My parent go to native place where there is lots of load shedding throughout the day. So they needed a torch which should be powerful,handy,light weight and lastly rechargeable. What i designed in this instructable satisfied their needs and feels great to put forward my design to help others.
WARNING : Do not expose your eyes to direct LED since i felt nauseous and was down with severe headache when exposed to direct view of LED's.
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Step 1: Required Materials
> Old waste phone (for battery + panel + connectors FOR USE)
> LED (1-watt) + Heat Sink (Rs.25 = $0.5 per piece)
> Wires for connections
> Press button switch (taken from $2 china made mosquito racket)
> Adhesive (Feviquick Rs.10)
>A very small Acrylic piece or anything that satisfy the needs will do
> Solder (for soldering connections)
Step 2: Gathering Material
Battery + Panel + Connector from old mobile
I had a nokia 6630 which was completely damaged and was beyind repairs. So removed the battery and unscrew the mobile to remove the panel where the battery rests.
Till this step we have the Panel.
Now since we dont want the wires to be directly soldered or anything fuzzy about the torch we hooked the connectors of the battery too which is used in mobile, means of which the battery will be used just as if we use in mobiles.
Till this step we have Panel + Connector
Now i didnt wanted to but those press button switches. So i used one in electric racket, was waiting for the racket to malfunction then rig the racket but ten patience and repairs by me it worked again so finally removed the switch with some modifications in wiring so both racket still working and me having the button switch too :)
Till this step we have Panel + Connector + Switch
Step 3: Assembly
The LED which i used is 1Watt since they are small and flat rather than round cylindrical but majorly used it since it have a great luminisence a single LED is enough to light the entire room sufficiently.
Remember to use the heat sink since these generate plenty of electricity.I just soldered the ends on heatsinks taking into account that the LED's back is touching the heatsink.
Now stick those LED on the panel at back-side. Place the Switch at bottom, i did taking into account that it will be easy to press and feel comfortable also not block the light.
Till this step we have LED + the switch glued with no connections.
Lastly the final stick for connectors (a very tricky here)
for connecting the connector to horizontal panel i cut the acrylic piece so that the small black connector fits inside it.Once, its been done i glued it to panel(so sorry but didnt have those images since i did it and then took the pic). One can have many diff ways to do it and can use other material too. The only thing one must take care that after fitting the battery it should directly be in front of those pins on battery and should touch too. One can do trial and error before final gluing.
Till this step we are done almost we have all stuff glued in and waiting for connections.
Step 4: Connections & Final Product
Now lets do the connection it will be straight forward and can be done by seeing the images.
But still i will explain, the positive connection will go to one of the point in switch since we want the LED to light when we press button. The second connection will be from negative of battery to LED's negative. And lastly LED's positive to switch's other end.
And the product is ready test it by pressing the switch ....... remember to connect the batteries.
If things dont light up things to check :
> check the connections +ve & -ve
> check if the connector pins are touching the pins on battery (Major problem)
> check soldering (Majorly on connector pins)