After seeing the new Pelican flashlight using an inverted Luxeon LED, I was inspired to

see if I could make one myself. I was also curious as to the effectiveness of using a sapphire

lens as the heat sink base itself. The LED is attached directly to the sapphire lens with

thermal epoxy. The lens is very quick to heat up and seems to be more than adequate in

conducting the heat from the LED die. A good thermal bond between the lens and the head

of the flashlight should allow for further conduction.

Ideally, the wire leads would radiate out on the plane of the lens and then pass beyond the

reflector. This prototype was put together rather hastily and the focus of the LED itself

leaves a bit to be desired as well.

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