Materialism:

Flashlights

Stanislav Shalunov, Dec 2002

The best flashlight is Surefire L2 Digital LumaMax. It's small, rugged, bright, and long-lasting.

In this article, I cover the selection of battery and flashlight. I am no expert on batteries and flashlights (not even a hobbyist). What I collected here is a compilation and derivation of data that helped me understand the subject; perhaps it will help you, too. I was just shopping for a light.

Non-rechargeable Batteries

Non-rechargeable batteries come in very different availability, with different prices, different capacity, and different sizes. The following table (data comes mostly from theLIGHTsite and a bulk battery dealer, also Candle Power Forums, the LED Museum, and Sean's Flashlight Site) should help make sense of a few common types of batteries.

SizeVmAhH,mmW,mmm,gWhWh/kgcentsmWh/cent
AAAA1.559542.58.36.50.89251371009
AAA1.5112544.510.511.51.68751473548
AA1.5256550.514.5233.847516735110
C1.5835050.026.266.212.52518970179
D1.51800061.534.2141.92719080338
F1.52600087.832.220139194??
N1.5100030.212.091.516712512
9v (=6*AAAA)959548.526.5x17.545.65.35511711547
Lantern (=4*F)62600011566.7885156176225693
MN21/23 (=8*LR932)124028.510.37.50.4864??
123A6130034.517.015.57.850320039
AA Lithium1.5290050.514.514.54.3530025017

Notes:

It seems that overall the following types of batteries make the most sense (for different purposes):

Lantern 6v
Very cheap per unit of capacity, good capacity per gram (comparable to other alkaline batteries: somewhat better than AAA and AA, but slightly worse that C and D); but, it's large (certainly not pocketable). Excellent for work lights or a light in the car, or an emergency light at home (if a variety with long shelf life is bought).
Type D
Good compromise: cheap (only lantern batteries are cheaper) and good capacity, not too huge.
Lithium 123A
Not much more expensive than AAA or 9v, very high capacity per gram, small, very long shelf life.

Rechargeable batteries seem to only make sense if you are a very heavy regular user. They have no place in emergency and backup lights. Even if (and especially if) you are a heavy user, you still need a backup light, to which the considerations of this section will apply.

Rechargeable Batteries

For a regular user rechargeable batteries offer lower price of energy (at the price of lower energy density).

Rechargeable batteries come in the following types:

Unfortunately, at this time it appears to be impossible to get a flashlight that would use rechargeable Lithium Ion 18650-type cells. Large Lithium Ion batteries conservatively provide about 2Wh/cent over their life time, assuming daily -- or more frequent -- charge cycles (almost three times cheaper than lantern batteries). They are also maintenance-free and have energy density only slightly worse than non-rechargeable alkaline batteries (about 120Wh/kg). Lithium Ion batteries rapidly become very expensive if used infrequently due to their aging properties.

NiCd batteries made to fit type D sockets can provide up to 10Wh/cent with regular maintenance. Improperly maintained NiCd would provide approximately 3Wh/cent. NiMH batteries can yield about 2Wh/cent with proper maintenance.

Lamps

Light Emitting Diodes (LEDs) have very long life (essentially never needing to be replaced), produce light that can appear more white than that of other lamps, have very good lumen/Watt ratio. However, they cannot have very high wattage, and, therefore, even with their good lumen/Watt ratio cannot be made very bright (the new Luxeon 1W LEDs seem to be an exception: they can compete in brightness with a conventional lamp; the coming 5W LEDs may very well obsolete many incandescent lamps). Since they typically have low wattage such as 100-150mW, LEDs are often combined to produce a flashlight with higher light output; however, this way they cannot be all placed in the focal point of a reflector to produce a beam. Several LEDs make a good flood light, while a single LED makes an excellent key-chain light.

Xenon lamps are used in high-end automobile headlights. They produce absolutely the most amount of light for their size, if we are to ignore HIDs. They burn out much faster than LEDs and, of course, use much more power.

Conventional and halogen lamps appear inferior to Xenon lamps for serious-beam applications in terms of total output, while they lose badly to LEDs for flood or small light applications.

Halogen lamps have better than xenon lumen/Watt ratio, so they might be preferable in a flashlight with only incandescent bulb and no LEDs. They are also cheaper than xenon bulbs.

High Intensity Discharge (HID) lamps are very expensive (up to $100 per bulb), very fragile (no dropping!), large, and take tens of seconds to come to full output. They produce a lot of light. The main application is stationary lights.

Reflectors

LED lights often come with no reflectors at all. However, all `beam' lights (and most lights in general) are equipped with paraboloid reflectors. Assuming point light source, an ideal manufacture process, and no diffraction, the flashlight with a smooth paraboloid reflector and a lamp in the focal point would emit a perfect beam of parallel rays. Since lamps actually have non-zero size and manufactured paraboloids are not perfect (often, they are simply approximated by spheres to simplify the specification), typical flashlights with smooth reflectors produce rings and dead spots. The rings are unavoidable if the light allows for wide beam setting (moving the lamp out of focus). One can alleviate this problem by introducing facets or minor random imperfections: the beam will be smoother at the expense of throw. A faceted reflector consists of a large number of tiny flat mirrors. A textured reflector has a fine texture; it is also known as a stochastic or an orange peal reflector. Faceted and textured reflectors help produce smooth light out of focus. Textured reflectors work better than faceted (and are harder to make, so they are found in more expensive lights).

Some reflectors can be combined, so that the outer part is smooth (resulting in a tight beam with a good throw) while the inner part is textured to reduce rings in wide beam setting.

Switches

There is the familiar push-button on/off switch, the cap or bezel twist, and tail-end `tactical switch'. Tactical switch is so known because this is what police officers and other users of flashlights for pistol shooting in the dark use; it works by momentarily turning the light on while the button is pushed in (usually with a thumb). A bright flashlight can, in addition to illuminating the target, temporarily blind or dazzle an opponent. [It should be noted that `serious' types, such as the military, would not use a light for shooting in the dark at all, since night vision equipment is readily available.]

The tactical switch is ideal for very bright beam lights: not least because they use a lot of energy and it is convenient to be able to turn them off as soon as they aren't necessary. It is almost always combined with a way to turn the light on and keep it on, often by twisting the tail cap.

A growing number of lights come with both an incandescent lamp and one or more LED. These require the selection of a mode for their operation. Unfortunately, the most common way to allow to select one of several modes is to provide a button that cycles through the states. This has the unfortunate consequence that after you're done using a low-level mode and want to turn the light off (perhaps to regain night vision) you have to go through a high-output mode that erases your night vision. A much better user interface would be to provide an on/off switch (perhaps a tactical switch as described above) along with a separate selector of modes.

Case Materials

Flashlights are commonly made of plastic, aluminum, steel, and (synthetic) rubber. Plastics lights (and pure rubber lights) are cheaper than metal ones, but they do not protect the content well and are hard to make even marginally watertight. Steel is unnecessarily heavy. Any light should have an aluminum case with rubber edges for grip, water protection, and cushioning. Rubber cases can be OK for cheaper lights that use inexpensive bulbs/LEDs and have no electronics to protect.

Electronic Parts

Many lights don't have any and are just fine. Many lights need step-up or step-down circuits; these will often regulate voltage for constant brightness throughout battery life. Regulated power supply is a nice thing, except the user has little warning that the light is about to go out. I'm ambivalent about these.

The Ideal Flashlights

Flashlights fall into three general categories:

Lights that can be used for more than one purpose are convenient and popular. Traditionally, a combination beam/flood light was implemented as a beam light with a conventional bulb and an adjustable focus: when such light is seriously out-of-focus, the beam is wide (in reality, irregular and unsightly). With the advent of LEDs (which are ideal for flood lights) these combinations are becoming obsolete.

Further, flashlights can be portable (those that you intend to carry) and non-portable (for the home, the car, etc.). For non-portable lights, there's no reason not to provide both flood capability with LEDs and a beam capability with a xenon bulb and a smooth reflector in a package that includes a lantern battery (or, more expensively, several type D batteries). Portable lights are trickier.

In a portable light, at least the choice of batteries is very clear: lithium type 123A. Nothing small comes close in capacity per gram, and they are only slightly more expensive than AAA or 9v batteries (and much cheaper than AAAA, N, or AA Lithium). Ideally, a portable light should provide a combination of key-chain, flood and beam. If the light has integrated LEDs, the incandescent bulb will not be (ab)used for flood light purposes and will therefore only be used sparingly; therefore, in a LED/incandescent light combination, xenon bulb makes the most sense since it provides highest total light output.

The ideal non-portable light:

Comparing this light to existing lights, such a light would have the following running times: 30 hours in full-illumination flood mode or 7-10 hours in beam mode, depending on whether the LEDs are on.

The ideal portable light:

Comparing this light to existing lights, such a portable light with one 123A cell should have the following running times: about 300 hours in keyhole mode (comparable to low-output mode of the PAL), 10 hours in flood mode, and 1 hour in beam mode (with output similar to the E1).

It is too bad that as far as I know no-one makes either of these lights. The absence of a good combination non-portable light can be tolerated: the light would already be huge, why not keep separate flood and beam lights? The absence of an ideal portable light is regrettable.

Existing Models of Portable Lights

Some interesting flashlights:
Lifestyle Fascination Aluminum Xenon/LED Hand Torch
Unknown manufacturer, possibly exported by a Taiwanese company Nuwai; reportedly very sturdy construction. Costs $40 plus shipping with two 123A batteries and a faceted plastic reflector, has three modes: 3 LEDs (26 hours), 6 LEDs (9-12 hours), xenon (1.75 hours). Comes very close to being perfect, but has an annoying cycle-through-three-modes push-button switch and is a bit too large. In the same league for center brightness as the Scorpion and the 6P (is about 30% dimmer than these lights).
Streamlight Scorpion
Supposedly similar to the Lifestyle Fascination light in xenon mode, but has no LEDs and comes with a well-designed tactical switch and a spare bulb. About $40.
Princeton Tec 40
A submersible halogen light with four easy-to-find AA batteries (3-5 hours), plastic case, and a textured reflector for $16. Quite bright. (Supposed to be in the same league as Surefire E2 for center brightness.) Very economical (but not the smallest) tight beam light. Excellent backpack light, I suppose.
Surefire E2
Very small bezel (and very small two 123A battery light overall). Otherwise, similar to Streamline Scorpion with less focused beam and with a price tag of $75.
Brinkmann Legend LX
Another xenon light with two 123A batteries for about an hour of runtime. People complain that the bulb falls out; otherwise, well-built. Tail-end on/off switch. Supposed to be $20 at Walmart and $30 on the net.
Surefire E1e
Single-cell version of the E2. The smallest bright light (an hour of run time, twice less bright than E2). Gets all the rave. Huge wow factor for $70.
PALight Survival
Single LED with a reflector; 9v battery; about $20; low (200 hours), high (40 hours), and strobe (200 hours) modes; rubber case. Another beam LED light. Has the distinctive advantage of long run time and a distinctive feature: always on low-level glow.
Surefire 6P
Killer xenon light for $75, made mostly for the police. Two 123A batteries give one 60 minutes of light. However, unless you're going to buy the P61 high-output lamp assembly (HOLA) that only works 20 minutes on these batteries, forget it: Streamline Scorpion for $40 is very similar and comes with a spare bulb that can be carried in the light. (The ``forget it'' part does not necessarily apply if you actually want it for tactical use, where extra ruggedness can very well be worth it, while extra bulb in the light is not very useful.)
Some not so interesting but popular flashlights:
ARC-LS-123A
Uses the right battery, has single Luxeon 1W LED with a reflector and a package that is supposed to be very well built; the ideal key-chain light, right? Wrong. It's $120-150. Get a Surefire E1 if you're into super-expensive key-chain lights: it has a tighter beam and is twice cheaper.
Streamlight Stylus
Keyhole light for $20: Single LED, no reflector. Pen form factor (convenient if you have pen holder pockets). Uses three outrageously expensive AAAA batteries. Forget it unless you are the type to take apart Duracell 9v cells, take out the (almost) AAAA cells and insert spacers. Supposed to be well-built, but who cares?
Inova X-5 Tactical
A well-built 5-LED beam light? Well, apparently it doesn't have any throw (how could it?), but works poorly as a flood light, too. Have some $50 to waste?

Conclusion

I'll wait for Luxeon 5W white LEDs. They'll probably cost around $30 retail and have light output of 120 lumens (same output as the HOLA option of Surefire 6P, but larger than xenon bulb, so beam would be wider with less intensity for the same size reflector); but, on the same two 123A cells they'll burn for an hour rather than 20 minutes. Rumor has it that their white version has some 1000-hour problem that should be corrected perhaps in early 2003. Once the LED is available, a number of flashlight manufacturers in likely to take advantage of it.

In the meantime, I'll use assorted lights; maybe I'll buy the Princeton Tec 40.

Update: September 2003

Since the last time I checked, two things happened: the 5W LEDs started to show up in production lights and a new light that pretty much answers my call for a combination light came out. Both innovations are produced by Surefire. Their flashlights are very highly regarded by the experts (of which I am not one).

The 5W LEDs did not turn out to be the wonder they were touted to be, but they are still really good. Their rated life expectancy is 500 to 1000 hours for different versions (so, they may need replacement, but the cost of the LEDs is negligible compared to the cost of batteries). They have better lumen/Watt ratio than xenon bulbs, but the difference is not as great as was expected. But they are shock-proof. Xenon lamps with outputs up to those found in lights up to 6P are essentially obsolete at this point.

Surefire A2 Aviator has a xenon bulb plus three standard 5mm LEDs. It has two modes (LEDs only and xenon lamp plus LEDs), regulator, soft-start for the xenon bulb, and is otherwise similar to the E2. $140.

Surefire L4 Digital Lumamax (and KL4 bezel for any E series light) has a single 5W LED and blows away any xenon-based E series flashlight in light output (but not in center luminosity) while having very similar power consumption. One intensity level only. Regulator that results in constant light output for about an hour. $140.

Surefire L1 with a single 1W LED and a two-stage tail switch is otherwise similar to the L4. $100.

All of the above lights take two CR123A cells.

What I want now is an L4 variant with two-stage switching mechanism to be able to save battery.

Update: May 2005

Surefire has granted my wish in its L2 LumaMax: two-stage switch and more total output on ``high'' (100 lumens) than L4. One hour on ``high'' or 18 hours on ``low.'' $165, more expensive than anything mentioned above. Some minor nits include the fact that it's a bit longer than other two-cell lights and supposedly makes a high-pitched noise on ``low.'' About as good as it gets. They also have the U2 Ultra ($270, whew!), which has more levels of output, but isn't as bright as the L2 at the highest setting and is larger and heavier; not sure who would buy it.

Update: November 2005

Since nothing major (like a one-element 5-W LED) seemed to be coming out, I bought the Surefire L2 Digital LumaMax flashlight. I can find no fault with it. I'm sure a more miniature version with less light output will be coming out one day.
I am no flashlight expert. This document is an amateur's personal opinion only.