Personal 5 volt box with digital voltage display and more features.

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vap engineer

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Jun 6, 2010
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Hey fellow modders, I am Vap Engineer and I just wanted to tell you about my newest box. It has several really cool features.

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First, I used two flat cell lithium batteries 2650 mah. This is unique because the capacity is huge and also that they are flat cells. I so far haven’t read of anyone else using flat cells yet. I wanted to make a 5 volt box using them…unfortunately the size was too odd for me to be able to purchase exactly the size box I wanted.. SO I decided to build the box too. I made it out of 0.9” clear polycarbonate Lexan. The final dimensions came out to 2.9 x 2.9 x .95 “ and this perfectly fit the components that I used. By the way it is held together by a special glue specific for acrylic and polycarbonate materials. It actually bonds the plastics together very strongly.
The 510 atomizer is recessed a half inch and sealed out from the components of the box. This is actually a really cool feature. I designed it this way so that when the atomizer is overfilled (which tends to happen a lot to me because I like to drip instead of use cartridges) the e-liquid does not puddle up and drip all over the box and get on my hands and stuff. The liquid is instead captured around the outside of the atomizer and thusly, it ends up getting sucked back up into the atty when it dries out.

It is a 5 volt box and utilizes a switching regulator up to 3 amps and is 95% efficient. The unit has 4 switches total. The main momentary switch is a simple horn switch. The box has a slide master switch. Also built in is a small digital voltage display readout it is wired to show the total voltage and then the voltage of each individual cell. This small voltage display is triggered by a small tactile button; else it would be on all the time and just get obnoxious. The fourth final switch is a sliding toggle switch like the master. It is located inside the box. It completes the negative connection for a total of 3 LED lights. A slow color changing 5 mm LED , a fast color changing 3 mm LED, and a super bright brilliant blue 5 mm LED indicator light. The last LED only comes on with the atomizer; the others are on whenever the box is on.
The light show is one of my favorite features after all, the whole unit is clear. I like to show off this hobby to my friends and people at parties, so a clear box is pretty cool to show off. Then being at parties, I like it to have the flare of a colorful light show. However, this box is too expensive to only use at parties and to show off, so I didn’t want the light show going on all the time, I like to vape discretely such as in the movie theater. So I put the light show on that clever separate switch.

Lastly I should mention, I also have a charging port connector built in as I do all my previous 5 volt boxes, I have a specific two cell lithium charger that hooks up so I never have to open any of my 5 volt boxes to change the batteries. In this case I don’t know how else I would charge these batteries or use this box at all without this feature.

So, I’m out of ideas here. What else should I build into my next box? Advice as to where I can get a good booster regulator? Someday I’d like to build a single cell 5 volt box, or variable voltage, with charging board build in. Thanks for reading, Thanks for advice and support :)
 
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Java_Az

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Looks pretty awesome. Do those li po batteries come protected or did you have to add a protection circuit? I used to use them back when i flew RC planes. Back then they always came unprotected and when stacking it was recommended to run a balancer on them after charging. Also it was recommended to charge them in a fire proof sack they would try to sell you. I just used a empty ammo can. I ruled out using them in mods due to all that. But it has been quite awhile since i have flew so maybe they have changed.
 

vap engineer

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Jun 6, 2010
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I've responded to this twice now! both times a failed internet connection and I have to re-write. Pain...

Unfortunately Java_Az, the batteries did come with a protection circuit board (PCB) but I was unable to use it. The PCB had very small caliper wires coming off of it. I figured this meant the PCB had a low current output. If I had wired it with the PCB's, it probably would register the current draw as a short circuit anyways. I immediately decided to remove the board and then manually wire the batteries in series. I figure this is a safe move because I use an intelligent charger to prevent overcharge, and the box features a voltage display so I can monitor the low voltage drop out (of individual cells too). It was a necessary sacrifice to make it work.

I am proud to announce that the battery charge has lasted me a full week. I decided to charge up when the voltage was total 6.8. So i probably could have gone a couple days longer still. Very proud of the unit.
 

Java_Az

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Aug 29, 2010
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A full week, thats a nice vape time. Sorry to point it out but with out protection it is not really safe, even though your monitoring your voltage you have no over discharge protection. But if it is just you using it not a big deal pretty sure you know the risks.


Edit: Might want to consider adding something like this if your charging at 8.4 volts http://www.all-battery.com/pcbfor72vli-poandli-ion186501850072vbatterypacks7alimit-pcb72v7a.aspx max discharge amps might be a bit high but if you shop around you can find one lower.
 
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