Wireless Charger Puck (QI Charger)

thingiverse

I travel extensively for work, recently acquiring a smartphone with wireless charging capabilities. At home, I have a device mounted in my desk, but while traveling, I need to resort to physical connections. I discovered several QI charger modules on eBay at an affordable price and purchased one. To create a protective case, I designed it with no requirement for fixings; the internal components are secured by melting the plastic stand-offs over them, and the two halves are bonded together with glue. I've included an image of the charger's PCB/circuit used in this project. **Update 07/07/2019** My phone slipped from my hands, resulting in unexpected impact testing. During this incident, I identified a potential area for improvement. The coil was secured by a small central support that broke when it hit the floor, causing the coil to rattle and become misaligned. To address this issue, I increased the size of the central hub and added a ring around the core of the coil. This will prevent movement while also providing an additional point for securing the coil with melted plastic. An unexpected benefit is that I can now share photos of the construction process on this platform as well. I'll update the post when the new design is printed. **Update 2 07/07/2019** New files have been uploaded to the project. The upper half of the puck has had the central support removed, which was originally too large and caused damage to the plate holding the coil. After cutting it off, I discovered that it wasn't essential for securing the unit. I've also added photos to demonstrate how the different components come together. This should provide a clearer understanding of the assembly process. **Update 3 14/07/2019** I have redesigned the previous version with a lower resolution than the original, resulting in smaller file sizes without compromising print quality. The outer edges are now composed of "only" 192 segments, as opposed to my initial mistake of using 960 (which should have been 96 segments). This change allows for more efficient use of resources. Additionally, I've incorporated 6mm cutouts on the base plate for adhesive feet and a single cutout on top to prevent the phone from sliding. However, this feature requires further testing and refinement to ensure effective results. A platter has also been designed to slide over the top half, providing a more stable base for the phone. It can be easily slid down and secured flush with the top half of the case. The updated files will now bear the "LR" designation, indicating that they are the preferred versions moving forward.