This is a simple phone charger that is using an 7805 voltage regulator.

Materials/parts/tools:

7805 voltage regulator

small aluminum plate (38x27mm)

thermal Paste

USB female socket

terminal block (for power connection)

screw

2x 10uF capacitors (SMD)

180 ohms resistor (SMD)

red LED (SMD)

9V connector

JB weld

Varnish (coating the PCB)

For PCB building:

I used toner transfer method(laser printer, glossy paper and ironing)

PCB

sandpaper

pliers

screwdriver

soldering station

tweezers

solder

SMD Flux

IMPORTANT!

Use Design Spark PCB (free: http://www.rs-online.com/designspark/electronics/eng/page/designspark-pcb-home-page) to open the .pcb and print with the Top Copper, Bottom Copper, Board Outline and all colors black selections made!

Phone.pcb
Download

Step 1: Building the PCB

When building the PCB make sure that your aluminum plate will fit.

Cut the PCB (39x44mm)

Use toner transfer method to make the PCB, after etching use fine sand paper (or acetone) to remove the toner

and clean with alcohol.

Drill holes in the PCB.

Drill a hole in the aluminum plate to mount the 7805, use thermal paste.

Solder the components, begin with the SMD components (use SMD Flux) then solder the USB connector, terminal block and finaly the 7805. Screw the 7805 to the PCB.

Connect the 9V connector to the terminal (red to + black to -), the 9V battery can be changed with a 12V or an 12V car plug for in car use.

Use JB weld under USB connector so it doesn't move.

For protection (anti corrosion) use the transparent varnish, spray the PCB 2-3 times from 30cm distance.

Step 2: Testing

Connect your battery or accumulator (9V-12V).

The red LED should light up.

Measurements:

You should get around 5V output and 660mA (0.66A)(depending on the phone you are charging).

The best result are from any 7.4-12V, but 2-5(or higher) amperage accumulators such as car(best results if used in car). With my 600mA 9V accumulator i have ~1h of power to the charger.

Make sure that the amperage doesn't exceed 1A.

The aluminum plate may get warm or hot, this is normal since 7805 is dissipating heat.

Have a nice day.Thank you!