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Building a LED Task Light Part 1

Discussion in 'Electronic Basics' started by Watson A.Name - Watt Sun, Dark Remover, Nov 12, 2003.

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  1. I stuffed a PC board with 28 white LEDs and resistors, and now I'm
    trying to make a gooseneck task light with it.

    I bought a couple small C clamps so I can clamp the light onto the
    edge of the bench. Then I used a piece of 12 AWG solid electrical
    wire as the gooseneck and mounted the wire to the clamp with a couple
    wire ties. I folded the end of the wire over on itself a few inches
    so the wire wouldn't twist under the wire ties.

    I mounted a PCB with 6 LEDs on it as the head for this gooseneck lamp,
    and powered it with a wall wart. The 12 gauge wire is okay for this
    smaller hear, but it could be a bit stiffer for a head with 20 or more
    LEDs.

    So I went back to the hardware store and bought a few feet of 6 AWG
    solid bare copper wire. I couldn't find any solid wire bigger than 12
    gauge, everything was stranded. Instead of wire ties, I used the
    small sized hose clamps, the stainless steel ones with the worm screw
    tightener. They hold the copper wire very solidly. But I have to
    insulate a few inches of the bare wire so I can strap the head to it
    with wire ties. I'm not enclosing the PC board because there is so
    much buildup of heat from the LEDs that an enclosure would have to be
    heatsinked and well ventilated. Each LED takes about 100 mW, so 28
    LEDs plus resistive drops takes nearly 4W.

    I would like to get some PC boards etched and predrilled with a
    circular pattern of LEDs and resistors. I looked around for some on
    the web, but I didn't see any. Let me know if there are some
    available. Thanks.

    I thought that it might be a better heatsink if the LEDs were mounted
    on a 1/8" thick aluminum plate, maybe epoxied into the holes. But I
    don't have a way to accurately drill a lot of holes into 1/8"
    aluminum. Maybe a better PC board would use heavier board with
    thicker copper traces. Any added thoughts appreciated.


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