Intro: DIY - Wireless Charger
In the last decade, Smartphones have become one of the most popular and useful gadgets. This gadget indeed a great invention has now become a necessity for everyone. Since the battery technology has not improved significantly as compared to a smartphone, we need to charge it frequently.
Earlier a wired charger was an only option to charge the phone but since the inception of wireless technology, the wireless chargers are gaining pace at an impressive rate. I also needed a wireless smartphone charger as well.
So, in this Instructable, i decided to make a powerful Wireless Charger for my smartphones. This DIY wireless charger is a good quality 10 watt Fast Charger that can easily charge a 3000mAh battery in around 2 hrs.
Step 1: Watch the Video
A video is a genuinely very wonderful tool that provides deep insight to the procedure and makes it easy to follow. However, it is also recommended to visit next steps for additional details and images.
Step 2: Order Parts
Wireless Charger PCBA - https://rover.ebay.com/rover/1/711-53200-19255-0/1...
Heat Shrink Tubes - https://rover.ebay.com/rover/1/711-53200-19255-0/1...
Soldering Stand - https://rover.ebay.com/rover/1/711-53200-19255-0/1...
Soldering Iron - https://rover.ebay.com/rover/1/711-53200-19255-0/1...
Stationary Knife - https://rover.ebay.com/rover/1/711-53200-19255-0/1...
Wireless Charger PCBA - https://amzn.to/2CzB3bj
Heat Shrink Tubes - https://amzn.to/2CFJi5H
Soldering Stand - https://amzn.to/2N8fKSY
Soldering Iron - https://amzn.to/2N4gw3B
Stationary Knife - https://amzn.to/2Nx1Yca
Wireless Charger PCBA - https://amzn.to/2Qj7Tjy
Heat Shrink Tubes - https://amzn.to/2NxpTIm
Soldering Stand - https://amzn.to/2QkBx83
Soldering Iron - https://amzn.to/2QlZFXF
Stationary Knife - https://amzn.to/2O8GwXY
From Home & Local Store - Cardboard, compass (with pencil), superglue, Lighter(or matchstick), connecting wires and a smartphone with wireless charging capability.
Step 3: Principle of Operation
A wireless Charger basically works on the principle of "Electromagnetic Induction". When the current passes through the coils of wire in the base, it generates "magnetic field".
Similar charging receiver coils are located beneath the back cover of a smartphone. When the mobile phone is placed above the wireless charger, the induced magnetic field produces electric current in the receiver coils which is then transferred to and controlled by the charging circuit in the phone. This charging circuit in the phone provides controlled optimal power to charge the battery properly.
Note: The wireless charging is only about 70% efficient as compared to the direct cable connection charging. But it does provide a lot of comfort and ease of use.
Step 4: Prepare Wireless Charger PCBA
- After the Wireless Charger Printed Circuit Board Assembly is delivered, carefully open the box.
- Make sure not to break any wires while opening the package.
- Inspect the circuit carefully and if everything seems fine, place a cardboard sheet over the charger coils and turn the circuit ON.
- Place the mobile phone over the cardboard and test the charger circuit.
- Only continue if the charger performs well, if not return the product or get an exchange.
- After the product is tested, desolder all the coil connections from the circuit board.
- There is no need to disconnect status LED board with the main PCBA.
- Using connecting wires extend the original charging coil connections. (Make sure to use good quality thick copper wires).
- Properly insulate the joints with heat shrink tubes.
Note: Make sure to note down all the connections because we will need to re - solder the coil connections later.
Step 5: Make Enclosure for Circuit Board
- On a sheet of cardboard, draw a circle of about 6 inch diameter.
- Place the circuit at one of the sides and mark the boundary as shown in the image above.
- Using a stationary knife, cut the cardboard along the marked lines.
- Make sure to make two such pieces.
- Cut a long strip from a flexible cardboard with a width of about 2 cm.
- Using superglue, paste the strip along the boundary of one of the pieces to make a bottom base.
Step 6: Fix Circuit on Base
- Apply some hot glue or double sided tape over the cardboard base.
- Refer to the images above and paste the circuit board over the two sided tape.
- Observe the position of status LED's on the board.
- Mark and cut appropriate slits on the boundary of bottom base.
- Position the status LED's in place and secure the small board with hot glue.
- The circuit board should be well fixed to the bottom base.
Step 7: Re-connect the Coils
- Cut two small strips with width of about 1 cm from the flexible cardboard.
- Paste both the strips opposite to each other on the inner boundary of the base.
- These strips will support the top platform over them.
- Place the coils near the circuit board.
- One by one solder all the wires to the circuit board in the exact sequence as they were removed.
- Double check the connections and make sure the coils are properly connected.
Step 8: Enclose the Coils
- Cut a circle of about 6 inch diameter.
- Cover the circuit board using the cardboard circle as can be seen in the image.
- Apply some hot glue or double sided tape over the cardboard.
- Paste the charging coils over the two sided tape.
- Position the coils such that they are almost at the center of the cardboard.
- Look at the images carefully and cut a cardboard piece such that it can be used to cover the micro USB port.
- Cover the joints with a brown color paper.
- Now, close the enclosure with the top platform and secure it with Super Glue.
Note: Make sure not to use a very thick cardboard as the top platform because the wireless charger might not work if there is too much distance between the charger coils and phone.
Step 9: Designing
- Using any image designing software, make a design for your wireless charger.
- I used Gimp software and referred to google images to make my design.
- You can easily make a new design or you can download my design.
- Take a printout of the design on an A4 size paper.
- Cut the required graphic and using glue, paste the design over the top platform.
- The wireless charger now looks wonderful.
Step 10: Testing
- Let any glue under the pasted design dry properly. Now, once the charger is complete connect a wall adapter to the wireless charger.
- Turn ON the switch and you will notice the status LED's changing colors from red to blue and then ultimately get stable on Red.
- When a mobile phone is placed over the charger, status LED will turn to Blue and the phone will start to charge wirelessly.
Note: many of you might argue that i didn't make a wireless charger rather just made a cardboard enclosure. Yes, you might be right but this is the best way to get a customized good quality wireless smartphone charger without spending much.
So friends, this here concludes the tutorial, stay tuned and SUBSCRIBE to receive regular updates. You can also get in touch through social media, Facebook, Twitter and Instagram. In case you might have missed, watch the video and see how i made my wireless charger.
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Thanks for your Support..!!