Purpose: How does the head lamp work?

Hypothesis: The head lamp works buy running electricity through LEDs emitting energy as light.

Sketch:
Functional Analysis-
The main function of this product, the headlamp, is to add a point of view light source. In
summary there are three AAA batteries that are the energy source. Through wires and circuit
boards the electricity evenly flows through 20 different Light Emitting Diodes (LEDs) radiating
energy as light.
The batteries work by having chemical reactions that release electrons in the anonde.
This build up of extra electrons is unsafe and the extra electrons want to move to a place where
there are fewer. The only place this is in is the cathode. Between the cathode and anode there
are electrolytes that keep the electrons from flowing between the cathode and anode inside the
battery. This creates a closed circuit. The the battery is connected to a circuit and the extra
electrons flow out of the battery into the indented object. After the electrons flow to the object
they flow back into the battery through the anode.
The circuit board acts like an electricity street map to evenly distribute the energy to all
the LEDs. There are resistors and capacitors linking everything together like miniature metal
streets. The resistors are there to limit the electricity to each LED. If too much electricity flow the
LED will not be able to handle it and will break. The capacitors are used to store energy inside
the circuit. ​Common applications of capacitors include local energy storage, voltage spike
suppression, and complex signal filtering.
The LEDs are two-lead semiconductor light source. It is a pan junction diode that emits
light when activated. When a current is added to the LED, electrons are able to recombine with
electron holes within the device, releasing energy in the form of protons.
A few other functions of the headlamp is the mount on the head and the on/off button.
The lamp is attached to an elastic fabric that wraps around the head. The elasticity of the fabric
allows for a tight fit on the head and allows for minimal movement. The on/off button has a very
specific and simple function. Its duty is to turn on and off the light by completing the electricity
circuit allowing for the flow of energy and by un-completing the circuit by taking away the flow of
energy.

Structural Analysis-

The headlight has many different parts. The LED lights are a big part of the headlamp
allowing it to complete what it was made for. The LED lights are connected to the circuit board
which allows a signal to go through and turn on the headlamp. A button on the top of the
headlamp activates the circuit board. Glass is covering the LEDs and a rubber ring is on the
back side of the LEDs to seal them. A strap is connected to the side of the headlamp to allow
someone to wear it. Batteries are connected on the side giving the headlamp power.
The main purpose of the structure of the headlamp is to provide safety for the LEDs and
keep the headlamp securely on the head allowing the headlamp to provide light for the user. In
the lamp there are two rubber washers to create a watertight seal. This is extremely important
because water can short circuit the wires and break the lamp. The pressure to keep the seals
tight is created from two things. First, small metal screws are used to fasten the internal parts
together. Next, twisting the clear plastic end piece is used to force the all the parts together one
last time.
The purpose for the LEDs is to allow the headlamp to accomplish what it was designed
for. The circuit board gives information to the LEDs from the button that is on the top of the
headlamp. The battery pack fits three batteries to bring power to the headlamp. The purpose of
the strap is to securely put on the headlamp and to make sure it doesn’t fall off. There are three
electrical wires to transfer the information from the circuit board to the LEDs.

Material Analysis-(what materials are used and what are their properties?)

The material that is used to provide structure on the outside of the headlamp is plastic.
There are rubber washers that separate the pieces of plastic to provide a waterproof seal on the
outside. The plastic used for the headlamp is made of 32% ​polypropylene, 17% polyurethane,
16% PVC, as well as miscellaneous plastics for the remaining percentages. The plastic used for
headlamps is pretty ubiquitous because is is lightweight and is very sturdy overtime.
Towards the front of the headlamp there are 20 LEDs. LEDs are enclosed by a thin
plastic layer called an epoxy which protects materials such as wire bonds, a reflective cavity, an
anvil/ post to provide support, and a semiconductor die that is composed of gallium and an
element in group 5.
The inside of the headlamp has a hollow hole in the form of a cylinder which holds 3
AAA batteries. The batteries used to complete the circuit are ​typically made of zinc, and
manganese dioxide. The electrolyte between and inside those electrodes contains ions.
There is a small circuit board that feeds wires through to the plastic and to the LED lights
at the front. The circuit board is made of ​fiberglass epoxy resin with a copper foil bonded on
both sides.​The LED lights on the headlamp are able to produce white light, but other LEDs can
emit a wide variety of colors due to the different compounds of gallium used.
The resistors that are used for the headlamp are wirewound, carbon composition, carbon
film, metal film, metal oxide film, and foil. Finally, to secure the headlamp to your head there is
fabric attached to both sides of the plastic that can stretch to your head size.

Manufacturing Analysis-
This product is made by LE, Lighting Ever, that manufactures a wide range of LED light
products. There are several variations of this headlamp, but this one features 20 LEDs. They
plug in the LEDs into a circuit board below, and the rest of the head of the lamp is centered
around that same central circuit board. LE is a company based in the United States, but also
serves countries around the world. LE gets top international certifications, including: TUV GS,
Dekra, TÜV Rheinland, BSCI, VDE, CE and RoHS in Europe, Energy Star, UL and FCC in
North America. They use only the best possible products, and due to their efficient assembly
line process, they are able to keep their prices low.

The process of creating an LED has several steps:

 1. Creation of the semiconductor wafer: a crystalline semiconductor is grown in a chamber
mixed with chemicals and there is so much pressure that they are pushed into a solution.
This is then cooled and solidified, now called a boule.
2. Cutting: The boule is sliced repeatedly into thin wafers, 1 single crystalline thick.
3. Adding layers: Additional layers are melted onto the wafer, and now it is several microns
thick.
4. Adding metal: Metal contacts are melted onto the wafer, depending on whether it will be
used alone or with other LEDs. Metals are then vaporized and condense onto the wafer,
and go through an annealing process so they chemically bond together.
5. Repetition/ additional cutting: The metal melting process can be repeating over 6000
times if necessary, depending on the size and function desired. The diodes can also be
cleaved or sawed into additional ¨die¨.
6. Mounting & Packaging: If it is a single LED, it will be put onto two metal leads and
molded. If it is meant to be one of many, they will be molded together at this stage.
Finally, this is packaged and shipped off to where it will be used.

Once the LED´s are made, LE assembles the headlamp with them. The molded series of LEDs
are placed into the lamp body, which will be screwed together to form the main light of the
headlamp. From there, the headlamp is secured to a plastic backboard that is able to pivot. The
backboard is attached to the elastic headband, thus finishing my headlamp.

Cites:
Functionality Sources:
https://learn.sparkfun.com/tutorials/capacitors
https://en.wikipedia.org/wiki/Light-emitting_diode
http://www.qrg.northwestern.edu/projects/vss/docs/power/2-how-do-batteries-work.html
https://science.howstuffworks.com/environmental/energy/circuit.htm

Material:
http://www.resistorguide.com/materials/
https://en.wikipedia.org/wiki/Light-emitting_diode
http://www.madehow.com/Volume-1/Light-Emitting-Diode-LED.html

Manufacturing:
https://www.lightingever.com/3w-140lm-waterproof-ip44-led-headlamp-3200012-2.html
https://www.lightingever.com/about-us
http://www.madehow.com/Volume-1/Light-Emitting-Diode-LED.html#ixzz5QoGL9VZI
http://www.madehow.com/Volume-1/Light-Emitting-Diode-LED.html#ixzz5QoDTsZG1