510 Batteries

[Tarzan]

Hi.

I don't want to ruin any of my working batteries to find out, but has anyone done a circuit diagram for a 510 battery, or any similar battery (I guess they're all more or less the same). Closeup pictures of a disassembled battery might also do, if anyone has a worn-out one lying about. Also, any experience with actually disassembling the battery would be handy before I start experimenting on my own.

I've ordered a portable battery pack with USB interface that I'll try to turn into a high-capacity PCC (3.5 Ah), and in that respect I'd like to be able to just slide the e-cig into the case and leave it charging whenever I'm not using it, without having to unscrew the battery. Eventually I'll want another charger on my desk that the cigarette can just rest and recharge in when I'm not using it. This would extend the useful life of the battery by many months (by making reduced capacity less of an issue) and also just be damned convenient.

So anyway, that requires a connector for the charger either on the tip of the battery or somewhere along the sides. Information would be useful.

 

[Tarzan]

Oh, and the battery pack I'm talking about is this one, although there's a number of other options. It's USB in, USB out, and the circuitry for the normal 510 USB charger would connect to the e-cig.

 

[invidregis]

I have gutted a few. I will try to explain what is inside. I will start at the circuit board that is smaller than a dime in diameter. There are 7 wires coming off the board. 2 wires go to the brass atomizer connector, 2 wires to the switch, 2 wires to the battery, and 1 to the LED. The other led wire connects directly to the negative pole of the battery. I will try to take some pics as I am gutting another this weekend, problem is my camera has a crappy macro setting. If you have any questions, fire away.

PS that pack looks good, 1000mah out put current.

 

[Tarzan]

Yeah, the battery pack looks perfect for the job. It should arrive tomorrow. Yay.

What would be the best way to get into the battery? I'm looking to do the minimum amount of damage, mind you.

 

[invidregis]

Sometimes those brass ends can be a pain, so this is what I do...

First I use a mini tube cutter like this:

I line up the cutting wheel where the brass bit meets the tube and tighten. The wheel shouldn't be cutting, just wedging itself between the brass and the tube. This should loosen the glue. After it separates a bit, remove the plastic that covers the led end, and push the whole lot out.

 

[Tarzan]

Ahh.. right. The brass connector was so firmly attached I assumed it was welded or glued. But it came off with enough force, and the whole battery assembly came out easily. I only broke one of the wires to the pressure switch, but I can fix that.

And the good news is there seems to be enough room for an extra pair of wires to run past the battery cell, and I suspect adding a diode could prevent the charge current from powering the atomiser.