote:

With a 1.1mm wire diameter though, it is about as good as 22AWG wire.

With a 1.2mm wire diameter, almost as good as 21AWG wire.


So no need for a bypass for once with these springs.


∅1.2mm wire has π(½(1.2mm))² = 1.131mm², with 38% IACS that equals almost 0.43mm² of copper wire.

My Electrodroid app lists 0.41mm² for AWG21 wire, thus it should be a little bit better.


 


Cheers Smile

A spring is longer run of wire though so the drop is greater. However im not sure how to calculate that when the spring is compressed. Would it take a shorter path or would it have its own resistance? A 22 gauge wire and 19 gauge wire of double the length are almost the same

klrman
klrman's picture
Offline
Last seen: 1 hour 5 min ago
Joined: 11/07/2016 - 22:44
Posts: 1840
Location: Canada

I'm in for 20 big and 20 small thanks!

djozz
djozz's picture
Offline
Last seen: 7 hours 39 min ago
Joined: 09/07/2012 - 17:04
Posts: 13827
Location: Amsterdam

You do not want a spring this size in 1.2mm wire thickness, it is too thick, will be mechanically inferior and the coils will get in each others way. 1mm is plenty thick, already thicker than most steel springs the same size out there.

MRsDNF
MRsDNF's picture
Online
Last seen: 14 sec ago
Joined: 12/22/2011 - 21:18
Posts: 12617
Location: A light beam away from the missus in the land of Aus.

20 small as well. Thumbs Up

My current and or voltage measurements are only relevent to anything that I measure.

Budget light hobby proudly sponsored by my Mastercard and unknowingly paid for by a hard working wife. 

djozz said "it came with chinese lettering that is chinese to me".

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

vinte77
Offline
Last seen: 9 hours 32 min ago
Joined: 03/04/2014 - 18:43
Posts: 699
Location: California

I would like to add 20 small to my order.

giorgoskok
giorgoskok's picture
Online
Last seen: 1 min 33 sec ago
Joined: 11/13/2015 - 10:46
Posts: 2659
Location: Greece
giorgoskok wrote:
Sign me for 20

Change please , not 20 but 30 for me , big size .

Thanks

johnkey68
Offline
Last seen: 1 day 16 hours ago
Joined: 10/12/2017 - 06:29
Posts: 82
Location: Russia

30 Large
30 Small

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

OK then.

I will keep the spring thickness at 1mm.

I knew something would be wrong if we increased the wire thickness. Thanks for confirming my doubts djozz Thumbs Up

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

List updated.

We are at 961 big springs, and 407 small springs.

Since there are so many people wanting small springs too, I will now inform the manufacturer to make a batch of smaller spring with these dimensions along with the big springs:

- Spring top diameter: 4,5mm

- Spring bottom diameter: 5mm

- Spring thickness: 0,8mm

- Spring height: 8mm

- Plating: Zinc plating

Doing this allows for lower shipping costs and lower bulk costs per spring.

If anyone wants to change something about these dimensions above, say it to me.

Thanks again for the community. LOL

djozz
djozz's picture
Offline
Last seen: 7 hours 39 min ago
Joined: 09/07/2012 - 17:04
Posts: 13827
Location: Amsterdam

Oh well, I still have a few djozz-springs leftover but I’m curious how these turn out.

10x big, 10x small please.

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

The manufacturer has said that while it is possible to make 1.2mm wire without a cost increase, making a 1.1 mm is not directly available without a cost increase, so I will keep the thickness to 1mm as initially said, and corrected by djozz, as 1.2mm is too thick and will hurt memory elasticity and may make the spring collapse under a cell.

thijsco19
Offline
Last seen: 10 hours 6 min ago
Joined: 12/14/2012 - 16:18
Posts: 1265
Location: Nearby Rotterdam, the Netherlands

Is there a limit on them?
Might be in for 20 big and 20 small.

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

No limit. 1000pcs is just the minimum order. The more spring we can get manufactured though, the lower the price per spring will be.

Bulk purchases really help getting the cost down by a huge factor.

808Hi
Offline
Last seen: 2 hours 4 min ago
Joined: 01/21/2018 - 04:30
Posts: 191
Location: Hawaii

Please add 30 small to my original order post #8
Thanks

BlueSwordM
BlueSwordM's picture
Offline
Last seen: 1 hour 28 min ago
Joined: 11/29/2017 - 12:34
Posts: 2297
Location: Canada

List has been updated.

One other thing: would you prefer better spring mechanical properties using Beryllium Copper 38% IACS C17530, or slightly better conductivity using Beryllium Copper 45% IACS C17510?
I would like to know your choices.

jmm244
Offline
Last seen: 3 hours 31 min ago
Joined: 07/23/2012 - 22:39
Posts: 169
Location: US North Coast

20 Large
15 Small

Pages