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How I built a Solar iPhone Charger for under $50.

Step 3The Simple Circuit

The Simple Circuit
After gathering all of the materials, I sat down and got to work.

I cut 2 pieces of Black wire and 2 pieces of Red Wire. The lengths were around 5-6 inches. Then, I cut a little bit less than an inch off both ends of each wire.

With my black and red wires ready, I cut my USB extension cable in half and stripped the cut half of the female end to expose all of the individual wires. There are 4 wires in all USB cables- Green, White, Red, and Black. The Green and White wires are for data, so those are not needed. I snipped the Green and White wires, along with all of shielding and fiber - leaving only the Red and Black wires coming out about an inch and a half from the USB cable. I stripped a little bit less than an inch off the Red and Black wires on my USB extension.

Since the 5V regulator only has one Ground pin, I used the two black wires that I cut initially- to make the soldering a little bit easier. I took both of my black wires, along with the black wire coming from my USB extension, and twisted them all together carefully and securely. I put some solder on that connection to make sure that all of the wires stayed together. Then, to keep things safe, I covered the 3-way connection with electrical tape.

Once all of the wiring was prepped, it was time to put the 5V regulator into the equation. Soldering wires onto the tiny pins from the 5V regulator can be a task. I used a small Zip Tie to hold my wires to the 5V regulator to make things much easier. It really helped - I was able to do pretty clean solder jobs on each of the pins. Since neither of the red wires were connected to anything, it didn't matter which ones I soldered to which pins. Just make sure you know that if your 5V regulator is laying flat, the input pin is on the bottom, and the output pin is on the top!. I also bent the pins in opposite directions to keep everything separate.

The fantastic part about this charger is that we're already done with our circuit. Once I was done soldering to my 5V regulator, I connected the Red wire from the Output pin on the regulator - to the Red wire coming from my USB extension cable. Now, I only had 2 wire ends left. A Red wire connecting to the input pin on my 5V regulator, and a Black wire connecting to the regulator's Ground Pin and my USB extension cable.
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3 comments
Sep 1, 2011. 8:17 AMginbot86 says:
Instead of a linear regulator, you could pick up a switched-mode PTH08080W from Texas Instruments. They offer sample parts free of charge, and even shipping is free. These offer over 2 amps of current compared to one of the linear regulators, and is adjustable with a simple potentiometer.

http://www.ti.com/product/pth08080w
May 19, 2011. 7:23 AMsdobbie says:
There is a much quicker way to do this. If you got a usb car charger and connected it to the solar panel you would have a more efficient charger. Car chargers accept voltages from 12 to 24 volts usually.
Sep 23, 2009. 5:51 AMRazorConcepts says:
A better alternative would be a LM2949 or 2954 low dropout regulator, 7805s are very wasteful
Sep 23, 2009. 7:23 PMwestfw says:
won't help too much, since it's not an app needing low dropout. It's not that the 7805 is particularly inefficient, it's that LINEAR REGULATION is going to be inefficient in this case. You could use a switching regulator module like http://www.dimensionengineering.com/DE-SW050.htm, but it would add to the price. Or you might be able to find a ~6V (nominal) solar panel (cheaper) and use that with an LDO...

Like the author said (sorta), the most efficient setup (price-wise) may not be the same as the most efficient setup (electrically.)

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Author:akbrennan(Personal Blog)
My name is Brennan and I'm a Computer Engineering undergraduate at Colorado State University. I'm very tech oriented, but I am a serious outdoors kid. The combination of the two has developed a passi...
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