Thermal Potting a P60

Flashlight Modding and DIY Parts
1

Ok, got my first p60 - citipower x5.

I've got plenty of copper foil here, and looked at some of the discussions on wrapping the drop-in.

Lots of guys mentioned a desire for something a little more refined.

Well, this isn't a new idea (see relevant discussion here http://laserpointerforums.com/f42/custom-copper-powder-heatsinks-42792.html)

but I'm thinking about trying to pot mine w/ epoxy mixed with copper powder.

I did some research and found some good info on this

I found 1lb copper powder delivered for ~$35. That's spherical powder - I think it'd work better than flakes Although (w/o epoxy) flakes should have more copper in a given volume, I think they'll tend to clump in less than desireable orientation when epoxy is introduced.

I don't 'think' this will conduct more heat than carefully wrapped foil - I just think it will end up looking better...which is good for gifts n such...

Anyway, is there enough interest in this for a group buy? I don't need a pound of copper powder... (and an ounce is ~$11 delivered).

2

Maybe I'm missing the boat here, is this just for filling a space that does not transfer heat?

What about filling the area with solder? Just asking. Any potting compound, epoxy or filler is really a poor heatsink material even with copper powder added in it. I mean, if silver is a 100 on the scale of thermal transfer, then potting compounds are about a 5 on the scale of thermal transfer. With that being close to 0, then do you need it at all? Even solder is a poor at heat transfer, but way better than epoxy (depends on the type of solder).

3

yes, they got 5 times the conductivity w/ copper filler (at 15% by weight)

and that's still 5x to 25x worse than solder

W/ the right solder, I think you could do it w/o discoloring the ano - but I wonder about the reflector's electroplating

there's almost no thermal contact between drop-in and body so anything at all would be an improvement...and eliminate the layer of insulating air.

also, this could help ditch the outer spring, but maybe someone has an easier way to do that

4

Pictures of what you are needing to fill? I guess I am not getting it fully yet.

If I had a drop in that didn't fit right, I would probably find something that was the same ID as the host and put the drop in (minus the reflector), in it and fill it in with solder. (sort of like making a form) and removing the outer skin that I used. Kind of like using thin aluminum for the skin, so it would not stick to the solder.

5

I'll take some after I feed the dogs. Part of the problem is the shape of the body -- its curved on the inside (or I'd use plumbing parts).

Sticking would only be a problem w/ the brass part - the pipe solder I have won't stick to aluminum or ano at all.

6

7

I would just use copper foil strips; quick, easy, and efficient.

And that way you can always move your drop-in to a different host if you want to.

8

I will for mine. I'd feel odd if I gave one to someone like that though.

A combination of the two (mostly foil w/ putty to hold it together and look better if disassembled) might be the winner, if I ever drop the coin for the powder....

9

I didn't get to look till I got to work and Of Course, I can't see the pictures till I get home at midnight!

They're so protective here, but yet you can google all kinds of photosSurprised

10

there are ways around that I could share if you're interested - ie portable firefox (runs from flash drive) w/ an add-on - but depending on the work environment...subverting their restrictions is probably not a good idea...

11

It’s not worth it with these guys. I need the job, bad as it is. If anyone even tries to use a usb port, they get a phone call asking what they are doing. Seriously, I tried a flash drive and within minutes I got a call from my boss asking what I was doing. Hell, why don’t they just plug up the ports then.

12

WOW

I'm glad I'm not a sys admin there!