Battery Charging Module Design

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General (prev)
Project
Here’s an in-depth walkthrough of your “TP4056 USB-C with Battery protection” design.
1. Project Purpose
A compact 1-cell lithium-ion charger and protection module that
  • Accepts 5 V from a USB-C jack
  • Charges a single Li-ion cell up to 4.2 V at up to 1 A
  • Provides over-charge, over-discharge, and over-current protection
  • Indicates charge status with an LED
Commonly used in DIY power-banks, portable electronics, and battery maintenance rigs.

2. Core Functional Blocks

BlockKey ComponentsFunction
Input & NegotiationUSB-C 2.0 Receptacle (J1)Receives 5 V USB power; CC pin resistors (not shown) set default current mode.
Charge ControllerTP4056 (U2)Linear charger IC; controls constant-current/constant-voltage profile.
PROG Resistor1.2 kΩ 0603 Resistor (R3)Sets charge current: ICHG≈1200 mVRPROG=1 AI_{CHG}\approx\frac{1200\text{ mV}}{R_{PROG}}=1\text{ A}
Decoupling Caps10 µF 0603 Capacitor (C2)
& 100 nF 0603 Capacitor (C3)Stabilize VCC rail and ensure IC stability.
Protection ICDW01A (U1)Monitors cell voltage & current; outputs fault signals.
Dual MOSFET SwitchFS8205A (U3)Implements charge/discharge cut-offs under control of U1.
Status IndicatorLTST-C19HE1WT (LED1)
& 1 kΩ 0603 Resistors (R4, R5)Shows charging (CHRG) and standby/full (STDBY) via TP4056 status pins.
Battery & Power PortalsPower net portals (BAT+, BAT-, VCC, GND)Tie rails across the schematic for clarity; connect to external pads.
3. Signal & Power Flow
  1. USB-C Input (J1)
    • 5 V appears on the VBUS pin.
    • (Note: CC1/CC2 resistors should be added externally to advertise 500 mA or 1 A.)
  2. Charger Stage (U2)
    • VIN → internal linear regulator → charges BAT pin.
    • R3 programs ~1 A charge current.
    • C2/C3 decouple VIN and BAT for stability.
    • CHRG and STDBY open-drain pins drive LED1 through R4/R5.
  3. Protection Stage (U1 + U3)
    • U1 monitors cell voltage on VDD/VM and current via FS8205A sense.
    • On fault, U1 toggles CO/DO signals to turn off both MOSFETs in U3, isolating the cell.
    • R1 (1 kΩ) and C1 form a local decoupling/filter network for U1.
  4. External Connections
    • BAT+ / BAT- portals feed the cell or holder.
    • P+ / P- portals supply the load when protection MOSFETs allow discharge.
    • GND and VCC portals tie rails for peripheral connections or test points.
4. Key Design Choices & Trade-Offs
  • Linear vs. Switching Charger
    • TP4056 is simple and low-noise but wastes power as heat at high charge currents.
    • For >1 A or multi-cell, a switching solution would be more efficient.
  • USB-C CC Implementation
    • This design omits CC pull-downs. Without proper CC resistors (5.1 kΩ), some hosts may not enable VBUS.
    • Improvement: Add two 5.1 kΩ resistors from CC1/CC2 to ground to advertise default current.
  • Thermal Management
    • At 1 A, TP4056 dissipates (5V−VBAT)×I(5 V - V_{BAT}) \times I → ~4 W at empty cell, requiring a heat sink or PCB copper pour.
  • Component Sizing
    • R3 = 1.2 kΩ (E24) chosen for 1 A.
    • LED resistors (R4/R5) sized at 1 kΩ to limit LED current to ~2 mA.
5. Potential Challenges & Considerations
  • Thermal Runaway
    • Ensure adequate copper area under U2 for heat spreading.
  • Cell Chemistry Variants
    • TP4056 is tailored for Li-ion; LiFePO₄ needs different voltage target.
  • False Disconnects
    • Transient currents can trigger protection; consider adding small RC on U1 sense pins.
6. Real-World Applications
  • DIY power banks
  • Battery maintenance/trickle chargers
  • Embedded backup power modules
  • Portable sensor / IoT battery packs
7. Future Enhancements
  • Add USB-C CC resistors for host compliance.
  • Switching regulator front-end (e.g., 5 V→4.2 V) for higher efficiency.
  • Battery fuel gauge (e.g., coulomb counter) for SOC display.
  • Thermistor on CELL pin for temperature-based charge control.
  • Multi-pack support by paralleling TP4056 or using a multi-cell charger IC.
This modular, low-cost design balances simplicity and safety, making it a versatile starting point for many Li-ion charging applications.
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U3
BAT
LED1
U2
J1
1
C2
Capacitance
10u F
C1
Capacitance
100n F
2
C3
Capacitance
100n F
2
1
BAT+
R3
Resistance
1.2k Ω
Vcc
BAT+
P+
BAT-
Vcc
R2
Resistance
100 Ω
R4
Resistance
1k Ω
BAT+
BAT-
BAT+
BAT-
U1
R5
Resistance
1k Ω
P-
  • Ground
    Ground
    A common return path for electric current. Commonly known as ground.
    jharwinbarrozo
    20.5M
  • Net Portal
    Net Portal
    Wirelessly connects nets on schematic. Used to organize schematics and separate functional blocks. To wirelessly connect net portals, give them same designator. #portal
    jharwinbarrozo
    43.0M
  • Power Net Portal
    Power Net Portal
    Wirelessly connects power nets on schematic. Identical to the net portal, but with a power symbol. Used to organize schematics and separate functional blocks. To wirelessly connect power net portals, give them the same designator. #portal #power
    jharwinbarrozo
    11.4M
  • Generic Resistor
    Generic Resistor
    A generic fixed resistor for rapid developing circuit topology. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard resistor values: 1.0Ω 10Ω 100Ω 1.0kΩ 10kΩ 100kΩ 1.0MΩ 1.1Ω 11Ω 110Ω 1.1kΩ 11kΩ 110kΩ 1.1MΩ 1.2Ω 12Ω 120Ω 1.2kΩ 12kΩ 120kΩ 1.2MΩ 1.3Ω 13Ω 130Ω 1.3kΩ 13kΩ 130kΩ 1.3MΩ 1.5Ω 15Ω 150Ω 1.5kΩ 15kΩ 150kΩ 1.5MΩ 1.6Ω 16Ω 160Ω 1.6kΩ 16kΩ 160kΩ 1.6MΩ 1.8Ω 18Ω 180Ω 1.8KΩ 18kΩ 180kΩ 1.8MΩ 2.0Ω 20Ω 200Ω 2.0kΩ 20kΩ 200kΩ 2.0MΩ 2.2Ω 22Ω 220Ω 2.2kΩ 22kΩ 220kΩ 2.2MΩ 2.4Ω 24Ω 240Ω 2.4kΩ 24kΩ 240kΩ 2.4MΩ 2.7Ω 27Ω 270Ω 2.7kΩ 27kΩ 270kΩ 2.7MΩ 3.0Ω 30Ω 300Ω 3.0KΩ 30KΩ 300KΩ 3.0MΩ 3.3Ω 33Ω 330Ω 3.3kΩ 33kΩ 330kΩ 3.3MΩ 3.6Ω 36Ω 360Ω 3.6kΩ 36kΩ 360kΩ 3.6MΩ 3.9Ω 39Ω 390Ω 3.9kΩ 39kΩ 390kΩ 3.9MΩ 4.3Ω 43Ω 430Ω 4.3kΩ 43KΩ 430KΩ 4.3MΩ 4.7Ω 47Ω 470Ω 4.7kΩ 47kΩ 470kΩ 4.7MΩ 5.1Ω 51Ω 510Ω 5.1kΩ 51kΩ 510kΩ 5.1MΩ 5.6Ω 56Ω 560Ω 5.6kΩ 56kΩ 560kΩ 5.6MΩ 6.2Ω 62Ω 620Ω 6.2kΩ 62KΩ 620KΩ 6.2MΩ 6.8Ω 68Ω 680Ω 6.8kΩ 68kΩ 680kΩ 6.8MΩ 7.5Ω 75Ω 750Ω 7.5kΩ 75kΩ 750kΩ 7.5MΩ 8.2Ω 82Ω 820Ω 8.2kΩ 82kΩ 820kΩ 8.2MΩ 9.1Ω 91Ω 910Ω 9.1kΩ 91kΩ 910kΩ 9.1MΩ #generics #CommonPartsLibrary
    jharwinbarrozo
    1.5M
  • Generic Capacitor
    Generic Capacitor
    A generic fixed capacitor ideal for rapid circuit topology development. You can choose between polarized and non-polarized types, its symbol and the footprint will automatically adapt based on your selection. Supported options include standard SMD sizes for ceramic capacitors (e.g., 0402, 0603, 0805), SMD sizes for aluminum electrolytic capacitors, and through-hole footprints for polarized capacitors. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard capacitor values: 1.0pF 10pF 100pF 1000pF 0.01uF 0.1uF 1.0uF 10uF 100uF 1000uF 10,000uF 1.1pF 11pF 110pF 1100pF 1.2pF 12pF 120pF 1200pF 1.3pF 13pF 130pF 1300pF 1.5pF 15pF 150pF 1500pF 0.015uF 0.15uF 1.5uF 15uF 150uF 1500uF 1.6pF 16pF 160pF 1600pF 1.8pF 18pF 180pF 1800pF 2.0pF 20pF 200pF 2000pF 2.2pF 22pF 20pF 2200pF 0.022uF 0.22uF 2.2uF 22uF 220uF 2200uF 2.4pF 24pF 240pF 2400pF 2.7pF 27pF 270pF 2700pF 3.0pF 30pF 300pF 3000pF 3.3pF 33pF 330pF 3300pF 0.033uF 0.33uF 3.3uF 33uF 330uF 3300uF 3.6pF 36pF 360pF 3600pF 3.9pF 39pF 390pF 3900pF 4.3pF 43pF 430pF 4300pF 4.7pF 47pF 470pF 4700pF 0.047uF 0.47uF 4.7uF 47uF 470uF 4700uF 5.1pF 51pF 510pF 5100pF 5.6pF 56pF 560pF 5600pF 6.2pF 62pF 620pF 6200pF 6.8pF 68pF 680pF 6800pF 0.068uF 0.68uF 6.8uF 68uF 680uF 6800uF 7.5pF 75pF 750pF 7500pF 8.2pF 82pF 820pF 8200pF 9.1pF 91pF 910pF 9100pF #generics #CommonPartsLibrary
    jharwinbarrozo
    1.5M
  • Generic Inductor
    Generic Inductor
    A generic fixed inductor for rapid developing circuit topology. *You can now change the footprint and 3D model at the top level anytime you want. This is the power of #generics
    jharwinbarrozo
    15.1k
  • Terminal
    Terminal
    An electrical connector acting as reusable interface to a conductor and creating a point where external circuits can be connected.
    natarius
  • RMCF0805JT47K0
    RMCF0805JT47K0
    47 kOhms ±5% 0.125W, 1/8W Chip Resistor 0805 (2012 Metric) Automotive AEC-Q200 Thick Film #forLedBlink
    jharwinbarrozo
    1.2M
  • 875105359001
    875105359001
    10uF Capacitor Aluminum Polymer 20% 16V SMD 5x5.3mm #forLedBlink #commonpartslibrary #capacitor #aluminumpolymer #radialcan
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  • CTL1206FYW1T
    CTL1206FYW1T
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TP4056 USB-C with Battery protection

TP4056 USB-C with Battery protection
Description

Created
Last updated by mcprince96
1 Contributor(s)
mcprince96

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