USBC-PD (Power Delivery) 100W Power Bank (Airline Safe)
Description
PDFThis 144Wh 100w USB-PD power bank is the the little brother to my 288Wh version. My main motivation was to have a large power bank that I could travel on airlines with. The TSA regulation is 160Wh max. I ended up with this 144Wh power bank using 8 5000mah 21700 cells in a 4s2p configuration and leveraged a 100w USB-C PD module and 4s BMS for the build. I used PLA because I like the way it looks but PETG may be better for heat/mounting.
Please refer the pictures for assembly. You will need six 30mm m3 screws for the latches and hinges and two m2 screws to mount the pd module. I also used Kapton tape for wrapping the battery pack. Feel free to ask any questions or post suggestions/comments.
I consider this a WIP and will be adding more features. The module gets extremely hot in and out of the case. So far no issues with it though. The BMS seems to stay relatively cool. For more detailed pictures of assembly, please see the 288Wh version.
Enhancements over 288Wh version
- More compact bottom and lid
- Spacer arms added to lid to hold batter in place while closed
- Mount for 100w board is closer to the top allowing for more room
Update 2023-10-9
- Added an .stl for a lid with much more venting to help with overheating under heavy load in hot weather
- Added .stl for seal which should be printed in TPU
- Flew with no issues going through security
Useful Items
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Model origin
The author remixed this model.
Differences of the remix compared to the original
Half the size of the original which can be taken on airplanes!