Laptop Emergency Charger, one square inch

100W Synchronous Boost Converter to emulate a laptop charger from a 3S/4S Battery Pack for #SmarterPowerPack in a square inch form factor

Kumar, Abhishek

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Description
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Description

Disclosure: Since I'm a part of the organizing team of #Square Inch Project, this is a reference entry.

Originally supposed to be a part of my #Smarter Power Pack project, I'm spinning this off as a separate project as an integration challenge and a module which you can (re)use.

"Square Inch board on a square foot heatsink" - courtesy Hackaday.IO member and fellow SquareInch judge @SUF

Will this thing power my laptop or will we see magic smoke before I strap a square foot heatsink on this thing? Stay tuned for more updates!

Details

This is a 20V, 5A i.e. 100W boost converter that functions from 9V up to 19V input voltages. So you can use it as a pass-through for your existing adapter diode-ORed with a 12V SLA Battery or with my #Smart Battery, Smarter Power Pack (recommended and optimized for it :) ).

What's in it? A TPS43061 synchronous boost controller, a dual power MOSFET block, a Bourns SRP1270 inductor and if I can squeeze in, an INA219 current shunt monitor.

The schematic is based off TI's WEBENCH design tool which picks the components needed to make the complete design. I made a few equivalent part swaps based on what was available (and within my limited budget) but that's pretty much it.

Schematics and board layout will be up shortly.

Disclaimer: Specs are subject to change at any moment without prior notice.

Components

1 × TPS43061 Evaluation, Demonstration Kits, Boards and Modules / Evaluation Kits, Boards and Modules
1 × CSD86330Q3D Power Management ICs / MOSFET, Bridge Drivers and Controllers
1 × SRP1270 Inductors, Chokes, Coils and Magnetics / Fixed Inductors, Chokes and Coils
1 × INA219B Power Management ICs / Power Supply Support
3 × 10mOhm shunt resistors

Project Logs

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Schematics Done.
Kumar, Abhishek • 10/12/2015 at 19:44 • 0 comments

Inserted an optional INA219B for monitoring load current. And a 10A Schottky for bypassing the boost converter so that this thing can be a straight pass-through your existing laptop charging cable.
You can see where this is going, no points for guessing that there'd be another board on top of this to emulate the third charging pin like this . Also I could display the current state? How about a 0.96" OLED?
Now BOM-complete.
Kumar, Abhishek • 10/12/2015 at 16:54 • 0 comments
With the parts that arrived this weekend, I now have a complete set of BOM parts for building 3 units. Here are a select few from the collection:
The three inductors with a 10A current rating (SRP1270-6R8M) are much heavier than regular components.
Schematic design in progress.