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.