Sugru is the new self-setting rubber for fixing, modifying and making stuff.

Hand formable

Hand formable

Sugru can be formed and shaped by hand for up to 30 minutes once it has been removed from its packaging.

Sticky

Sticks to almost anything

Sugru forms a strong bond to metal, ceramics, glass, wood and some plastics like perspex and ABS and rubbers like silicone and butyl rubber.

Air cures

Air cures at room temperature

Sugru is like modelling clay when you take it from its pack. Once it's exposed to air, it cures to a tough flexible silicone overnight using the moisture in the air.

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How to make a solar charger for a mobile phone

Portable, lightweight, waterproof and can be positioned in 3 ways:

1. Position it in 45 degree angle, facing the window up to a meter away, if indoors. You just have to experiment a bit, if it doesn't charge, move it closer to the window and if you are after quick charge, it is good idea to set mob to energy saving mode I think.
2. It can be attached to the bag or ruck sack, by placing leg in a pocket with your phone plugged in, so you can charge while out and about.
3. Can be hung on the window with the string, so even in limited light you can still get charge.

Kit list

  • 2 x Flexible solar panel 0.8W, 2V
  • DC-DC step up converter charger with USB female DC 2.5V-5V
  • 6 x sugru minipacks
  • Soldering iron
  • Some solder
  • Red and black wire
  • Wire stripping tool
  • Voltmeter
  • Tubing, like irrigation pipe or a straw, something similar, not too bendy as it needs to support the panel, 2 x 11-12cm long
  • Pill box

Step 1

1

When choosing solar cells for this application, make sure it has a decent current and voltage of 4V or 5V even better if you planing to use it indoors more, this way you can still charge in darker conditions, in addition to this to achieve 5V needed to charge, the dc voltage booster is necessary, I've chose 2.5-5V, so if your 4V panel only produce 2.5-3V its enough to charge, so it doesn't have to be in direct sunlight. To increase current you need to connect cells in parallel, to increase voltage connect in series. For the 2 panels I have I need to increase voltage, so if you getting same panels you need to connect them in series to achieve 4V and the current is high enough.

Step 2

2

First measure voltage of your solar cells to check if its the same as in manufactures/sellers specs, this gives you a chance to check the distance from the light source ( window) and before soldering test polarity of the cells to determine the positive and negative (+ and -) when your voltmeter shows minus - you have it wrong way round, just switch it round and just like on your voltmeter you have black and red wire, solder wires about 15cm long in same way red to plus, black to minus and to connect your the cells in series you need to solder short peace of wire from + to - ( doesn't mater what colour) Then you need to connect solar panel to the charger module in the same way solder red to plus and black to minus and before you do that don't forget to stick tubing on wires, if you would be using this.

Tip: (if you are not familiar with soldering) put a drop of solder on the clean surface first then add wire, I would advice practice before soldering panels, I haven't solder myself for long time, but i did not practice, thats why my joints on cells don't look too good, so its good idea to practice before, but don't worry if it doesn't work out very nice, it will still work. Also you need to strip wire before soldering.

Step 3

3

Prepare box, if your pill box same as mine AM and PM joint together, you need to cut half of it away with sizers, then open the lid, cut the hole for USB at the top, so it would just slide in and space for wires to slide in from sides. Unfortunately, the box is slightly too big for this module, so to secure it add some material inside at the bottom and back. when all done close the box. (if it does not close, adjust the insides and try again, it will close eventually;)

Now place sheet of cling-film on your preferably flat work surface and form some sugru with your hands and apply, start from middle, make a thicker strip, add sides by rolling a thin sting and attach, thickness depends on the cell, they can vary dramatically, apparently made by hand, but the idea is cover white surface from the front and the back insulate wires and joints, attach string for hanging option. Eventually attach/secure ends of tubing to panel and the box. Leave it to set for 24h and the cling-film prevents it from sticking to surface, it can be easily pulled off.

Tip: If you find it difficult to do it all in one go, do it in sections, leave to set then do another section.

PS: you can attach string to the top rather than bottom, up to you...