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In this Instrucatble I'm going to show you How to build a virtual USB charger using Sugru. This projects is ment to build a constant 5V voltage source at 1A to charge your smart phone. This uses two Li-Ion batteries to give a long charge for your mobile phone just like a power bank, making this virtual USB is cheaper than buying a power bank.

Sugru is the star of the project making just a piece of electronic board, strong and portable and easy to just pop it in your pocket to travel on the go. This is a simple Instrucatble and can be built by a person with some knowledge about soldering. So enjoy making the Instrucatble and don't forget to share it by clicking the "I made it" button on the top of the screen.

Step 1: Tools and Components

Lets start with collecting all the components just like always, the components are easy to find and if you can't leave a comment of what you can't, there is always an alternative and I will let you know.

Components

  • Sugru
  • LM7805 IC
  • USB Input Pin
  • 2x 0.33uf Capacitor

Tools

  • Soldering iron
  • A ruler
  • Pliers

Step 2: USB Port

Well once you have collected all of the parts, Lets Start Building. Lets start with with cutting the board to the required size, in may case I cut it to a width of approximately the USB size. The USB connector goes at the extreme end of the board and use a drill to get the USB pins to fit into the PCB. once in solder it and lets move to the next step.

Step 3: Soldering the Circuit

If you have approached this step then I asume that you know how to solder if "No". There are plenty of videos on "How To Solder". Follow the circuit and make sure you have the pins in right, a lot of people usually make this mistake. The Circuit features L805 IC which is a 5V voltage regulator and it uses two capacitors to stabilize the circuit. The led is optional i used it just to show the circuit is ON if you don't want an led consuming power you can skip adding it.

Step 4: Circuit Finishing

Once you have completed soldering the circuit create two terminals to connect to the battery to power the board. Cut down the excess of the board remaining and test the circuit by adding two Li-ion battery in series. Each of the Li-ion battery is 3.7V and we give a input of 7.4V to the circuit the circuit regulates the voltage to give an output of 5V at the USB connector.

Step 5: Sugru Time

Once completed the circuit cover the circuit with insulating tape, so that the surface remains even and Sugru and mold it to a box like shape using some molding tools. I did not have any molding tools so I just used a plastic ruler to mold it into a box. Sugru takes 24 hours to set, as it says on the box and once its done you will have a tough covering for the surface of your charger so that you can use it without thinking about any damage to the PCB.

<p>How the Sugru Master do you charge this thing?</p>
<p>I got two terminals at the back if this which I connect to a solar panel, I forgot to get a picture of that.</p>
<p>How do you re-charge the batteries?</p>
<p>Cool, I love the sugru details, definitely the best way I've seen to keep ones circuitry protected from the elements.</p>
<p>you need a protection circuit with li-ions to stop over discharge and you need a special circuit for charging them </p>

About This Instructable

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Bio: Hey I'm a College school student, I love to work on projects and Arduino powers most of them. Follow me @ https://www.facebook.com ...
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