A Guide On How to Make A Portable Battery Pack

As we all know we are living in a constantly moving world with advancements that not only provide us entertainment but also make our life easier. Such an invention is mobile devices. They act as windows to entertainment, internet, and social media. Some of them come with impressive battery life but the fact is that they do not offer infinite battery supply. When the battery dies your handheld communication disconnects. Now think how many times you have experienced such a situation? To overcome this problem, we have come with a great idea to help you out. A portable battery box is an on-the-go solution that will provide you with a quick charge.

The battery packs available in the market come in all different sizes and shapes with different functionality and features. The best battery pack is the one that combines high-capacity batteries with low weight and small form factor, making them portable and easy to carry around. USB battery boxes are compatible with nearly all devices just make sure you have the right cable to connect.

Building a portable battery box on your own can be a fun activity. We have come up with a guide and you only have to follow the steps to build one yourself. You can also use this portable power source with raspberry pi or Arduino projects. The battery has a small form factor and you can recharge it using your smartphone charger easily. Let’s start building one.

Components Required

The first thing you have to do to make a portable battery pack is collecting the components required. You would need below-mentioned components

  • Lithium-ion batteries
  • A good charger module but we prefer to buy TP4056
  • A dc-dc booster module

Along with these components, you would need some soldering skills to build a reliable battery pack.

The Battery

The battery should be specifically 18650 Li-ion. You can see them in flashlights, but you will be amazed to know that they can be used as a rechargeable cell. The reason why we suggest this battery is that it is the best option for those who need a simple cell to install and replace with a lot of juice. The battery has 5800mAh capacity at 3.7 volts. It has a standard discharge current of 0.2C – 1C and can handle nearly 1000 charge cycles. To place the battery, you would need a battery holder. You can either make one on your own or can buy from any local hardware store.

If you are interested to make a battery holder on your own, then you would require a PVC pipe cut into half. You can also use any cylindrical pipe or any other stuff which can hold the battery tightly. Use plastic pieces to glue on the ends of the pipe and lastly add 3 nut bolts so that you can make connections easily. And here you are done with your hand-made battery holder. 

The Charger

The TP4056 charger module will work as a charging hub. It is a very small yet effective module with a 1A charge current. It requires a 5-volt power supply, this can either be soldered directly to the board or from a mini USB connector. Let’s have a quick view of its specifications

  • 25 x 19 x 10 mm in size (LxWxH)
  • Linear charging module
  • 1A current
  • 1.5% charge precision
  • 4.5V – 5.5V input voltage
  • Red LED indicates charging and Green LED indicates fully charged
  • Micro USB input interface
  • No inverted polarity
  • -10°C to +85°C working temperature

Things to Remember

  • Ampere meter should only be connected to the 5V input end.
  • For a 1000mAH battery, 400A current is enough, and so on.
  • Ensure the connection is tight enough.
  • Connection wire should not be thick.
  • Do not connect the battery in reverse manner otherwise the circuit will burn.

The Booster

Before using the dc-dc booster, search for tutorials to understand how the booster works. It is like a converter that provides greater output voltage than the input voltage. It belongs to a switched-mode power supply (SMPS) class comprising a minimum of two semiconductors (a transistor and a diode) and at least one energy storage element (inductor or capacitor). Let’s have a quick view of its specifications.

  • 28 x 19 x 8 mm in size (LxWxH)
  • Non-isolated booster
  • 2.5V – 4.9V input voltage
  • V output voltage
  • 1000mA output current
  • Up to 92% efficiency
  • -40°C to +85°C working temperature

The Connections

The connections of the battery pack are quite simple and if you know basic soldering then you can do it easily. The charger has two connections; + and – with capital B written with them and + and – with OUT written with them. The B+ and B- pins should go to the battery’s respective ends whereas OUT+ and OUT- pins should go to the booster’s respective ends. If you are having trouble understanding the connections, let’s have a look at the visual representation of the connections. 

As you can see the connections of the battery pack are very simple and you can do it on your own easily. All you need is basic electronics knowledge so that you can make connections. Once you have completed the connections, your portable battery pack is ready.

If you want to make your battery look nice, you can arrange the components in a box. By doing so, you will make sure that the connection does not loosen.

The Performance

The battery pack requires constant 8-hour charging to get fully charged. After that, you can enjoy charging your smartphone of up to 2200mAh battery. The only problem that might arise is heat dissipation. 

To overcome this problem, you can use the heat sink added to the charger module. In this way, your battery pack can absorb the heat ensuring lasting performance. With cheap components, you have made quite an efficient portable battery pack. Now you can use your mobile phone all day long without the worry of battery. 

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