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.
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.
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.
…
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
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
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.
“I used to think that top environmental problems were biodiversity loss, ecosystem collapse and climate change. I thought that thirty years of good science could address these problems. I was wrong. The top environmental problems are selfishness, greed and apathy, and to deal with these we need a cultural and spiritual transformation. And we scientists don’t know how to do that.” (Gus Speth)
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.
“I used to think that top environmental problems were biodiversity loss, ecosystem collapse and climate change. I thought that thirty years of good science could address these problems. I was wrong. The top environmental problems are selfishness, greed and apathy, and to deal with these we need a cultural and spiritual transformation. And we scientists don’t know how to do that.” (Gus Speth)
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.
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.
50 Large
30 Small
.
Thank you!!
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"
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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
Well, this is what I am probably going to do once I receive my testing samples and test the voltage drop at 6A.
I’m interested in 20 large springs and 20 small springs. Thanks BlueSwordM!
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.
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.
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.
Cheers
Looking for interest on copper pills for SK98 flashlights gals and guys…
Sofirn C8F's Barkuti review
A little call for help…
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.
40 + 20
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.
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.
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
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.
∅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
Looking for interest on copper pills for SK98 flashlights gals and guys…
Sofirn C8F's Barkuti review
A little call for help…
I’m in for 20 big, 20 small. Thank you!
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
I'm in for 20 big and 20 small thanks!
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.
link to djozz tests
“I used to think that top environmental problems were biodiversity loss, ecosystem collapse and climate change. I thought that thirty years of good science could address these problems. I was wrong. The top environmental problems are selfishness, greed and apathy, and to deal with these we need a cultural and spiritual transformation. And we scientists don’t know how to do that.” (Gus Speth)
20 small as well.
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.
I would like to add 20 small to my order.
Change please , not 20 but 30 for me , big size .
Thanks
- George
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30 Large
30 Small
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
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.
Oh well, I still have a few djozz-springs leftover but I’m curious how these turn out.
10x big, 10x small please.
link to djozz tests
“I used to think that top environmental problems were biodiversity loss, ecosystem collapse and climate change. I thought that thirty years of good science could address these problems. I was wrong. The top environmental problems are selfishness, greed and apathy, and to deal with these we need a cultural and spiritual transformation. And we scientists don’t know how to do that.” (Gus Speth)
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.
Is there a limit on them?
Might be in for 20 big and 20 small.
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.
Please add 30 small to my original order post #8
Thanks
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.
20 Large
15 Small
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