instructables
How to Make a Mobile PowerBank
by Techgenie
Powerbanks are an essential products for our Energy
consuming gadgets..It is very difficult to maintain the
battery charge throughout the day while using your
phone to even half its potential. So, it is important to
keep a backup supply always.
In this Instructable, i decided to use my old Laptop
battery and make a mobile powerbank from the
salvaged cells. A Laptop battery needs replacement
every few years but all the Li-ion cells inside it are
never damaged. They can be extracted and used for
How to Make a Mobile PowerBank: Page 1
various other purposes.
Note: This PowerBank is only capable of charging
Android devices. To charge an ios device it needs a
special value of voltage (D+ = 2.76v & D- = 2.06v for
1A current draw and d+ = 2.0v & D- = 2.0v for 500mA
current draw) at the data pins that can be easily made
using a voltage divider circuit with few resistors. But
since i needed it for android devices, so didn't worry
much about providing voltage at data pins.
Step 1: Order Parts

Ebay.com

1. TP4056 Charging Module - https://rover.ebay.com/rover/1/711-53200-19255-0/...

2. 3.7v to 5v Boost Converter - https://rover.ebay.com/rover/1/711-53200-19255-0/1...
3. Solder Tabs - https://rover.ebay.com/rover/1/711-53200-19255-0/...
4. Switch - https://rover.ebay.com/rover/1/711-53200-19255-0/...
5. Soldering Iron - https://rover.ebay.com/rover/1/711-53200-19255-0/1...
6. Hot Glue Gun - https://rover.ebay.com/rover/1/711-53200-19255-0/...
7. 3.7v Li-ion Battery - https://rover.ebay.com/rover/1/711-53200-19255-0/...

Amazon.com

1. TP4056 Charging Module - http://amzn.to/2qcIACn

2. 3.7v to 5v Boost Converter - http://amzn.to/2BxwZDM
3. Solder Tabs - http://amzn.to/2zFEqvb
4. Switch - http://amzn.to/2xUtkjS
5. Soldering Iron - http://amzn.to/2r3IX6g
6. Hot Glue Gun - https://amzn.to/2Sf7oad
7. 3.7v Li-ion Battery - http://amzn.to/2npKA8m

Amazon.in

1. 3.7v Li-ion Battery - http://amzn.to/2mMlK5z

2. TP4056 Charging Module - https://amzn.to/2C6Jh8D
3. 3.7v to 5v Boost Converter - http://amzn.to/2zAcKUL
4. Solder Tabs - http://amzn.to/2BmWV48
5. Switch - http://amzn.to/2wu3K1P
6. Soldering Iron - http://amzn.to/2qC47qG
7. Hot Glue Gun - http://amzn.to/2rjNE9r

From Home & Local Store: Cardboard, Double Sided Tape and Connecting Wires.

How to Make a Mobile PowerBank: Page 2

Step 2: Watch the Video

A video is a wonderful tool that provides deep insight to the procedure and makes it easy to follow. However, also
visit next steps for additional details and images.

https://www.youtube.com/embed/Ry5gVFIalAs

Step 3: Prepare Li-Ion Batteries

In case you bought new Li-Ion cells, you can skip this step.

If you are also using an old Laptop battery like me, then you can proceed. The laptop batteries are made up of
multiple Li-ion cells connected together in certain combinations. When the battery stops charging or becomes
faulty, it has mostly been seen that only few cells get damaged, whereas all other cells work well. We will use
those cells to make a powerbank at home.

1. Carefully open the laptop battery without damaging the cells inside.
2. Using wire stripper, cut the solder tabs connecting the cells.
3. Separate each cells and clean them with a damp cloth to remove the adhesive.
4. Using a multimeter, check the voltage of each individual cells.
5. Discard the cells with voltage less than 2.5v as they might be damaged and will be difficult to revive.
6. I got four perfectly working batteries out of six.

How to Make a Mobile PowerBank: Page 3

Step 4: Connect the Cells

1. Clean the cell terminals properly and if required, you can also sand them gently using sandpaper.
2. Place all the cells adjacent to eachother.
3. Apply some solder over the terminals. Note: Make sure to be quick and prevent cells from getting
hot.
4. Take solder tabs and apply solder to both the edges.
5. Place the solder tab over the cells and connect it to the cell terminal using soldering iron.
6. Connect all the cells in parallel using the solder Tabs.
7. Each cell is 3.7v 2200 mAh, so now we have a 3.7v 8800 mAh battery bank.
8. Also, connect wires to the battery terminals.

How to Make a Mobile PowerBank: Page 4

Step 5: Make the Enclosure

1. Take a sheet of cardboard.

2. Place the battery over the cardboard and mark the dimensions.
3. Using the dimensions, make a box to fit the batteries and the electronic circuit.
4. The design can very with your choice of placement of the components.
5. Be creative and make your own design.
6. Mark the space for the components, so they can be placed easily.
7. Using knife, cut the slots for switch, USB port and Micro USB Port carefully.

Note: Make sure to refer to the images attached above or watch the video.

Step 6: Connect the Components

1. Using Double sided tape, attach the batteries to the Enclosure Base.
2. Place the TP4056 charging Module at the designed space and secure it with Double sided tape.
3. Similarly, place the 5v boost converter in the designed space and secure it with double sided tape.
4. Secure the switch in the slot using Hot Glue.
5. Refer to the circuit schematic above and connect the components using Soldering iron.
6. Before testing the powerbank, it is important to check the output voltage in order to protect your
mobile phone from any damage.
7. Using multimeter, test the output voltage of boost converter and regulate it to 5v using potentiometer
knob.
8. Plug in a USB cable and test the powerbank.
9. Cut a piece of cardboard piece to cover the box.
10. Make a slit at the top for the indicator light on the charging module as shown in the image above.
11. Using Hot glue, seal the box completely.

How to Make a Mobile PowerBank: Page 5

How to Make a Mobile PowerBank: Page 6
Step 7: Test Mobile Powerbank

Our Homemade Mobile Powerbank is now ready.
Plug in a USB device and see it charging quickly with
this 8800 mAh powerbank.
So friends, this here concludes the instructable, stay
tuned and Follow to receive regular updates. In case
you might have missed, watch the video and see how
i made this mobile Powerbank at home.
Youtube Channel GOODTECH - Creativity And Scien
ce, where i frequently post new and creative content.
I also made a emergency hand operated mobile
charger that uses DC motor as generator. Have a
look at the instructable here or watch the video below.
https://www.youtube.com/embed/qobAAPmfHug

Make this amazing gadget yourself and contact us or

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Minutes....are your each cell are PROTECTED....IF NOT, I NEVER DO THAT ....because the cell
will not be charge equal...not balance....the MODULE IS FOR SINGLE CELL CHARGER, READ
the Datasheet ....im NOT a Pro but i dont want burn down my house...dont play with Li-Po if your
not sure
Hi
can i use this without switch?
Regards
Which Switch..??

How did you contol the current (every phone needs different like 1amp or 2.1 amp)

No, you don't need to control the current. The powerbank should be capable to supply enough
current and the device only draws the current it needs.
I connected four 2000mAh Li-ion batteries in parallel making a current capacity of 8000mAh or
8Ah.
Is that work for sure??

Yes, why not..??

The design you showed seems good but the batteries cannot be charged with a 5v mobile adapter
because the two batteries connected in series have resultant of 7.4v 4000mah current(two such
piar makes it 7.4v, 8000mAh), for this you atleast need a 9v 2A power adapter to efficiently charge
all the 4 batteries in around 5 hrs. Also, there is no over-discharge protection.

How to Make a Mobile PowerBank: Page 7