DIY BluRay - 1xAA boost

[chimo]

I purchased a PS3 module with the intent of putting the BluRay Laser Diode from it into something smaller than my last project. http://www.laserpointerforums.com/forums/YaBB.pl?num=1194303946 Ideally, I was looking for a 1xAAA sized package using a boost converter. I could tweak the 1xAAA drivers to get it to lase but it wasn't bright enough for me. It didn't help that the Vf of the BLuRay LD was over 5V @ 20mA!

I got a cell charger from a local surplus store. You can Google "Charge2Go" for additional info on the charger.


*Tech Notes*
1. I tried a 1xAA boost circuit from a cell phone charger on three red LEDs connected in series. The output current/voltage seemed just about right so I tried it with the BR LD and measured 33mA (that included a sense resistor and longer wires so I expect the assembled unit's output current will be higher - probably in the 40s of mA). The board has 2 SMD red LEDs that blink about once per second when it is on.

2. There are several variants of this charger. Other modles use different boost circuitry and will likely not work the same.

3. My BR LD had a fairly high Vf - a lower Vf LD may have been severly over-driven.

4. The charger had no switch - it was a twisty - not really suitable for a pointer so I had to add a switch (momentary contact). That involved adding a battery contact board to feed a switch. I have cut down the switch length and I will likely glue on a switch guard ring to prevent accidental turn-on.

5. Current draw from the battery is 160 mA (180mA when the red LEDs blink) so the battery should last a while.

Here are some photos.

Host (Charge2Go cell charger - there are different versions of these)


Driver board (top & bottom)


BR in Aixiz module


Switch epoxied in


BR module added


BR soldered on board


Switch wiring


Battery contact board (goes to switch)


Assembled


Size comparison to iPod Video 5G


Size comparison to 9V BLuRay mod and AA battery


Thanks for looking,

Paul

 

[Brlux]

Nice Job! I made a similar setup using a red DVD burner diode and an old Infinity flashlight.

Keep up the good projects.

 

[chimo]

Nice Job! I made a similar setup using a red DVD burner diode and an old Infinity flashlight.

Keep up the good projects.

Thanks, and thanks for posting your link. Great job on that infinity!

 

[liveforphysics]

Great work Chimo!

I made this little 1 AA sized blu-ray laser about a month after the PS3 released last year.

Here is a shot of the adjustable controlled current power supply I built sitting on the head of a quarter.

Rather than boosting, I went for bucking a pair of RCR2 3.7v Li-Ions in series.

Both methods will get the job done, but your method is able to use normal batteries, which is a nice feature.

Great Work!
-Luke

 

[chimo]

Thanks Luke! I was lucky about the properties of the TES103 chip used in the driver. Nice job on yours!

Paul

 

[IgorT]

Hi Chimo!

I was wondering...

Did you measure the max output voltage this thing can create? Or is it exactly 5V?

What is the max current?


Thanks!

 

[chimo]

Hi Chimo!

I was wondering...

Did you measure the max output voltage this thing can create? Or is it exactly 5V?

What is the max current?


Thanks!

Max current is 350mA, HOWEVER, that is for well below 4.2V (the TEC chip is designed for a hybrid power supply (primary cells providing charging to a secondary cell). This usage is well outside the planned purpose of the chip, however, it was laying around and I decided to test it.

You can get the chip info from the manufacturer's web site.

 

[IgorT]

You can get the chip info from the manufacturer's web site.

Thanks, Chimo!

BTW: On the manufacturers web page, i noticed that TEC103 & 104 have an variable charge current..

Oh.. That's not the same as adjustable, right? It says it allows you to turn the phone on, if you need to.

If it was adjustable, you could convert it into a current source.. Now that would be great - a current regulated step up converter.

That would eliminate the need for first boosting up the voltage above what you need, only to then use the LM317 to regulate the current..


Does anyone have any links to current regulated step up converters?

 

[IgorT]

I made this little 1 AA sized blu-ray laser about a month after the PS3 released last year.

Where did you get that host? Was it a flashlight?

It looks very good, i love how small it is and i would like to use it.

 

[knifebright]

chimo pretty cool use!!!
I have a few of those boards i pulled from charge-go's i am using fo led mods but i never thought of this route!!
now i just need a blue diode and houseing to have some more fun!!
jimmy