Flat Plug

Why are car accessory plugs so bulky?
Why are they barrel-shaped?
If you travel for a living and bring gadgets you also need to bring along all the charger and adaptors.
Having a USB car accessory plug adapter/battery charger isn't a necessity but is a life saver in an emergency.
To pare down the bulk of all your gadgets and accessories, wouldn't it be great if the car charger was smaller?
In this Instructable we show you how to make a flat USB charger for the car or airplane.

This Instructable is very easy.
We use just two components.
The venerable LM7805 5V regulator and a USB connector.
The 7805 takes 12 volts and converts it to 5 volts.
5 volts is what's needed for USB power.
The body is made from sheet ABS plastic and has an unusual shape.
The shape was designed to utilize the plastic's elasticity.
This eliminates the need for spring mechanisms as found in most car accessory plugs.
Keeping it simple!

Tools:
Dremel tool
Drill
Hot Glue Gun
File
Sandpaper
Scissor
Centerpunch
Soldering Iron

Parts:
ABS Plastic Sheet 3/32 inch thick
Brass tube 5/32 inch diameter
Brass channel 3/16 x 1/8 inch
LM7085 5V Voltage Regulator - Radio Shack 276-1770
USB Type A Jack Female - Digikey 151-1082-ND
Recycled White Plastic Bottle
Misc Wire
Contact Cement
Clear Self Adhesive Labels
Silicone Sealant
Crazy Glue

Step 1 Make the Body

Print out the template in the attached "TemplateandWiring.pdf."
Cut it out and cement it to the sheet plastic.
Rough cut the template from the larger sheet plastic.
Center punch and drill relief holes.
The body is too small to hold while using a Dremel so mount it to a piece of scrap wood first.
Screw down the cut-out to the wood.
Using a Dremel tool cut the template to shape.
Finish it off with a file then sandpaper.
Remove the paper template.

Note: Some of the photos show "feet" included in the shape.
These feet were supposed to be a grip to pull out the plug.
It was found these feet were not needed in the final design.

Comments

[adamazing]

Of course, the moment he published it on Instructables for all the world to see he gave up his right to patent it. (IMHO, IANAL etc.) Nevertheless, great idea, and implementation, and I love the jet-pack dude :)

[garagemonkeysan]

Thanks for the vote of confidence alll! But I am okay with "open sourcing" it. I support sharing so that others are free to make it themselves. : )
Thanks for the comments! I appreciate them!

[technosasquatch]

hurry and patent this!

[junits15]

as shadow7341 said, this really deserves a patent, its a great idea!

[shawdow7341]

this should be patent