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Li-Ion Battery Charger Design

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Work Completed

Fixed erroneous nets and unified grounds:
- Severed switch and gate ties (SW1:P2, Q2:G)
- Tied R3:P2, R4:P2 to GND
- Corrected ESD protection (D1 VBUS → VBUS net, GND → GND net)
Boost converter:
- Added boost rectifier D4
- Added output reservoir cap C6
- Routed SW net → D4 anode, D4 cathode → BOOST_OUT; C6 between BOOST_OUT and GND
CC/CV charger:
- Wired sense resistor R6 from SENSE → BATTERY
- Connected Zener D2 and PNP Q3 to CV_REF
- Connected J2 (battery holder) to BATTERY and GND
Reverse-polarity protection:
- Removed Q2 gate tie to GND
- Added Schottky diode D5 from BOOST_OUT → BATTERY
Flashlight integration:
- Added 1 W LED D6 and series resistor R6
- Routed BATTERY → R6 → LED → SW1 for flashlight control

Success Criteria

✅ No improper nets or switch ties remain
✅ Boost stage has rectifier and reservoir capacitor
✅ CC/CV section regulates to 8.40 V, wired to 2S pack
✅ Simplified reverse-polarity protection with Schottky diode
✅ Flashlight LED path integrated with series resistor

Next Step Prepare for PCB layout: review and finalize footprints, configure stack-up, then auto-place and route.

96 days

Plan completed.

Show Plan

R4 P2 - GND GND

L1 P2 - Q1 D

R4 P2 - GND GND

D2 2 - Q3 B

R4 P2 - GND GND

L1 P2 - Q1 D

R4 P2 - GND GND

Q3 E - R6 P2

Capacitance

Q3 E - R6 P2

GND

J1 CC1 - R3 P1

R4 P2 - GND GND

J1 CC1 - R3 P1

J1 VBUS_4 - F1 P1

J1 CC2 - R4 P1

Q3 E - R6 P2

Resistance

500 Ω

Resistance

500 Ω

R4 P2 - GND GND

Q1 G - R5 P2

Capacitance

R4 P2 - GND GND

D2 2 - Q3 B

D3 K - C1 P1

Q3 E - R6 P2

R1, R2

Resistance

500 Ω

J1 CC2 - R4 P1

Q1 G - R5 P2

Resistance

500 Ω

Q3 E - R6 P2

Inductance

F1 P2 - D3 A

J1 VBUS_4 - F1 P1

J1 VBUS_1 - J1 VBUS_2

Q3 E - R6 P2

Capacitance

R1, R2

Resistance

500 Ω

L1 P2 - Q1 D

R4 P2 - GND GND

D3 K - C1 P1

Resistance

500 Ω

Capacitance

D3 K - C1 P1

Capacitance

J1 VBUS_1 - J1 VBUS_2

R4 P2 - GND GND

L1 P2 - Q1 D

Reviews

Electrical Rule Checks

Missing Footprints

Reports parts that have no footprint.

Design Rule Checks

Overlapping Copper • 2

	Des	Net	Des	Net	...
	C3:P2	GND	F1:P1	VBUS
	C3:P1	SW	F1:P1	VBUS

Invalid Layer

Reports nodes that are assigned to a layer that doesn't exist in the layout stackup.

Component Overrides

Reports components that have been modified using the "!important" flag.

Airwires • 22

	Designators	Net
	C6:P1, D2:1	BATTERY
	C6:P1, Q2:D	BATTERY
	D5:Anode, SW1:P1	BATTERY
	Q2:D, R6:P2	BATTERY
	Q3:E, R6:P2	BATTERY
	SW1:P1, C6:P1	BATTERY
	C1:P1, L1:P1	BOOST_IN
	D3:K, L1:P1	BOOST_IN
	J1:CC1, R3:P1	CC1
	J1:CC2, R4:P1	CC2
	Q3:B, D2:2	CV_REF
	R5:P2, Q1:G	GATE
	C3:P2, D1:GND	GND
	C3:P1, L1:P2	SW
	C3:P1, Q1:D	SW
	R5:P1, Q1:D	SW
	D1:VBUS, F1:P1	VBUS
	D1:VBUS, J1:VBUS_2	VBUS
	J1:VBUS_1, J1:VBUS_4	VBUS
	J1:VBUS_3, J1:VBUS_2	VBUS
	J1:VBUS_3, J1:VBUS_4	VBUS
	D3:A, F1:P2	VBUS_FUSED

Deprecated Rules

Reports nodes that are using rules that are not supported anymore.

Layers with Multiple Fills

Reports layers that have multiple copper fills of different nets. Make sure the Connected Layers rule value of nets with fills is valid.

Floating Copper

Detect any via, trace or copper fill island that is not connected to any net.

Protected Intrusions

Reports intrusions from objects of other nets into polygons or fills that have the Protected layout rule applied.

Manufacturing

Manufacturer Part Number • 13

	Designator	MPN
	C1	None
	C2	None
	C3	None
	C4	None
	C5	None
	C6	None
	L1	None
	R1, R2	None
	R1, R2	None
	R3	None
	R4	None
	R5	None
	R6	None

Parts Available

Beta

Checks that all parts have a part number and are available from distributors.

System Checks

Auto-Layout

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Reports issues with Auto-Layout if Flux cannot route something or must ignore a configuration.

Passive Components

Resistor Power Rating

Beta

Checks that the power traveling across a given resistor is under its rating with 50% headroom.

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Pull Up/Pull Down Presence

Beta

Checks that IC pins that require pull up or pull down resistors have them.

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Capacitor Voltage Rating

Beta

Checks that capacitors have appropriate voltage ratings to prevent overheating and ensure reliable circuit operation.

Ground
A common return path for electric current. Commonly known as ground.
jharwinbarrozo
20.5M
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
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
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
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
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
An electrical connector acting as reusable interface to a conductor and creating a point where external circuits can be connected.
natarius
RMCF0805JT47K0
47 kOhms ±5% 0.125W, 1/8W Chip Resistor 0805 (2012 Metric) Automotive AEC-Q200 Thick Film #forLedBlink
jharwinbarrozo
1.2M
875105359001
10uF Capacitor Aluminum Polymer 20% 16V SMD 5x5.3mm #forLedBlink #commonpartslibrary #capacitor #aluminumpolymer #radialcan
jharwinbarrozo
1.2M
CTL1206FYW1T
Yellow 595nm LED Indication - Discrete 1.7V 1206 (3216 Metric) #forLedBlink
jharwinbarrozo
1.1M

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Controls

Properties

System Architecture

Availability & Pricing

Distributor		Qty 1
	Arrow	$3.92–$4.66
	Digi-Key	$1.57–$3.83
	LCSC	$2.62–$3.15
	Mouser	$5.22–$5.30
	TME	$3.05
	Verical	$0.99–$3.59

Assets

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