3rd world CCFL lamp (2007 model)

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Cold cathode^WP lamp

CCFL stands for Cold-Cathode-Fluorescent-Lamp

This is a new kind of Fluorescent-lamp that has cold Cathode tubes. Because there is no heat production there is less energy loss. The cathodes are on the outer end on the inside of the CCFL-tube-lamp. This tube-lamp needs very high voltage to work; the inverter-transformer produces this voltage. The CCFL parts are the CCFL-tube-lamp and CCFL-inverter.

Other names for this kind of lamp:12-Volt Heavy-Duty Inspection-lamp, work-lamp, garage-stick-lamp, Fluorescent portable lamp

Contents 1 Introduction 2 benefit tubes in PET bottles 2.1 Safety 3 shape form 4 electric 5 Sustainability 6 Ease of Use 7 Tools to make the CCFL-lamp cap 8 Material to make the CCFL-lamp cap 9 Outside PET-Bottle 10 Inside PET Bottle 11 Reflecting chips-bag material 12 Melt twelve holes in the plastic foil 13 Nylon fishing-thread 14 Bamboo sate-sticks 15 Soldering the CCFL parts 16 Glue plastic material 17 Wrap plastic around electronic-transformer(s) 18 Binding tube-lamp(s) to the Stick 19 Slide in second and third sate-Stick 20 Slide in Bottle bottom 21 Slide in Bottle in Bottle 22 Make water and air-tight 23 Printable building instruction 24 Tube-lamp-cap with more CCFL units 25 External Electrode Fluorescent Lamp(EEFL) 26 Tube-lamp-cap with old model fluorescent tube 27 Fluorescent lamp tube 28 PET bottle double pivot 29 Thick nylon fishing thread 30 Hook or eye 31 Stick out end 32 Assemble joint parts 33 links

[edit] Introduction

The extreme light-weight Cold-Cathode-Fluorescent-Lamp (CCFL) lamp.

This is the new model third-world-CCFL-lamp.

This lamp can have up to four CCFL-lamps and inverters, taken from electronic equipment like old document-scanners.

The benefits of this new lamp design:

-Is very simple and fast to make.

-Is very simple to explain how to make.

-The CCFL-tube-lamps and inverters are much more energy efficient than the normal fluorescent-tubes.

-Can produce more light without heat

-Is more light-weight

-Can survive more vibration and higher fall from heights.

-No insects can get inside and is more water tight.

-Does not easily compress mechanically because it is air tight

[edit] benefit tubes in PET bottles

[edit] Safety

[edit] shape form

• Have no sharp edges.
• Is lightweight only 0.2 kg, if the lamp-cap falls
• outside is made of soft elastic materials.

[edit] electric

• Is watertight.
• No metal outer parts that can conduct dangerous electricity.

[edit] Sustainability

• If the lamp-cap falls, the elastic plastic breaks the fall.
• the lamp-cap is air tight and hard to compress.
• the tubes-lamps are protected against vibration and shocks.
• The tubes have a very long life.
• Insects, dust and water can not get inside this lamp-cap.
• The bottle material Polyethylene-Terephthalate (PET) remains clear and strong for years
• The chips-bag material (Metallized PET/LDPE) remains reflective for years.

[edit] Ease of Use

• Pivotable in every direction.
• The outside of the PET-bottle material is very clear and smooth, and easy to clean with water.

[edit] Tools to make the CCFL-lamp cap

Measure tool

Sharp knife

Cigarette lighter or matches

Sewing needle

Soldering material

Wire cutter

more

[edit] Material to make the CCFL-lamp cap

2mm thick sticks, like sate sticks

Gummy type of (spray) glue.

Chips-bag reflecting Metalized foil material LDPE^WP

CCFL^WP-inverters and tube-lamps out of old document-scanners.

Thin Nylon fishing-line.

Flexible electric-wire like 2x0.75 MM2.

Two PET-bottles Recycling of PET Bottles^WP

To make a rotation joint you need:

A Third PET-bottle.

1 mm Thick nylon fishing-line

A metal hook

(bamboo)wood stick

[edit] Outside PET-Bottle

Make the bottles more smoothly formed Bottle smooth formed Plastic

Cut and melt holes in the outside PET-bottle.

Outside PET-Bottle sizes

Measure	Shape	Size in mm
72	L	240mm
74	Ø	81mm
76	L	5mm

[edit] Inside PET Bottle

Make the bottles more smooth formed Bottle smooth formed Plastic

Inside PET Bottle sizes

Measure	Shape	Size in mm
82	L	120mm
84	Ø	80mm

[edit] Reflecting chips-bag material

Use Chips-bag material with reflective inside.

The plasic is Metallized PET/LDPE.

This material remains reflective for years, much better than aluminum-foil.

Cut out a piece of the reflecting foil out of a chips-bag

Chips bag material

Measure	Shape	Size in mm
01	L	280mm
02	L	190mm

[edit] Melt twelve holes in the plastic foil

Take 3 layers if Chips-bag reflecting foil

Test this plastic to make sure it is flame-resistant.

Do NOT use PE-plastic or PP-plastic plastic^WP

Melt twelve holes in the plastic foil

holes in reflecting plastic

Measure	Shape	Size in mm
11	L	280mm
12	L	190mm
14	Ø	1mm
15	L	120mm
18	L	50mm

[edit] Nylon fishing-thread

Take transparent thread if possible

CCFL nylon fishing thread

Measure	Shape	Size in mm
25	Ø	0,2-0.7

[edit] Bamboo sate-sticks

There are three sticks needed

Use good quality wooden sate-sticks

Sate-sticks

Measure	Shape	Size in mm
20	L	1.5mm
23	L	80mm

[edit] Soldering the CCFL parts

Here is more information where to find CCFL material Cold_Cathode_Fluorescent_Lamps

WARNING the CCFL inverter can have a dangerous high voltage output.

Soldering the Cold Cathode Fluorescent lamps and the 12 volt CCFL-inverter

[edit] Glue plastic material

Cut the reflecting material in the right size and glue it on the PET-foil material

Use glue that does not damage the reflective layer.

Spray a thin layer of glue like Tixotrope on basis of polychloropreenrubber.

Put the layer parts together without air bubbles in between.

Roll up the plastic layers so it stays in the rolled-up position, use some heat.

[edit] Wrap plastic around electronic-transformer(s)

Put the electronic-transformer(s) in the roll and leave the Tube-lamp(s) outside.

[edit] Binding tube-lamp(s) to the Stick

Press one sate-sticks trough three holes of the foil

Bind with one peice of thin nylon fishing-thread the tube-lamp(s) to this sate-stick.

[edit] Slide in second and third sate-Stick

Slide in the second sate-Stick trough one hole in the foil, through a knot in the electric-wire, and through the other holes of the foil.

The knot is to protect the inverter for pulling forces on the electric-wire.

And slide in the third sate-stcks through the four holes in the foil.

Do not bind the CCFL lamp-tube to all three of the sate-sticks, otherwise the lamp-tube will break more easily.

[edit] Slide in Bottle bottom

Make a rough surface on the inside of the PET-bottle-bottom, using coarse sandpaper or other tool.

Pull the whole length of wire through the hole in the PET-bottle-bottom and slide in the assembled parts

The second knot is to protect the electronic-transformer(s) for pulling forces on the electric-wire

[edit] Slide in Bottle in Bottle

This is the top view of the Tube-lamp-cap

Make a rough surface on the outside of the shortest-bottle-bottom, using coarse sandpaper or other tool.

Slide in shortest bottle-bottom inside the longest one. (Do not slide the longest bottle bottom inside the shortest one.)

Otherwise the long bottle of the lamp-cap can compress and let air in, which would make the Tube-lamp-cap less stiff

Make sure the coarse surface on the inside- and outside bottle-bottoms are in contact with each other.

This is to prevent the bottle-bottom from sliding unwanted out of each-other.

[edit] Make water and air-tight

Glue the electric-wire in the hole in one side of the bottle-bottom with Hot-melt glue or gummy type of glue. If you take the same size bottle halves it is almost air tight already. A good air-tight lamp-cap is better protected against mechanical compression. If this kind of lampcap can be made air tight it can be extremely strong.

[edit] Printable building instruction

(press to enlarge)

1. Cut 3 layer reflecting chips-bag plastic A4 format, same length tube lamp

2. Reflecting surface on the outside

3. Melt 12x small holes in plastic with a needle.

4. Cut 3x thin-stick on length of diameter PET-bottle.

5. 2x knot in 12-Volt-wire.

6. Put 2x thin-stick through plastic and 1x thin-stick through plastic and knot

7. Put plastic through opening between inverter and tube-lamp

7. Put 3x thin-stick through holes

8. Knot tube-lamp to thin-stick with thin wire

9. Put 3x thin-stick through plastic

Steam 2x PET-plastic bottle

A. Cut 1x bottle in part A,B,L

A. Do not use part A

B. Put part B around part E

C. Cut second bottle in part C,F

C. Do not use C

D. Drill hole in bottom F

E. Put 12-Volt-wire through hole in F

F. Put F around part E and part B

G. Make hole in F air-tight

K Put thick plastic wire loop on hook M

L. Fit L on stick N

M. Make hook on stick N

N Stick N

O. part F through part K

[edit] Tube-lamp-cap with more CCFL units

Two, three, or four CCFL units

This drawing is to show how you can use more than one CCFL-lamp and inverter(s) in the 3rd world Tube-lamp-cap.

With the same building instruction it is possible to make a lamp-cap with two three or four CCFL units Some inverters can feed two or more CCFL tubes.

This is the top view of a Tube-Lamp-cap with more CCFL-tube-lamps and CCFL-inverters

[edit] External Electrode Fluorescent Lamp(EEFL)

EEFL looks like CCFL with external Electrodes

There are EEFL inverters that can feed more than two parallel EEFL tube lamps .

[edit] Tube-lamp-cap with old model fluorescent tube

Some people want to make a new clean lamp-cap for their old fluorescent-tube-lamp(S) and electronic ballast.

Clean the fluorescent-tube-lamp(s) for more light.

With the same building instructions it is possible to make a lamp-cap with one or two old tube-lamp(s) and electronic ballasts.

This type of electronic transformer (electronic ballast) has the same dimensions as a electronic inverter.

The thyristor component does heat up; do NOT let it touch the plastic foil.

In this tube-lamp-cap you have the space to make a bigger aluminium heat-sink cooling plate.

The fluorescent-tube-lamp can not handle the heat of tin-soldering.

Tin-Solder the flexeble electric-wire to a two self-made tinplate clamp for every fluorescent-tube-lamp that slides over the two pins of the fluorescent-tube-lamp. Do not use masive electric-wire Use verry thin metal tin plate.

This tube-lamp-cap design is stronger and is more lightweight than the factory model fluorescent tube-lamp-work-light. The PET material is more clear and the chipsbag material reflex better the light.

Tin-Solder the electric-wire to the tinplate clamp

thumb|right|tube-lamp wire clamp |200px

flexible isolated copper Wire

Soldering wire on clamp

[edit] Fluorescent lamp tube

Use Fluorescent lamp 12 INCH or 285mm 12 Volt/8 watt for holder/socket type T5 or G5 

Do NOT use a 110 or 220 Volt Fluorescent lamp

http://en.wikipedia.org/wiki/Fluorescent_lamp

Size of TL lamp

Part	Measure	Shape	Size in mm
P109	1	Ø	16mm
P109	2	Ø	1mm
P109	3	L	5mm
P109	4	L	285mm

[edit] PET bottle double pivot

With this pivot you can point the lamp to needed direction

Make the bottles more smooth formed Bottle smooth formed Plastic

PET bottle double pivot

Measure	Shape	Size in mm
91	Ø	70-80
92	L	70-80
93	Ø	70-80
96	Ø	22

[edit] Thick nylon fishing thread

Thick nylon fishing thread

Measure	Shape	Size in mm
98	Ø	1mm

[edit] Hook or eye

Hook or eye

Measure	Shape	Size in mm
101	Ø	10-15
102	L	20-25

[edit] Stick out end

The PET-bottle must slide over the out-end easley.

Stick out end

Measure	Shape	Size in mm
104	L	20
136	Ø	21

[edit] Assemble joint parts

The nylon fishing thread is very slippery Use the right type of knot to connect the ends together A knot named the "Water knot"

Link Water knot

Connect the lamp cap to 12 volt DC power,

Use a Car socket 12 volt to prevent mistakes about the electric plus and minus polarity.

Low voltage connection basics

[edit] links

3rd world arm lamp

Electrical_wiring_and_switching

Cold_Cathode_Fluorescent_Lamps

Electrical wiring and switching

Low voltage connection basics