Self-Glowing Ring Is Its Own Battery

April 4, 2020 by 19 Comments

LED jewelry has always been a popular part of the maker community. Oftentimes, coin cells are used as a compact source of power, or wires are run to discreet hidden battery packs. [OguzC3] went another route, however, creating a glowing ring which works as its own battery.

The design will be familiar to those who have done high-school experiments on basic batteries. An aluminium pipe forms the inner surface of the ring, which is then wrapped in a layer of newspaper. A copper outer ring is then placed outside. When soaked in a salt water solution, this forms a basic battery. The voltage output is only around 0.5 volts, so a joule thief circuit is built into the ring to step this up high enough to drive an LED. [OguzC3] reports that the ring lasts several hours at a time, and only needs a quick rinse in fresh salty water to recharge.

It’s a creative concept, and the final piece looks like a magical object from the world of fantasy. It would make a great addition to any cosplay, and we’re sure the technique could be adapted to other accoutrements, too. A similar experiment done in a more extreme way is this electric car charged via lemons. If you’ve got your own battery chemistry project cooking up at home, be sure to let us know!

Ammo Can Battery; 50 Ah LiFePO4 Clad In Army Green

March 30, 2020 by 23 Comments

For the price of a mid-range Android phone, [Kenneth Finnegan] turned a 50 caliber ammo can into a 50 amp-hour portable power supply. The battery pack uses four 3.5 V LiFePO4 cells wired in series to achieve a nominal 12 V supply that stands in for a traditional lead-acid battery. The angel of second-hand purchases was smiling on this project as the cells were acquired on eBay in unused condition, complete with bus bars and mounting spacers. All it took to fit them in the case was to grind off the spacers’ dovetails on the outer edges.

There are many benefits to Lithium Iron Phosphate chemistry over traditional lead acid and [Kenneth] spells that out in his discussion of the battery management system at work here. While the newer technology has a much better discharge curve than lead-acid, there’s a frightening amount of power density there if these batteries were to have a catastrophic failure. That’s why there are Battery Management Systems and the one in use here is capable of monitoring all four cells individually which explains the small-gauge wires in the image above. It can balance all of the cells to make sure one doesn’t get more juice than the others, and can disconnect the system if trouble is a-brewin’. Continue reading “Ammo Can Battery; 50 Ah LiFePO4 Clad In Army Green” →

What’s In A Name For A Tool Battery Pack?

March 26, 2020 by 17 Comments

Power tools have come a long way. It used to be you needed extension cords or a generator for your tools, but now you can get just about anything with a nice rechargeable battery pack. As it turns out, most of those packs are made by the same company, and [syonyk] wanted to see how similar two different Makita packs and a Rayovac pack were. What he found was surprising. The outsides were very similar, but what was on the inside?

The Rayovac pack was easy to open and had a controller, a thermal cutoff device, and two layers of 18650 batteries. The similar Makita pack looked identical from the outside until he tried to take it apart. The maker had plugged one screw hole and used security screws instead of the Phillips heads like on the Rayovac.

Continue reading “What’s In A Name For A Tool Battery Pack?” →

New Part Day: Battery-Less NFC E-Paper Display

March 22, 2020 by 30 Comments

Waveshare, known for e-ink components aimed at hobbyists among other cool parts, has recently released a very interesting addition to their product line. This is an enclosed e-ink display which gets updated over a wireless NFC connection. By that description, nothing head-turning, but the kicker is that there is no battery inside the device at all, as it harvests the energy needed from the wireless communication itself.

Just like wireless induction charging in certain smartphones, the communication waves involved in NFC can generate a small current when passing through a coil, located on this device’s PCB. Since microcontrollers and e-ink displays consume a very small amount of current compared to other components such as a backlit LCD or OLED display, this harvested passive energy is enough to allow the display to update. And because e-paper requires no power at all to retain its image, once the connection is ended, no further battery backup is needed.

The innovation here doesn’t come from Waveshare however, as in 2013 Intel had already demoed a very similar device to promising results. There’s some more details about the project, but it never left the proof of concept stage despite being awarded two best paper awards. We wonder why it hadn’t been made into a commercial product for 5 years, but we’re glad it’s finally here for us to tinker with it.

E-paper is notorious for having very low refresh rates when compared to more conventional screens, much more so when driven in this method, but there are ways to speed them up a bit. Nevertheless, even when used as designed, they’re perfectly suited for being used in clocks which are easy on the eyes without a glaring backlight.

[Thanks Steveww for the tip!]

Solar Panel Keeps Car Battery Topped Off Through OBD-II Port

March 10, 2020 by 47 Comments

Up until the 1980s or so, a mechanic could check for shorts in a car’s electrical system by looking for sparks while removing the battery terminal with everything turned off in the car. That stopped being possible when cars started getting always-on devices, and as [Kerry Wong] learned, these phantom loads can leave one stranded with a dead battery at the airport after returning from a long trip.

[Kerry]’s solution is simple: a solar trickle charger. Such devices are readily available commercially, of course, and generally consist of a small photovoltaic array that sits on the dashboard and a plug for the lighter socket. But as [Kerry] points out in the video below, most newer model cars no longer have lighter sockets that are wired to work without the ignition being on. So he chose to connect his solar panel directly to the OBD-II port, the spec for which calls for an always-on, fused circuit connected directly to the positive terminal of the vehicle battery. He had to hack together an adapter for the panel’s lighter plug, the insides of which are more than a little scary, and for good measure, he added a Schottky diode to prevent battery discharge through the panel. Even the weak winter sun provides 150 mA or so of trickle charge, and [Kerry] can rest assured his ride will be ready at the end of his trip.

We used to seeing [Kerry] tear down test gear and analyze unusual devices, along with the odd post mortem on nearly catastrophic failures. We’re glad nothing burst into flames with this one.

Continue reading “Solar Panel Keeps Car Battery Topped Off Through OBD-II Port” →

A Battery Sipping Cellular Mailbox Notifier

January 22, 2020 by 16 Comments

Like many of us, [Zak Kemble] has an indeterminate number of tiny packages coming his way from all over the globe at any given time. Unfortunately, the somewhat unpredictable nature of the postal service where he lives meant he found himself making a lot of wasted trips out to the mailbox to see if any overseas treasures had arrived for him. To solve the problem, he decided to build an Internet-connected mailbox notification system that could work within some fairly specific parameters.

For one thing, the mailbox is too distant to connect directly to it over WiFi. [Zak] mentions that 433 MHz might have been an option, but he decided to skip that entirely and just connect it to the cellular network with an A9G GPRS/GSM module from A.I. Thinker. This device actually has its own SDK that allows you to create a custom firmware for it, but unfortunately the high energy consumption of the radio meant it would chew through batteries too quickly unless it had a little extra help.

Not wanting to have to change the batteries every couple months, [Zak] added a ATtiny402 to handle the notifier’s power management needs. By using a P-MOSFET to completely cut power to the A9G, the notifier can save an incredible amount of energy by only activating the cellular connection once it actually needs to send a notification; which in this case takes the form of an HTTP request that eventually works its way to a Telegram group chat.

To cut a long story short, testing seems to indicate that the notifier can fire off approximately 800 requests before needing its 10440 lithium battery recharged. Given how often [Zak] usually receives mail, he says that should last him around five years.

The A9G module, the ATtiny402, a BME280 environmental sensor (because, why not?), the battery, and all the ancillary support hardware are on a very professional looking PCB. That goes into a relatively rugged enclosure that’s designed to keep the electronics from shorting out on the mailbox’s metal case as well as keeping any particularly weighty parcels from crushing it.

If you’ve got the freedom so mount whatever you want outside, then you can certainly build a more technically impressive mailbox. But considering the limitations [Zak] had to work around, we think he did an excellent job.

A Safer, Self-Healing Polymer Battery

January 15, 2020 by 4 Comments

Lithium-ion batteries are notorious for spontaneously combusting, with seemingly so many ways that it can be triggered. While they are a compact and relatively affordable rechargeable battery for hobbyists, damage to the batteries can be dangerous and lead to fires.

Several engineers from the University of Illinois have developed a solid polymer-based electrolyte that is able to self-heal after damage, preventing explosions.The material can also be recycled without the use of high temperatures or harsh chemical catalysts. The results of the study were published in the Journal of the American Chemical Society.

As the batteries go through cycles of charge and discharge, they develop branch-like structures known as dendrites. These dendrites, composed of solid lithium, can cause electrical shorts and hotspots, growing large enough to puncture internal parts of the battery and causing explosive chemical reactions between the electrodes and electrolyte liquids. While engineers have been looking to replace liquid electrolytes in lithium-ion batteries with solid materials, many have been brittle and not highly conductive.

The high temperatures inside a battery melt most solid ion-conducting polymers, making them a less attractive option for non-liquid electrolytes. Further studies producing solid electrolytes from networks of cross-linked polymer strands delays the growth of dendrites but produces structures that are too complex to be recovered after damage. In response, the researchers at University of Illinois developed a similar network polymer electrolyte where the cross-link point undergoes exchange reactions and swaps out polymer strands. The polymers stiffen upon heating, minimizing the dendrite problem and more easily breaking down and resolidifying the electrolyte after damage.

Unlike conventional polymer electrolytes, the new polymer also shows properties of conductivity and stiffness increasing with heating. The material dissolves in water at room temperature, making it both energy-efficient and environmentally friendly as well.