Simplest Wireless Chraging Cooling Solution

Wireless charging is really cool and futuristic way to charge your Pocket Personal Computer with telephone functionality or other devices. It saves your USB port from wearing out and generally is much more convenient. But, it has one major drawback – it generates a lot more heat that USB charging. And heat is very bad for battery health. Thus using wireless charging will decrease your device lifetime. Commercially available wireless chargers with cooling are super overpriced. So should you drop the idea of going wireless?

Fear not! This crafting recipe will show you how to transform cheap basic wireless charger into powerful cooled one, and decrease charging temperatures to even less than that of a USB charger!

• 120 mm PC Case Cooling Fan
• 12 V Power Supply
• A3 (297 x 420) 6 mm Plywood Sheet
• Empty Aluminum Soda Can
• Wooden cylinder 6 mm in diameter (go buy yourself some ice-cream to get it ;)
• 2 self-tapping screws 3x12 mm (you can use other, but no thicker than 3 mm and no shorter than 8 mm)
• Cooking aluminum foil
• Some wires
• Scotch/Insulation tape

Tools

• Hand or Electric Jigsaw
• Electric Drill/Screwdriver
• Soldering Iron
• Flux Core Solder
• Glue Gun or some strong universal glue
• File/Sandpaper
• Scissors

1. Cut out 220 x 150 mm piece
2. Cut out 150 x 100 mm piece
3. Cut out two 120 x 100 mm pieces
4. Cut small opening in the largest piece → 53 mm from the smaller edge, 20 mm wide, 10 mm deep (picture #2)
5. Glue everything together like shown on picture #3 (13 mm from edge, over the opening in base plate)
6. (Optional) At this point, if you have primer + paint you might want to paint the base (for example to better blend into your interior or with your wireless charger/fan colors). I decided to leave it as it is, for true "hardcore" style!

Arguably, this is most complex part of this primitive device:

1. Flatten your soda can and cut out 120 x 11 mm strip
2. Drill 2 holes in the middle of the strip, 10 mm from both end. Note: this will depend on your wireless charger height. Mine is 14 mm, so if yours is similar, you can safely use 10 mm for holes. Otherwise, fine tune optimal hole placement yourself according to your charger.
3. Cut wooden cylinder to 20 mm height
4. Drill pilot hole for self-tapping screw in one end of cylinder and drive the screw itself into it
5. Use file/sandpaper to sand screw's head off any zinc or other protective coating it might have for best conductivity
6. Solder one of 2 wires onto the base of it's head
7. Wrap it with aluminum foil for corrosion protection and better contact
8. Now, drill pilot hole in the middle of base plate's opening
9. Use file/sandpaper to sand 2nd screw's head, in similar manner to 1st, but this time also sand screw's sharp point too
10. Align 2 holes on your soda can strip and screw it on to the base tightly
11. Solder 2nd wire onto the base screw's sharp end, inside base plate opening (not the head)
12. Wrap it's head with aluminum foil
13. Now glue wooden cylinder in the top-middle of your soda can ring (like you can see on the photos)
14. Use a little bit of glue to fix foil in place
15. Use some more bits of glue to secure wires to the base all the way to the back of this device
16. Use sticky tape to strap fan to the base
17. Connect one wire of the button to the fan, then 2nd button's wire and 2nd fan's wire to the power supply
18. Plug it in
19. And that's it!