[DIY] Altoids USB Charger

[aeroencychris]

Well it just deteriorates them overtime if you keep overcharging it at a USB charging rate of 1Amp. It will basically make the batteries heat up and dissipate all that extra energy so it's not exactly the best thing for them, with a charge controller it would either lower the charge rate or stop once it reaches the proper voltages.

The problem with this is that there's no way to see when they're charged, so that's a pretty big concern.

[W-L]

The problem with this is that there's no way to see when they're charged, so that's a pretty big concern.

 

Only thing I can think of is adding a very small LED/numerical display to show the voltages of the cells during charging but you would still need to be mindful on not letting it go over a certain voltage. While it's bad to overcharge them Nimh aren't as volatile as lipo's which will expand or vent if they are the cell types.

[aeroencychris]

Only thing I can think of is adding a very small LED/numerical display to show the voltages of the cells during charging but you would still need to be mindful on not letting it go over a certain voltage. While it's bad to overcharge them Nimh aren't as volatile as lipo's which will expand or vent if they are the cell types.

That sounds complicated/expensive. I guess I'm just bothered there's no simple solution here, I feel like this shouldn't be that hard. *sigh*

[W-L]

That sounds complicated/expensive. I guess I'm just bothered there's no simple solution here, I feel like this shouldn't be that hard. *sigh*

 

Like I said you could just use the resistor dropper which is perfectly capable of charging the cells, just keep an eye on it when your plugging it via USB which is the only thing that is a concern. 

[aeroencychris]

Like I said you could just use the resistor dropper which is perfectly capable of charging the cells, just keep an eye on it when your plugging it via USB which is the only thing that is a concern. 

I was planning on mass producing these and selling/giving these as gifts, and I don't want other people to have to deal with that inconvenience (neither do I for that matter)

[W-L]

I was planning on mass producing these and selling/giving these as gifts, and I don't want other people to have to deal with that inconvenience (neither do I for that matter)

 

If you are making theses in large scale I would look at sourcing parts and getting either your own PCB's made it's not sustainable sourcing components or from other devices. 

[aeroencychris]

If you are making theses in large scale I would look at sourcing parts and getting either your own PCB's made it's not sustainable sourcing components or from other devices. 

I suppose "mass producing" was a bit of a strong term, more 40-50ish max. Not worth getting PCB's made.

[W-L]

I suppose "mass producing" was a bit of a strong term, more 40-50ish max. Not worth getting PCB's made.

 

for 40-50 I would say using a prototyping PCB board is your best bet in terms of keeping prices low and it will let you create your own wiring runs and layout.

 

Just to give you an idea of the process ~@3:00:

[aeroencychris]

for 40-50 I would say using a prototyping PCB board is your best bet in terms of keeping prices low and it will let you create your own wiring runs and layout.

 

Just to give you an idea of the process ~@3:00:

How much would something like that cost?

[W-L]

How much would something like that cost?

 

That's just an example but not for the application your planning since it's for lead acid solar batteries. Going back to say this here where if you were to source all the parts, it wouldn't be too expensive per unit maybe $3-5 or so then add in the cost of the booster for 5V usb charging and the two batteries. Main thing is assembling the units and soldering everything together which will take the most time.

http://www.stefanv.com/electronics/usb_charger.html

[MeDownYou]

That's just an example but not for the application your planning since it's for lead acid solar batteries. Going back to say this here where if you were to source all the parts, it wouldn't be too expensive per unit maybe $3-5 or so then add in the cost of the booster for 5V usb charging and the two batteries. Main thing is assembling the units and soldering everything together which will take the most time.

http://www.stefanv.com/electronics/usb_charger.html

 

 

Followed this thread today a little bit...looked up some parts and components that look like they would work any input?

 

http://www.ebay.com/itm/0-9V-5V-to-5V-DC-DC-Booster-Module-USB-Mobile-Step-up-Power-Supply-Module-HC-/381384032839?hash=item58cc428247:g:oYcAAOSwT6pV5kpt

http://www.ebay.com/itm/2-Pcs-Black-Red-Cable-Plastic-3-x-1-5V-AA-Batteries-Box-WD-/171889046574?hash=item280562b42e:g:~1MAAOSwHnFVyWEu

http://www.ebay.com/itm/Good-Quality-4pcs-BTY-2500mAh-1-2V-AA-Ni-MH-Rechargeable-Batteries-for-Toys-/262112844939?hash=item3d07249c8b:g:UawAAOSwo0JWLewV

http://www.ebay.com/itm/Blue-Mini-6-Pins-Toggle-On-On-Switch-AC-120V-For-Fender-Guitar-Useful-/111624235328?hash=item19fd52a940:g:EIwAAOSwuMFUaevs

http://www.ebay.com/itm/30-x-1N914-Small-Signal-Diode-200mA-100V-FREE-SHIPPING-/251095249338

http://www.ebay.com/itm/1-3-5-4-5-5-5-6-9-12v-Mini-Solar-Panel-Module-For-Battery-Cell-Phone-Charger-/361352606416?var=&hash=item54224b32d0:m:mkCmDbKcV6HLj6nxqpAnwzw

 

Or ways to streamline/cheapen it?

 

 

Would end up with one extra battery plastic mount, one extra battery, and 29 extra diodes lol

[aeroencychris]

That's just an example but not for the application your planning since it's for lead acid solar batteries. Going back to say this here where if you were to source all the parts, it wouldn't be too expensive per unit maybe $3-5 or so then add in the cost of the booster for 5V usb charging and the two batteries. Main thing is assembling the units and soldering everything together which will take the most time.

http://www.stefanv.com/electronics/usb_charger.html

$3-5 for all those individual parts? Sounds too good to be true. Send parts links and I'll consider.

[aeroencychris]

Followed this thread today a little bit...looked up some parts and components that look like they would work any input?

 

http://www.ebay.com/itm/0-9V-5V-to-5V-DC-DC-Booster-Module-USB-Mobile-Step-up-Power-Supply-Module-HC-/381384032839?hash=item58cc428247:g:oYcAAOSwT6pV5kpt

http://www.ebay.com/itm/2-Pcs-Black-Red-Cable-Plastic-3-x-1-5V-AA-Batteries-Box-WD-/171889046574?hash=item280562b42e:g:~1MAAOSwHnFVyWEu

http://www.ebay.com/itm/Good-Quality-4pcs-BTY-2500mAh-1-2V-AA-Ni-MH-Rechargeable-Batteries-for-Toys-/262112844939?hash=item3d07249c8b:g:UawAAOSwo0JWLewV

http://www.ebay.com/itm/Blue-Mini-6-Pins-Toggle-On-On-Switch-AC-120V-For-Fender-Guitar-Useful-/111624235328?hash=item19fd52a940:g:EIwAAOSwuMFUaevs

http://www.ebay.com/itm/30-x-1N914-Small-Signal-Diode-200mA-100V-FREE-SHIPPING-/251095249338

http://www.ebay.com/itm/1-3-5-4-5-5-5-6-9-12v-Mini-Solar-Panel-Module-For-Battery-Cell-Phone-Charger-/361352606416?var=&hash=item54224b32d0:m:mkCmDbKcV6HLj6nxqpAnwzw

 

Or ways to streamline/cheapen it?

 

 

Would end up with one extra battery plastic mount, one extra battery, and 29 extra diodes lol

I already have all of those parts. Right now I'm concerned about a charge controller. Thanks though.

[W-L]

Here's basically the list they have for parts just check ebay and you can find all of them basically they aren't specialized components:

 

Part     Description

R1       56kΩ ¼W, 5% resistor

R2       27kΩ ¼W, 5% resistor

R3       22kΩ ¼W, 5% resistor

R4       47kΩ ¼W, 5% resistor

R5       750Ω ¼W, 5% resistor

R6       220Ω ¼W, resistor

TR1    10kΩ @ 25°C thermistor, approx. 3.7%/C° NTC
                 Radio Shack #271-110 (discontinued†)

C1       0.1µF 10V capacitor

Q1       TIP32C PNP transistor, TO-220 case

Z1        LM393 dual voltage comparator IC, DIP

LED1   Red, green, or yellow LED, 10mA

Other   2-cell AA battery holder
            USB cable
            Small heatsink

 

Formatting kind of broke....

Edited November 1, 2015 by W-L

[aeroencychris]

Here's basically the list they have for parts just check ebay and you can find all of them basically they aren't specialized components:

 

Part     Description

R1       56kΩ ¼W, 5% resistor

R2       27kΩ ¼W, 5% resistor

R3       22kΩ ¼W, 5% resistor

R4       47kΩ ¼W, 5% resistor

R5       750Ω ¼W, 5% resistor

R6       220Ω ¼W, resistor

TR1    10kΩ @ 25°C thermistor, approx. 3.7%/C° NTC

                 Radio Shack #271-110 (discontinued†)

C1       0.1µF 10V capacitor

Q1       TIP32C PNP transistor, TO-220 case

Z1        LM393 dual voltage comparator IC, DIP

LED1   Red, green, or yellow LED, 10mA

Other   2-cell AA battery holder

            USB cable

            Small heatsink

 

Formatting kind of broke....

I'll consider that. Not ideal but might be my best option.

What about something like this?

[W-L]

I'll consider that. Not ideal but might be my best option.

What about something like this?

-https://www.youtube.com/watch?v=Qw4psECqpwI-

 

As said previously that would work great but only if you use 18650 cell which are lithium polymer batteries and work at 3.7V each, if you want to change over to using those cells instead then it would simplify things and not require building a charge controller itself.

[aeroencychris]

As said previously that would work great but only if you use 18650 cell which are lithium polymer batteries and work at 3.7V each, if you want to change over to using those cells instead then it would simplify things and not require building a charge controller itself.

I guess I'm a bit confused. Why wouldn't normal AA batteries work? What about these?

http://www.ebay.com/sch/i.html?_from=R40&_trksid=p2050601.m570.l1313.TR12.TRC2.A0.H0.X18650+battery.TRS0&_nkw=18650+battery&_sacat=0

(electronics noob, sorry)

[W-L]

I guess I'm a bit confused. Why wouldn't normal AA batteries work? What about these?

http://www.ebay.com/sch/i.html?_from=R40&_trksid=p2050601.m570.l1313.TR12.TRC2.A0.H0.X18650+battery.TRS0&_nkw=18650+battery&_sacat=0

(electronics noob, sorry)

 

Those are 18650 which are basically lithium cells and operate at a different voltage not to mention are larger than a regular AA cell. If you buy those online becareful though since most of the Ultrafire or china ones are half their rating. One very important thing with theses types of cells or any lithium battery is to never short the ends or it will explode.

https://www.sparkfun.com/products/12895

 

[aeroencychris]

Those are 18650 which are basically lithium cells and operate at a different voltage not to mention are larger than a regular AA cell. If you buy those online becareful though since most of the Ultrafire or china ones are half their rating. One very important thing with theses types of cells or any lithium battery is to never short the ends or it will explode.

https://www.sparkfun.com/products/12895

 

So is there an ideal battery to be using? I don't HAVE to do AA.

[W-L]

So is there an ideal battery to be using? I don't HAVE to do AA.

 

Most of those cellphone chargers/battery banks out there use the 18650 type cells for it's ability to store a more energy than a regular AA. With that micro USB charge controller and the single 18650 cell it would regulate the charging:

http://www.ebay.com/itm/2PCS-5V-Micro-USB-1A-18650-Lithium-Battery-Charging-Board-Charger-Module/400665522246?_trksid=p2047675.c100005.m1851&_trkparms=aid%3D222007%26algo%3DSIC.MBE%26ao%3D1%26asc%3D33874%26meid%3D48b4bc0d20084eac9a3a72bbd98b54a8%26pid%3D100005%26rk%3D1%26rkt%3D6%26sd%3D400665524431

[aeroencychris]

Most of those cellphone chargers/battery banks out there use the 18650 type cells for it's ability to store a more energy than a regular AA. With that micro USB charge controller and the single 18650 cell it would regulate the charging:

http://www.ebay.com/itm/2PCS-5V-Micro-USB-1A-18650-Lithium-Battery-Charging-Board-Charger-Module/400665522246?_trksid=p2047675.c100005.m1851&_trkparms=aid%3D222007%26algo%3DSIC.MBE%26ao%3D1%26asc%3D33874%26meid%3D48b4bc0d20084eac9a3a72bbd98b54a8%26pid%3D100005%26rk%3D1%26rkt%3D6%26sd%3D400665524431

I'm still kind of confused. Can you link a 18650 cell? Also does the battery holder I have now work?

[W-L]

I'm still kind of confused. Can you link a 18650 cell? Also does the battery holder I have now work?

 

I did just on the previous post but here, and no the battery holder will not work it's larger than an AA:

https://www.sparkfun.com/products/12895

https://www.sparkfun.com/products/12899

[aeroencychris]

I did just on the previous post but here, and no the battery holder will not work it's larger than an AA:

https://www.sparkfun.com/products/12895

https://www.sparkfun.com/products/12899

Sorry, didn't notice and was just clarifying on the holder. Would these work (since they're so much cheaper)

http://www.ebay.com/itm/18650-3200mAh-3-7V-Rechargeable-Li-ion-Battery-for-LED-Flashlight-CC-/161845361199?hash=item25aebc3a2f:g:Z9AAAOSwdvpWDj48

http://www.ebay.com/itm/Battery-Holder-Case-With-Wire-Lead-For-18650-Li-ion-Blk-/361312942420?hash=item541fedf954:g:pIgAAOSwBahVcJys

 

Also again, thanks so much for the help.

[W-L]

Sorry, didn't notice and was just clarifying on the holder. Would these work (since they're so much cheaper)

http://www.ebay.com/itm/18650-3200mAh-3-7V-Rechargeable-Li-ion-Battery-for-LED-Flashlight-CC-/161845361199?hash=item25aebc3a2f:g:Z9AAAOSwdvpWDj48

http://www.ebay.com/itm/Battery-Holder-Case-With-Wire-Lead-For-18650-Li-ion-Blk-/361312942420?hash=item541fedf954:g:pIgAAOSwBahVcJys

 

Also again, thanks so much for the help.

 

Yes they will work, as said be a bit weary on those cheapy 18650 cells since they are usually half of their rated capacity.

[aeroencychris]

Yes they will work, as said be a bit weary on those cheapy 18650 cells since they are usually half of their rated capacity.

So even with the 18650 cell I'd need that board as a charge controller? The microUSB connectors I bought won't work?