DIY Series 80: Portable Fan Battery Replacement

Portable Fan Battery Replacement (18650 Li-Ion Battery Pack)

Symptoms:

• Continuously charging but unable to operate using internal battery pack after disconnected from power supply
• Able to operate using USB supply, unable to operate using internal battery pack supply

Findings:

• 18650 Li-Ion Battery Pack is no longer in good condition, need to replace with new battery pack

Photos:

1. Example of OEM Battery Pack I bought previously (US$7.00 ~ US$8.00)
2. Example of 18650 Li-Ion Battery for this DIY project (US$0.50 x 2pcs = US$1.00)
3. Portable Fan after folded (top view)
4. Portable Fan after folded (bottom view)
5. Unscrew 6 screws at the bottom
6. Open up the bottom housing and removed the malfunction battery
7. Prepare nickel strip (using scissor) according to the length/size required
8. Shaped the DIY wire lug using wire stripper
9. Clamp the DIY wire lug onto the wire cut out from old battery pack
10. Use 2pcs of 18650 Li-Ion Battery for making custom DIY Battery Pack
11. Use Spot Welder to join 2pcs of 18650 batteries with nickel strip and connect the positive terminal (with DIY wire lug) using Spot Welder.
12. Use Spot Welder to join 2pcs of 18650 batteries with nickel strip and connect the negative terminal (with DIY wire lug) using Spot Welder.
13. Check the connectivity using multimeter, then connect the new DIY Battery Pack (2 sets) to the main board

Video:

1. Test the new DIY Battery Packs and it is working

Tools Required:

• Screwdriver
• Scissor
• Wire Stripper
• Multimeter 
• Spot Welder

Cost Involved:

• 18650 Li-Ion Battery (US$0.50 x 2 = US$1.00 / set)
• Total of 2 sets of DIY Battery Pack needed (US$1.00 x 2 = US$2.00)

Cost Saving:

• OEM Battery Pack:  US$7.00 / set
• DIY Battery Pack: US$1.00 / set
• Saving = (US$7.00 - US$1.00) x 2 sets = US$12.00

Related Links:

• Spot Welding Explained