Materials & Part Sourcing
Battery Options
11.1v 5.0 amp hr 3 Cell Lithium Polymer 32$ ea
Weight .88 lbs
Dimensions: 169x48x25mm
11.1v 8.0 amp hr 3 Cell Lithium Polymer $46
Weight: 1.4 lbs
Dimensions: 6.6 x 2.7 x 1 inches
12v 7.0ah Lead Acid $19
(for capacity/weight example)
Weight: 4.96 lbs
Dimensions: 6 x 2.5 x 4 inches
Notes about Li-Po in parallel:
https://sites.google.com/site/tjinguytech/charging-how-tos/parallel-charging
Solar Panels
Powerfilm 5, 10, 20, 30, 60 Watt Folding Panel $89-800
Best option for energy density and ability to produce stated charge rates. Highly portable and can fit within the lid of the case when closed and sealed. The 20 Watt version is $340 and is the version I would like, and the only one I can reasonably afford to buy, eventually.
Sunlinq 5, 25 Watt Folding Panel 225$
Purchased 4/10/12 – Returned (failed to make stated wattage, ran at .6 amps and was rated at 1.5)
Generic 40 Watt Mono-crystalline Outdoor Solar Panel $80
This is the type of panel that I currently use with the system. It was inexpensive and will charge at 2.5 Amps while providing more power than I can use while in full sun. I can leave it outside for extended periods of time and not worry about it.
Charge Controllers
Li-Ion/Polymer Solar Charge Controller 11.1v – 35$ – Purchased 2/8/12
Dimension (LxWxH): 5.5 x 3.6 x 1.2
Charging Lithium Ion or Polymer batteries is not something you can find in your average charge controller. The availability of this $35 unit was critical to building this system. Before I knew these existed I was designing a more complicated lithium polymer charging system that would not have worked nearly as well as this unit does. There is one other version that is over $100 so this 10 Amp option was ideal for the price.
DC – DC Voltage Buck/Boost Converters
Accessory Side – DC Step Up/Down Enclosed Unit – 27$ Purchased 1/3/12
6Amp – variable input, constant output voltage
2.8 x 1.6 x .9 inches
- Input Voltage: DC 8 ~ 30 V ( input Change, Output not Change )
- Output Voltage: DC 2 ~ 16 V ( auto Buck & Boost; Input change, output constant voltage, adjustable )
- Output Current: 0.5~6A ( adjustable, Constant current )
- Maximum Power: 80W Natural cooling
- Efficiency: 94 %
Amp Side – DC Step-Up – 9$ Purchased 1/3/12
10Amp – step up to 24volt for TAMP
65mm x 35mm x 23.5mm
2.5 x 1.4 x 1 inches
- Input voltage :10-32V
- Output voltage: 12-35V (adjustable)
- Output Current: 10A (MAX)
- Input Current: 16A (MAX) (Please enhance heat dissipation if more than 10A)
- Output Power: natural cooling 100W (MAX), enhance heat dissipation 150W (MAX)
- Conversion efficiency: 94%
Amplifiers
Dayton DTA-100A T-Amp 20-50 WPC $100
I wanted high quality audio out of the solar briefcase, so finding the right amplifier was critical. I needed something that was highly efficient in design and also able to power two outdoor speakers to a loud listening volume. I selected the Daton DTA 100A and have never looked back. It is a solid amplifier with excellent sound quality and as efficient as they come, as the T-Amp design is among the most efficient amplifier designs on the market. I powered my bookshelf speakers for a few months prior to installing it into the briefcase, and did not want to give it up!
2.2 x 3.8 x 5.5 inches
Dayton Amplifier Draw (Amps)
- Using 1 Channel w/Old Solar Radio Outdoor speaker with Buck DC/DC Converter set to 24 volts
- Medium Listening Volume: (.3 to .4 amps)
- Maximum Volume: (.5 average through .8 spikes)
4x100W @ 4 Ohm TK2050 Class-T Digital Audio Amplifier Board $49
Other options exist as well in the form of T-Amp circuit boards, this design may be more appealing if you choose to build an even smaller unit and would not want an external case to take up unnecessary space.
Cases
Pelican 1400 $75
Interior: 11.81″ x 8.87″ x 5.18″ Exterior: 13.37″ x 11.62″ x 6″
SeaHorse SE-520 Case $75
Interior: 13.49″ x 9.89″ x 6.0″ Exterior: 14.90″ x 12.13″ x 6.88″
Accessories
Blue Tooth Music Receiver – Play music from your cell phone $39
Connectors & Switches
External ‘Panel’ Connectors
Audio-In XLR
is a standard for industrial audio cables and parts are readily available. I am considering the following solution for keeping the case closed without having to crimp the cable in the seams of the case which is what I have been previously doing with the old briefcase radio. This resulted in cable failure after several years.
Female XLR Panel Connector (4 purchased) $8
http://www.ebay.com/itm/230712436505?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649
Male XLR to ⅛ Microphone Connector Cable (3M) $10
http://www.ebay.com/itm/320832209101?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649
Solar Input & Speaker Out Panel Connectors
You need a way to input power to the case while the case is closed and sealed. The solution I put together uses a pair of Male/Female panel connectors that screw on and secure to the case securely. Each connector has 4 pins which could be useful for multiple solar panels or for a solar/hydro input or to use multiple charging mechanisms. 2 pins could also be ignored and used for a future use. Since only one pair is required per case, the solution could be shared.
6 pcs – Male & Female Panel Chassis Connector Kit Purchased $13 2/8/12
Switches
3 Position Battery Use Switch 10 Amp $12
(Stackable Switch, 2 purchased, for stacking. One selector switch will switch two bodies, both + and -)
http://www.ebay.com/itm/170655659661?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649
