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In this, my first ever, Instructable, I will show you how to make a USB charger powered by 4 AA batteries. This is similar to the USB Solar Charger Instructables, except it runs off batteries. It costs about 25 dollars for the parts and that is a lot less than brand name chargers. Please don't over criticize my Instructable, as it is my first one.
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Signing UpStep 1Purchasing and Collecting Parts
For this Instructable, I used the following materials, all purchased at RadioShack.
1. ABS Plastic Project Enclosure (6x4x2 inches) ($4.99)
2. Red and Black 18 Gauge hookup wire ($6.99) Product # 278-1226
3. 4 AA Battery holder with snap connectors ($1.79) Product # 270-383
4. 9 Volt heavy duty snap connectors ($2.69) Product # 270-324
5. DPDT Toggle Switch ($2.99) Product # 275-666
6. 5 Volt Regulator ($1.59) Product # 276-1770
7. TO-220/TO-202 Aluminum Heat Sink ($1.99) Product # 276-1368
8. Green LED Power Indicator ($1.99) Product # 276-271
9. A screw to hold the 5 Volt Regulator to the Heatsink (can be found anywhere, just find one that fits.)
10. A cable with a connector compatible with your device.
Tools Needed:
1. Phillips screwdriver
2. Drill and bits to drill switch and LED holes, and wire hole
3. Soldering iron and solder
4. Wire cutter and stripper
5. Pliers
6. Digital Multimeter
Lets get building!
1. ABS Plastic Project Enclosure (6x4x2 inches) ($4.99)
2. Red and Black 18 Gauge hookup wire ($6.99) Product # 278-1226
3. 4 AA Battery holder with snap connectors ($1.79) Product # 270-383
4. 9 Volt heavy duty snap connectors ($2.69) Product # 270-324
5. DPDT Toggle Switch ($2.99) Product # 275-666
6. 5 Volt Regulator ($1.59) Product # 276-1770
7. TO-220/TO-202 Aluminum Heat Sink ($1.99) Product # 276-1368
8. Green LED Power Indicator ($1.99) Product # 276-271
9. A screw to hold the 5 Volt Regulator to the Heatsink (can be found anywhere, just find one that fits.)
10. A cable with a connector compatible with your device.
Tools Needed:
1. Phillips screwdriver
2. Drill and bits to drill switch and LED holes, and wire hole
3. Soldering iron and solder
4. Wire cutter and stripper
5. Pliers
6. Digital Multimeter
Lets get building!
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May 27, 2011. 9:45 AMtaoybb-TH
says:
WOAH!! There's a lot of loss!
Reply
Apr 16, 2011. 11:58 PMbadboy4a2
says:
Thats so cool.But what will be the amp rating if we use the AA batteries?i want to connect my phone directly to it.So when there is excess current,it may damage the phone.Can you tell how to control it?
Reply
Jun 6, 2010. 2:18 PMTubehacker01
says:
You dida pretty nice job soldering!! :D
Reply
1
Jul 18, 2009. 2:14 PMle-Sid
says:
Really nice one... I did one myself looking like yours, except that I use a single 9v battery or a cigarette lighter adaptor for car. It becomes kind of hot thought... Used a female usb connection for output. I can charge many things from there _
Reply
1
Jul 18, 2009. 6:57 PMjbyrns1993 (author)
says:
Here is why it gets hot: The voltage regulator will get hot if you choose to put 7-12 VDC, because there is a lot more amperage than using 4 AA or C batteries. You can get a lot more charge out of D and C cell batteries, as opposed to the 9 volt. 9 volt batteries are not the best power supply for this, but they are workable. The car charging situation is edgy, because car power supplies are REALLY high amperage. This causes heat as the excess voltage is turned into heat energy. You did add a heat sink in yours, right?
Reply
1
Jul 19, 2009. 9:57 AMle-Sid
says:
kind of... the backplate of the enclosure is metallic. I screwed the regulator plate-to-plate with thermal paste. Didn't really take measurement of the temperature, but I think it'll get about 30-40 degrees when charging my cellphone. Other devices seems to make the regulator colder. On other hand, you're right about the 9v batteries, it works but I don't get much charge time... should modify it someday
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