Most flashlights draw significantly more amps if measured without tailcap. So I wondered, is there a way to improve the tailcaps? Or are the switches the limiting factor?
Regards
I'd guess the switches are holding things back. Here's a teardown of the switch from an Aurora SH-034 which is an unusual design but shows the limited contact area (And inside the actual switch you have even less room
Yeah, I've unscrewed tailcaps, too.. hasnt anyone ever improved tailcaps? I mean, people solder copper cable to the springs, solder in thicker cables between driver and emitter and so on.. but the most limiting factor is the switch.
On an XP-G light, I measure about 1.5A without tailcap, 1.4A through tailcap without switch and only 0.9A through the complete tailcap.. sadly my DMM doesnt give very accurate resistance readings.
Spring thickness can influence the current also. That why some flashlights use brass or aluminum cap over the spring. Thus the resistance is decreased at higher currents.But the statement that most flashlight draw significantly more amps without switches is not realistic, depends on flashlights and current.
Yes, you are right, I was mainly talking about direct drive lights.
I took the clicky of an old flashlight apart (I destroyed it) and its no real surprise they limit that much.. thin metal with little to no contact.. arent there any good clickys out there?
If you're into tinkering, you could take a switch apart and (make) & replace all the contacts with copper ones. I've done it a few times. Of course I don't do amperage readings, but the resistance shows to be less after replacing with copper.