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Build a hidden Qi wireless phone charger!


by bobburghart on October 10, 2014

Table of Contents
Build a hidden Qi wireless phone charger! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intro: Build a hidden Qi wireless phone charger! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 1: Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 2: Disassemble the PowerBot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 3: Find the maximum charging distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 4: Get your CNC file ready (for ShopBot only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 5: Fit and attach naked PowerBot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 6: Flip your surface over and test! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

http://www.instructables.com/id/Build-a-hidden-Qi-wireless-phone-charger/

Intro: Build a hidden Qi wireless phone charger!


Phone docks are expensive and platform-specific. Charging cables are annoying and unsightly. Wireless chargers alleviate some of these inconveniences, but still leave
a lot of polish to be desired. I set out to eliminate all of these complaints, and in building a wireless charger into a nightstand or desk, I am now able to plop my phone
down on my nightstand and watch as the battery fills up - like magic.
For this Instructable, I will be demonstrating the process of building a wireless Qi charger into a desk or nightstand. The results are polished, convenient, and impressive.
Done right, you'll make your phone-charging experience seamless and attractive.

Step 1: Supplies
In terms of supplies for the project, you'll need the following parts and tools ready to use. You may have to hunt around to find a MakerSpace with a ShopBot CNC
Router, but you could (in theory) chisel out your wood surface instead.
PowerBot Qi standard induction charger (any color!)
I chose the red model knowing that I wanted to use one of the rubber rings to indicate where my charging pad is hidden.
This model comes with a USB cable long enough to use for this project!
Any 5v AC - USB power adapter, 1.5A output or greater works best
You can use any 5v USB adapter, including the one that came with your phone. A higher output adapter will charge your phone faster.
Small phillips screwdriver
Small flathead screwdriver
Hot glue gun
Router (CNC or manual)
I used a ShopBot, see if your MakerSpace has one!
You'll also need the obvious:
A desk or nightstand that you're comfortable taking apart and manipulating
I used a board of walnut to illustrate my project since my desk is made of glass and my nightstand is ugly.
A phone that supports induction charging via the Qi standard
iPhones are not supported
Most Samsung Galaxy phones are supported with a special back cover
Example: Samsung Galaxy S4 Qi Battery Cover
Many recent Windows Phones and Android Phones support Qi
Phones with MicroUSB charging ports that do NOT natively support Qi can use the following adapter to add Qi charging capability using the
MicroUSB port
MicroUSB Qi Charging Film

http://www.instructables.com/id/Build-a-hidden-Qi-wireless-phone-charger/

Step 2: Disassemble the PowerBot


Dig in! Peel away what you can of the plastic housing with your flathead screwdriver, then pry the rest off. The PowerBot casing is in two halves, you'll need to separate
the two. With the PCB exposed (it's screwed into the top half of the casing), use your phillips screwdriver to remove the guts of the PowerBot. What you see in my final
picture here is where the magic happens - that's an induction coil you're looking at! Your Qi compatible phone has a similar coil inside it, to receive the electromagnetic
field produced by the PowerBot.
The induction charging system can only work within a limited distance. The coil in your phone can't be too far away from the coil from the PowerBot, so removing the
PowerBot's casing reduces unnecessary obstruction between the two coils. This will come into play in the next step...

http://www.instructables.com/id/Build-a-hidden-Qi-wireless-phone-charger/

Step 3: Find the maximum charging distance


As you can see in these pictures, I've confirmed that the naked PowerBot is working with my phone, and I've confirmed that the PowerBot continues to charge my phone
when the phone is raised above the induction coil. I estimate from this test that it will continue to charge up until around 0.3 inches. If you have a case on your phone, this
may be a little tight - you'll definitely need to use a CNC router for better precision. If you keep your phone case-free, you may be able to get away with a hand router (or
even a chisel!).
Remember - GREEN means it's charging. RED means there's no connection.

Step 4: Get your CNC file ready (for ShopBot only)


I measured the size of the naked PowerBot, and accounted for the room that the included MicroUSB cable needs. After creating a quick 2D vector in Adobe Illustrator, I
imported the vector lines into my school's ShopBot software, figured out how deep I wanted the router to cut (With my 1 inch wood slab, I cut in 0.8 inches. This leaves
me with a little over 0.1 inches of wiggle room for charging.), and started the task.
Attached are all the files I used in the process of using the CNC router.

http://www.instructables.com/id/Build-a-hidden-Qi-wireless-phone-charger/

File Downloads

powerbot.crv (243 KB)


[NOTE: When saving, if you see .tmp as the file ext, rename it to 'powerbot.crv']

powerbot.sbp (149 KB)


[NOTE: When saving, if you see .tmp as the file ext, rename it to 'powerbot.sbp']

powerbot.ai (1 MB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'powerbot.ai']

Step 5: Fit and attach naked PowerBot


With my included CNC files, your naked PowerBot will fit in just about perfectly! You shouldn't have to use any excessive force sliding the naked PowerBot into the hole,
and the MicroUSB cable should fit happily, too. Make sure the MicroUSB cable is plugged in BEFORE sliding the naked PowerBot into place.
After confirming that the naked PowerBot fits and still functions (red light means "Ready to Charge!" in the second picture), use your hot glue gun to (CAREFULLY) glue
the naked PowerBot into place. This is key - you don't want your hidden charger falling fate to gravity. I glued in/around the existing screw holes, and my naked PowerBot
is held snugly in place. Keep your MicroUSB cable ATTACHED throughout this process, but keep your 5v AC/USB adapter UNPLUGGED from the wall.

http://www.instructables.com/id/Build-a-hidden-Qi-wireless-phone-charger/

Step 6: Flip your surface over and test!


Success! I drop my phone onto my hidden charger, and immediately it begins to charge. I also hot-glued the red rubber ring from the first step to the top of the surface
(desk or table) to indicate where the charger is. You can now reassemble your desk or table, and enjoy your hidden charger!

http://www.instructables.com/id/Build-a-hidden-Qi-wireless-phone-charger/

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http://www.instructables.com/id/Build-a-hidden-Qi-wireless-phone-charger/

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Comments
34 comments Add Comment

bobburghart says:

Nov 3, 2014. 8:20 AM REPLY

I'll be responding to any comments and questions here!

wonderbrett says:

Nov 5, 2014. 11:58 AM REPLY


Curious with the right tools and metal, would it be possible to make an entire tabletop like this? So regardless of where the phone sits, it would work?

bilge17 says:

Nov 4, 2014. 4:51 AM REPLY


Great work on this ible...I like the suggestion of recessing the red ring into the top surface also. I have another suggestion, make an clear acrylic ring the
same size to fit into the recessed space and drill a tiny hole where the green/red LED is on the Bot unit is below. it will always glow red until you set your
phone on it.

bobburghart says:

Nov 4, 2014. 12:29 PM REPLY


I like this idea, it keeps the surface flush while still indicating exactly where the wireless charger is. I'm personally not a fan of the LED light being
visible (my phone tells me when it's charging), but that's a preference thing.
Unfortunately, I won't be able to make the Illustrator files for the two sized rubber rings (as mentioned in my previous comment here). I used my
rubber rings from a knockoff PowerBot I disassembled, and it turns out the rings are not the same size as the genuine PowerBot's rings. I was hasty
in my disassembly of the genuine PowerBot and didn't think to save the red rings. Sorry!

bobburghart says:

Nov 4, 2014. 5:47 AM

(removed by author or community request)

TANZMEISTER says:

Nov 4, 2014. 9:27 AM REPLY


Filling said ring (or any design/shape you want) with Sugru might make a more finished/awesome looking product. Thanks for the great ible! I
might make one with a acrylic/glass window (I like the industrial sort of look of exposed parts) for my wife for Christmas.

bobburghart says:

Nov 4, 2014. 10:00 AM REPLY


I was thinking maybe laser engraving a design, I love the etched look of wood. If you do end up making the window (or the sugru variant), try
to post a couple pictures here! It would be great to have that variety showcased!

synthdust says:

Nov 4, 2014. 11:21 AM REPLY


Might be neat to simulate a light coffee/beverage ring to indicate where the charger is instead of an out of place red ring. Just a thought!

bobburghart says:

Nov 4, 2014. 11:36 AM REPLY


Of all the "where did I hide my wireless charger?" solutions so far, I like this one best. I'm going to "sticky" your comment so it shows up on top, so others
see your idea!

SparkySolar says:

Nov 6, 2014. 5:04 PM REPLY

wicked cool

zwilmes says:

Nov 4, 2014. 8:08 PM REPLY


I am definitely going to build one of these. I'm planning on inlaying a contrasting wood ring inside of the wood surface to indicate the charging area. Thanks so
much for this great idea!

bobburghart says:

Nov 6, 2014. 10:59 AM REPLY

Post pictures of the inlay! I think that'll look great!

Corhay says:
About how much does this cost?

http://www.instructables.com/id/Build-a-hidden-Qi-wireless-phone-charger/

Nov 4, 2014. 6:13 PM REPLY

bobburghart says:

Nov 5, 2014. 6:19 PM REPLY


Sorry, jarikcbol's response is incorrect. The Qi charger is less than $14 on Amazon right now, and that's Prime/free shipping eligible. The wall charger
part (AC adapter) is less than $11, with the same Prime/free shipping eligibility.
With Prime, that's $25 and tax for the Qi charger I used and a good USB AC adapter. Without Prime, you'll need another $10.02 in your cart to be eligible
for free "super saver" shipping.
The Qi charging film for MicroUSB phones is less than $8 on Amazon, with the same Prime/free shipping eligibility of the first two items. You can click on
my orange links in my first step to view these exact items.
I DO NOT recommend using the Qi adapter for iPhones. The ones available are not MFI (Apple) certified, and thus are not guaranteed to work. Often,
iOS firmware upgrades will break non-MFI charging accessories.

Corhay says:

Nov 6, 2014. 10:21 AM REPLY

Thank you very much

jarikcbol says:

Nov 5, 2014. 1:52 PM REPLY


the Qi charger is 39.99 on Amazon, and the adapter for an iPhone 5/6 is 35.00, so if you are modifying an existing table, about 75$ worth of hardware,
and some time. The parts are cheeper if you have Amazon prime, or shop around elsewhere a bit.

bobburghart says:

Nov 5, 2014. 6:22 PM REPLY


The cost for the Qi charger and USB wall adapter is closer to $25 in total. The Qi charger alone is $14. Please click my orange links in Step 1 to view
the exact items I used in this project, you can see the actual prices on the Amazon product pages. All items linked are eligible for free shipping, too.

Corhay says:

Nov 5, 2014. 2:16 PM REPLY

Thank you

smokin_cannon says:

Nov 6, 2014. 7:53 AM REPLY

Great project!
I've been wanting to do this, but thought that the charger was $100. If not for the link to Amazon, I wouldn't have read all the way through thinking it was cost
prohibitive.
Thanks for posting instructions and resources.

synthdust says:

Nov 4, 2014. 11:20 AM REPLY


Might be neat to simulate a light coffee/beverage ring to indicate where the charger is instead of an out of place red ring. Just a thought!

synthdust says:

Nov 4, 2014. 11:19 AM REPLY


Might be neat to simulate a light coffee/beverage ring to indicate where the charger is instead of an out of place red ring. Just a thought!

mikeasaurus says:

Nov 4, 2014. 9:42 AM REPLY

This looks sleek. I need to get me one of these induction chargers!

bobburghart says:

Nov 4, 2014. 10:02 AM REPLY


Thanks! You can get them really cheap on eBay, but shipping overseas takes a long time. I posted the Amazon link because it's prime eligible!

drohats says:

Nov 3, 2014. 5:46 PM REPLY

As an improvement you could have CNC a groove for the red rubber ring and made it flush to the top surface.

Eh Lie Us! says:

Nov 4, 2014. 9:40 AM REPLY

what about with textured paint?

bobburghart says:

Nov 3, 2014. 7:57 PM REPLY


Great suggestion! For anybody that does like the look of the rubber ring, and wants to make it a permanent part of their desk/table/nightstand, this is
actually a really cool idea. I hadn't thought of it at all!

http://www.instructables.com/id/Build-a-hidden-Qi-wireless-phone-charger/

kosborne2 says:

Nov 4, 2014. 5:29 AM REPLY

How slow is the charging as see the power bot only outputs 350mA?

bobburghart says:

Nov 4, 2014. 5:40 AM REPLY


The PowerBot outputs anywhere between 350mA and 1000mA. You can see that the input ranges from 500mA to 1500mA. I believe that that ~30% loss
in power is due to the relative inefficiency of induction charging, there is more resistance and distance involved with wireless induction charging than
there is with a traditional cable charger.
With a 1500mA power adapter, the PowerBot will charge your phone at 1000mA. This is equivalent to the speed that your phone would charge with a
1000mA cabled charger, and is still twice as fast as your phone would charge with a standard 500mA USB2.0 port on your computer.

JustinW2 says:

Nov 3, 2014. 5:39 PM REPLY

So with an S4 it only needs the back plate correct? Or does it need that Qi film as well?

bobburghart says:

Nov 3, 2014. 7:49 PM REPLY


Yes - the special backplate has the Qi receiver built in. The Qi Film is only necessary for MicroUSB phones that DO NOT have Qi built in and DO NOT
have a special backplate available.
Note that the S4 wireless charging backplate is a little bit thicker than the normal S4 backplate - not all cases will fit with that added thickness. See
customer reviews on the Amazon page for more info about that, it looks like certain Otterbox cases still fit.

pechurc says:

Nov 3, 2014. 1:33 PM REPLY

cool but if you do it on your desk will be fantastic :P

bobburghart says:

Nov 3, 2014. 2:08 PM REPLY


Absolutely - this would be a perfect project for a wood desk. My desk is glass, so that won't work for me. Glad you liked my guide!

RichardP4 says:

Nov 3, 2014. 9:04 AM REPLY

Nice project, I really like how it works with the LG G2 you have!

bobburghart says:
Thanks for the feedback!

http://www.instructables.com/id/Build-a-hidden-Qi-wireless-phone-charger/

Nov 3, 2014. 11:17 AM REPLY

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