MintyBuck!

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May 042010
 

IMG 1947

How do you keep an iPhone running for long periods of time when you are off the grid? You can’t change the battery in the phone, so carrying a spare isn’t an option. Devices like LadyAda’s excellent MintyBoost use AA batteries and can keep you going indefinitely, but unfortunately the MintyBoost and several other similar products don’t work with the iPhone 3GS. And anyway what I really wanted was a device that would take power from the high capacity 12V NiMH rechargeable pack that I use to power my portable ham radio gear. I could have re-purposed a charger meant for use with cars, but many of them use linear regulators and are therefore very inefficient, or aren’t compatible with the 3GS; plus they are overpriced. So instead I built a charger to suit my needs: the MintyBuck.


In the tin

The circuit is a simple step-down DC to DC converter, based on the National Semiconductor LM2674-5.0 switching regulator. The PCB is one of the little square perfboards from RadioShack. The USB connector was cut from a USB extension cable. The red and black power inputs are 30 amp Anderson PowerPole connectors. These are neat genderless connectors widely used in the ham radio community. The case is a random mint tin I had lying around. There’s not much to it, really, but it’s still quite handy.

I haven’t measured the output current, but it draws about 200ma when charging, and holds a steady 5v on the output. Supposedly the iPhone draws 500ma when charging, which would put the efficiency at around 95%. I bet it’s actually less efficient than that, but I’m sure it is still much better than an LM7805 would have been.

Schematic

If you want to make one yourself, you can follow this schematic. If you make a cigarette lighter plug adapter, you can use it in your car too. Note that the input capacitor I used for C1 is technically only rated for 10V, which is not enough for this application. I’m going to swap it out for a higher-rated part at some point. So don’t follow my example on that part. A few more photos are available on my Flickr page.

73, Dave, W2VV

  • http://dc401.org ducksauz

    Careful taking that battery pack on a plane. Some TSA goon might think it's dynamite!

  • jeff

    How do you recharge the 12v battery pack ?

    • daveclausen

      The pack and the charger came from batteryspace.com. I added a thermistor to the pack to help the charger detect when the pack is fully charged.

  • Charles

    Hey Dave
    I have a planned 8 day raft trip and wanted to recharge my 3GS. I decided on a 12 V sealed lead acid battery. I will take a 4AH and a 7 AH battery with me and use a car adapter. I am doing testing now, but it looks good. I dont plan to use the phone but I will be able to take video, stills, and listen to music.

    • daveclausen

      Sounds like fun. Be sure to try to find a charger that uses a switching regulator. Many of the cheaper ones use linear regulators, which waste most of your battery's power in heat.

  • http://twitter.com/v0dnik Vodnik

    So what did Apple change on their newer devices to make them more quirky?

    • daveclausen

      The new devices are more particular about the voltages that appear on the D+ and D- lines. It's not hard to generate those voltages (just four resistors), but most older chargers don't do it, because when they were made, it wasn't necessary.

  • Nate

    How did you choose the inductor? I don't have any laying around and not overly familiar with them. The datasheet says to use 68uH, but yours looks like 56uH. Is that just “in the ball park” component?

    • Nate

      Actually I just found my own answer, but please feel free to add to it. There is a graph on the datasheet that is Input Voltage versus Output/Load Current. That indicates the inductor to use.

  • http://9w2pju.blogspot.com 9w2pju

    wow. nice work

  • k. sirisha

    it's a very good project i want some more details about this can u please mail to me?

  • Anthony

    Hi I am Making on of these for a school project but I can not find the Inverter that you used but I can get one that is a 47 uF. Do you think that this would be ok?