Archive for January 31st, 2019
Because the COB LEDs dissipate 6W, far more power than I’m comfortable dumping into a 3D printed structure, I redefined a length of aluminum shelf bracket extrusion to be a heatsink and epoxied the module’s aluminum back plate thereto:
Unlike the flexible LED strips, the COB LED modules have no internal ballast resistors and expect to run from a constant-current supply. Some preliminary testing showed we’d want less than the maximum possible light output, so a constant-voltage supply and a few ohms of ballast would suffice:
With all that in hand, the heatsink extrusion cried out for smooth endcaps to control the wires and prevent snagging:
The central hole in the left cap passes 24 AWG silicone wires from the power supply, with 28 AWG silicone wires snaking down through the L-shaped rectangular cutouts along the extrusion to the LED module’s solder pads.
The model includes built-in support:
Assuming the curved ends didn’t need support / anchors holding them down turned out to be completely incorrect:
Fortunately, those delicate potato chips lived to tell the tale and, after a few design iterations, everything came out right:
The “connector”, such as it is, serves to make the light bar testable / removable and the ballast resistor tweakable, without going nuts over the details. The left side is an ordinary pin header strip held in place with hot melt glue atop the obligatory Kapton tape, because the heatsink doesn’t get hot enough to bother the glue. The right side is a pair of two-pin header sockets, also intended for PCB use. The incoming power connects to one set and the ballast resistor to the other, thusly:
The diagram is flipped top-to-bottom from the picture, but you get the idea. Quick, easy, durable, and butt-ugly, I’d say.
The next step was to mount it on the sewing machine and steal some power, but that’s a story for another day.
The relevant dimensions for the aluminum extrusion:
The OpenSCAD source code as a GitHub Gist: