Your One-Stop Charger PCB Manufacturer in China

Your Reliable Charger PCB Supplier

If you’re looking for the best manufacturer of energy meter PCB, you can count on our team. PCBMay is your no.1 energy meter PCB manufacturer and supplier in China! We are looking forward to working with you and build a strong partnership. Together, we’ll establish a successful business in the future.

PCBMay is a popular charger PCB manufacturer in China. We are an ISO-certified company that can help you in charger PCB sourcing. All types of PCB are available here specially charger PCB. We ensure to provide premium quality and great performance products to give you 100% satisfaction.

We have a wide range of charger PCB to exceed your project needs. You can find 5V 2A Charger PCB, AC mobile charger, DC mobile charger, USB Charger PCB, etc. Plus, we offer custom charger PCB with your specific requirements and stipulations. PCBMay commits to supplying second-to-none charger PCB according to customer’s requirements.

PCBMay Charger PCB features:

• High-accuracy voltage detection circuit,
• Effective life greater than 50000 hours
• Fine workmanship and durable
• Offer multiple protections such as overcharge protection, short circuit protection, over-discharge protection, overcurrent protection
• Use for a variety of applications, capacities, and various shapes
• It is very easy to install and convenient to use, etc.

To manufacture the exact dimensions and thicknesses of charger PCB, we utilize sophisticated machines and high-quality raw material per industrial standards. It allows us to deliver defect-free, perfect design, right functionality charger PCB in a wide range of applications and situations.

PCBMay provides custom and standard charger printed circuit board products and PCB assembly services to more than 3000 customers worldwide.

In our facility, a skilled 50 engineers for the R&D team, talented 500+ employees, and 30 overseas sales for the business team support us. We are equipped with 3 wave soldering production lines, 5 assembly lines, 6 fully automatic SMT production lines, and auxiliary testing and aging facilities. We ensure efficient manufacturing capabilities and guarantee fast delivery for your orders.

Aside from charger PCB, we also engaged in producing a wide range of products related to Rogers board, high-frequency high-speed board, multilayers, aluminum board, FPC board, flex-rigid board, halogen free board, and other types of boards. PCBMay is an expert in this industry with more than 10 years of history and experience. That’s why you can ensure high-precision and the right products when you purchase here.

In adherence to ISO production procedure and IPC class 2 quality surveillance standards, PCBMay develops PCB products fit for your business. You can trust us because we have passed many company authentications including ISO-9001 quality system certification, USA and Canada UL(E477880), RoHs, and ISO-14001 environmental system certification. In other words. PCBMay is your #1 PCB manufacturer and supplier with great manufacturing capabilities and certifications.

Contact us for more charger PCB information. We are 24/7 available to assist our customers.

Charger PCB: The Ultimate FAQ Guide

In electronics, the printed circuit board is one of the most key components. Certainly, you have a lot of electronics powered by a battery that needs to be charged. Because batteries can not perform without charging. Charger PCB is the component that is related to charge batteries.

If you are a PCB merchant, you might need to know basic knowledge about PCB including a charger PCB as well. Today, we are here with several questions and with their answers about charger PCB.

Let’s walk together till the end of this FAQ guide. You will find some essential question answers when you finish reading the entire article.

What Is Charger PCB?

Mobile charger PCB/battery charger PCB is a circuit that can charge a battery automatically when the power of the battery gets low. Mobile phones have become an integral part of our life nowadays. So, the battery charger is also the part as well.

It’s a basic approach that charges the battery with a tiny steady current throughout the charging period. CC charging ends when the battery is fully charged to its specified value. This technique is commonly used to charge NiCd, NiMH, and Li-ion batteries.

Battery charger circuits are vast. They might be simple, and intelligent, fast charging, slow charging, charger for phones’ batteries, vehicles’ batteries, USB-based charger, solar charger circuit, and so on.

Charger PCB

Charger circuits also vary with different categories. Chargers differ from each other among phone chargers, vehicle chargers, and charger stations.

There are two charging methods you will find. Fast charging and slow charging. Based on the charging categories, circuit designs vary from each other.

What Are The Applications Of Charger PCB?

As we mentioned before, the use of charger PCB is vast. In every sector, where there is a battery, the charger is needed there. There are lots of categorized chargers available which are used in different sectors. Here we have categorized the different charging options and show their uses.

Fast Charger

Fast charger PCB controls high voltage current and allows the battery to charge very fast without damaging the battery and circuit.

Example of a fast Charger

Simple Charger

A simple charger charges the battery in a typical way with the default DC power supply. It doesn’t use extensive current flow. Though this takes a long time to charge batteries. IT is also cost-effective as well.

Induction-Powered charger PCB

Electromagnetic induction is used to charge batteries through induction-powered charger PCB technology. It is usually used for charging electric toothbrushes and other gadgets in bathrooms. It doesn’t need any metal contact between the charger and batteries.

Smart Charger PCB

A smart charger can identify the current needs of a battery to charge. It does not push a constant current, rather the amount of current that is needed in different situations.

Timer-Charger

If you are charging a low power consuming battery that might be overcharged and damaged if there is more current, a timer charger is for this. In the 1990s timer-charger was popular for charging low capacity Ni-Cd cells.

USB Charger PCB

USB charger PCBs are used to charge smartphones, tablets, listening devices, cameras, and so on. Since a USB charger PCB provides five-volt power, USB cables are able to be connected with a power-supplying hub.

Let’s see how does a phone charger work:

How To Design A Charger PCB?

There are a lot of things that should be considered while a charger PCB is being designed. Here are the gradual steps that might be efficient to take for designing a charger PCB.

Schematic Design

The first step of generating the design of a charger PCB is to make a schematic design. It is the blueprint of the circuit boards. A schematic design shows every detail to be implemented on the circuit board. It includes which components will be used and how they will be connected, and how they will be related to each other.

Schematic Diagram of a Charger PCB

PCB Layout

Generate the PCB layout. You may now adjust the PCB form, dimensions, and layer stack up for your circuit if they have previously been defined. If you don’t need to accomplish such chores right now, don’t worry; you can modify the structure, dimension, and layer stack up afterward.

Component Placement

Now is the time to place the PCB components in the right places. Before placing the components, it is safe to rough;y proceed with the placements of the components. Once you are done with rough assessments, now you are ready to place all components at the right places.

Routing and Connection

Once the basic component placements are done, now the time is to connect the component with each other by soldering. It will accomplish this by utilizing the number of layers available for connections and generating via holes as needed.

Each layer is frequently designated as a ground plane, while another is designated as a voltage plane. Not only does this minimize noise, but it also allows for low source impedance interconnections for the electrical supply.

Now, the PCB is ready to rule.

What Are The Materials Used In Charger PCB?

PCBs typically laminate flat composites composed of non-conductive substrates with intrinsic or externally sewn copper circuit sheets.

There are six basic materials used to make a PCB.

Prepreg

Prepreg is a thin, resin-coated, and cured glassy material, termed prepreg processors, in specific machines. The glass is the conventional substratum containing the resin. FR4 epoxy, polyimide, Teflon, etc. are different types of resin.

Prepreg

Laminate

Laminates are made of layers of prepreg bonded with high temperature and pressure, with sheets of copping foil along both sides, often termed copper-retained laminates. Another name for it is Copper Clad Laminate.

Copper foil

Copper foil is the basic depth of external and internal layers of charger PCBs. The laminate maker can pre-associate Copper Foil to a mechanical properties core or it can be inserted as a copper foil preceding compressing into a multi-layer charger PCB.

Soldermask

Soldermask is the greenish resin overlay on the outside layers of the PCBs. The inner circuitry is concealed in prepreg sheets so that they will not be shielded. But the outside layers will tarnish and degrade with time if left untreated. This protection is provided by Soldermask to components outside the Circuit board.

Nomenclature

The white inscriptions that appear on the surface of the solder mask layer on a PCB are known as nomenclature or silkscreen.

Aluminum board:

Like every other PCB, they share the same layout. But it includes solder mask layers, silkscreen, and copper. Instead of a polymer substratum, a metal substratum is included in the Aluminum board.

What Are The Battery Charge Customization Factors In Charger PCB?

The battery charge customization factor is the substance of the precautions to take before customizing the different charger PCBs. The most common commercially used batteries are NiMH, NiCd, LiPo, and lead-acid and rechargeable batteries.

The factors you should consider for different batteries are:

NiMH- Nickel-metal hybrid battery

• Battery leakage
• Regulate the current flow while charging
• Cycle of charging
• Position of the battery

Nickel Metal Hybrid Battery

NiCd- Nickel cadmium batteries

• Have to ensure constant current
• Keep the count of charge and discharge cycle. Because it has on average 1000 charge and discharge cycle

LiPo- Lithium-ion polymer batteries

• LiPo batteries have less resistance to protect themselves from overcharging. So, a constant current is required for them. You should employ a step charging method to ensure the safety and longevity of the batteries.
• You have to keep an eye on the battery temperature thus the LiPo batteries have fast charging capabilities. It might overheat because of it.

What Are The Parts And Principles Of The Charger PCB for 12V Constant Voltage Batteries?

The parts that are used in 12v batteries are:

• 10kΩ Resistor x 2 (R1 and R2)
• BC546 Transistor (T2)
• Transistor BD140 (T1)
• 2 x 1N4148 diodes (D2 and D3)
• 1KΩ Resistor (R3)
• 12Ω Resistor x 2 (R5 and R6)
• 1N4001 Diode (D1)
• 18V Transformer
• 220µF Capacitor (C2)
• 6KΩ Resistor (R4)
• Green LED (D4)
• 1nF Capacitor (C1)

12v Constant Voltage Battery Charger PCB

Working Principle

A basic 12-volt battery charger PCB charges a battery by providing a steady DC or intermittent Dc power supply. The output of the basic charger is not affected by the passage of time. A 12v Battery charger’s PCB is capable of converting voltages from one type to the other which is generally from AC to DC voltages.

On a 12v constant voltage charger PCB, a secondary circuit with a 1N4001 diode bridge is utilized to adjust an 18V ac supply. This is provided by a converter. A 6 milliAmpere flow will be used to charge the circuit. This flow will recharge the exhausted battery. It moves from R2 to D2, then from R4 to R6. When it reaches D1, it stops.

What Are The Parts And Principles Of The Nickel-cadmium Battery Charger PCB?

The parts that are used in 12v batteries are:

• Resistor 10Ω x 2
• Step Down Transformer 0-6 6V 500mA
• Mains power cable with 230V AC Power Input
• Green LED
• 1N4007 PN junction rectifier diode

Nickel-cadmium Battery Charger

Working Principle

Charger for NiCd batteries,  Both 6-volt and 12-volt  Nickel-cadmium batteries can be charged using this PCB. It employs a transformer capable of producing a current of 4 to 5 amps between 12.6 and 15 volts. Unlike traditional chargers, which use a button to establish the voltage level, this design uses a smart current regulator.

4.2 ampere is the imposed current that is generated automatically. While the charging power becomes 4 amperes, the voltage drops to 600 mV at the point R1.

The state of charge is adjusted to 4.2 amperes efficiently. The potential difference at R1 is 600 mV after the charging power hits 4A. In this instance, the transistor T1 runs and supplies T2 with the current.

Transistor T2 then connects T3’s foundation to the surface, decreasing or completely shutting off T4’s foundation-biased current. T4 is the moderator here that lessens the power difference between the charging flow and actual charging power of the Nickel-cadmium battery.

The combination of the electric potential and the charging flow determines T4’s energy loss. T4 requires a cooling fan since the energy loss when charging 6-volt batteries can be as high as 40 watts.

What Are The Components And Working Principles Of A 12 Volt Battery Absorb And Float Charger PCB?

List of components:

• VR Adjustable (IC1)- LM317
• Op-Amp LM358 (IC2)
• NPN BC547 (T1)
• 2-Pin Jumper Connector (J1)
• N4007 Rectifier Diode x 5 (D1, D2, D3, D4 and D5)
• 270-Ohm Resistor (R1) with I¼-Watt +-5% Carbon
• Carbon 2.2K-Ohm (R2) with ¼-Watt +-5%
• Connector Terminal (CON1)- 2-Pin
• Potmeter (VR1) with 2K-Ohm
• Carbon 10K-Ohm (R3 and R6) with ¼-Watt +-5%
• Potmeter (VR2)- 5K-Ohm
• Potmeter (VR3)- 20K-Ohm
• Aluminium Electrolytic Capacitor (C1)- 220µF 40V
• 3 of 5mm LED (L1, L2, and L3)
• Zener Diode (ZD1)- 8V
• Ceramic Disk Capacitor (C4)- 1µF
• Aluminium Electrolytic Capacitor (C2 and C3)- 10µF 25V
• Carbon 22K-Ohm (R4 and R5)- ¼-Watt +-5%
• Carbon 0.2-Ohm (R7)- 5-Watt +-5%
• Carbon 4.7K-Ohm (R8 and R9)- ¼-Watt +-5%
• Heat Sink for LM317 (S2)
• Rechargeable battery (CON2)- 12V, 7Ah
• Switch for ON and Off (S1)
• Alternate Current Power Input- 230V
• Secondary transformer (X1)- 15V-0-15V

12 Volt Battery Absorb And Float Charger PCB Diagram

Working Principle

With this designed circuit, your battery will be charged which is up to 12V and 7Ah. With its highest absorption point, it will continue charging your batteries. It changed to the floating stage of voltage after crossing the absorption limit to handle the objects at their float voltage. The floating voltage is 13.8V, whereas the maximum float voltage capability is 14.3V.

The following are the main components of this charger PCB:

• A transformer with a voltage range of 15-0-15V,
• A few extra parts, an LM358 adjustable power regulator, and an operational amplifier comparator (IC2) (IC2).

The converter receives the 230V AC and lowers the battery voltage. The first two IN4007 diodes (D1 and D2) tweak that. It will then touch the LM317, flattening it out.

What Are The Parts And Principles Of Fast Lead Acid Battery Charger PCB?

Components

• 2 x 1-ohm resistors (R1 and R2)
• Secondary Main power Converter, 12V 600 mA (Tr1)
• DPST (S1) of On and OFF button
• Controller (IC1)- L200
• Potentiometer with a pre-set resistance of 500 ohms (P1)
• Volt Capacitor (C1) with 1000uF 25
• Capacitor (C2)- 330 n
• Capacitor, 1uF, 16V (C3)
• Green LED (D6)
• Heat Sink with 100 Ma Delayed Effect
• 500 mA Moving Coil Meter (M1)
• 470 Ohm Resistor (R5)
• Resistor (R3, R4) with 820 Ohm and 560 Ohm
• 1N4001  (D1,D2,D3,D4,D7 and D8)
• IN41148  (D5,D9)

Fast Lead Acid Battery Charger PCB Diagram

Working Principle

P1 is used to set the voltage if there is no battery to charge by the time. R1 and R2 resistors are utilized to restrict power, with R2 required solely for charging currents greater than 0.5 A or to enable further accurate simulation current.

The flow of current remains within [ 0.45 (R1 + R2) / R1R2 ] A, as indicated by M1. Its present design encourages quick charging, which saves time. This could, therefore, lead to a lower capability and cell lifespan.

To keep the input power constant, an L200 charge controller is used. The first two resistors, by exchange, are doing it to decrease the flow. Therefore, the additional resistor is just required if the current flowing is more than 0.5 A.

What Are the Components and Core Concepts of a High Current Li-ion Charger PCB?

Components:

• 240 Ohm Resistor (R2)
• 7K Ohm Resistor x2 (R1 and R5)
• LM338 (IC2)
• D1 and D5 of 6A4 – 400V 6A
• 1x D2 -1N4148
• Preset Potentiometer(P1 and P2)- 10K Ohm
• Resistor (R3 and R4)- 10K Ohm
• ZENER DIODE (D3 and D4)- 7V ½ Watt
• Op Amp for 12V input (IC1)-741

High Current Li-ion Charger PCB

Working Principle

Switch-mode power supply, auto-stop charger PCB, voltage reference PCB are the combination of this mobile charger PCB which plugs a single universal li-ion battery charger circuit with 3.7V.

First, the power source is supplied through the charger PCB. The built-in voltage regulation PCB has 2 distinct transistors, 13003H and 1HC, that decrease the voltage from high to low dc.

After rectification, the power output may be as much as 7.1V with no charge but decreases 5.3V extremely fast while charging the Li-ion batteries.

Secondly, the benchmark voltages, TL431, the system generates a 4.20V steady to securely charge the battery. An auto-stop charger PCB is applied to measure the procedure.

A PNP BC857 transistor and NPN BC847 transistor with minimal resistors are provided inside the surveillance PCB and are linked to an RG LED.

If a Li-ion battery voltage level amounts to around 3.7V, the red signal increases, and the batteries are charged. It will cease loading immediately once achieving the objective of 4.20 volts.

How Many PCB Surface Finishes Are Available For Charger PCB?

ENIG (Electroless Nickel Immersion Gold)

ENIG comprises a 2-5 μ inches immersion Gold of over 120-240 μ inches Electroless Nickel placed onto the surface via solvent extraction (Ni). The nickel coating prevents copper from corrosion and the gold coating preserves the nickel coating.

ENEPIG (Electroless Nickel Electroless Palladium Immersion Gold)

The finishing of ENPIG’s surfaces is made of four metal layers. It is nickel, copper, gold, and palladium. The distinction between both ENEPIG and ENIG is the palladium add-in layer. The palladium means preventing oxidation of the nickel coating, preventing the occurrence of “black pad.”

Electrolytic Nickel/Gold

Electrolytic nickel/gold has a gold coating on a nickel foundation. This finishing is examined in this section of solid gold (99.6%) or soft gold by its pureness (99.9%). The selection of solid gold or soft gold relies on how you design the application.

Hard Gold Surface Finish

The Hard Gold surface finish is made up of a reflective coating with additional hardeners for extra protection that is electrolytically coated more than a nickel protective coating.

Soft Gold Surface Finish

A soft gold surface finish is indeed the greatest electrodeposit of pure gold without any type of additional alloy ingredient. It has 99.9% pure gold.

Soft Gold Surface Finish

Immersion Silver Surface Finish

Immersion silver surface finish or IAg finish is a technique of surface coating, which produces a thin coating of IAg on copper surfaces. It involves temporarily immersing the item in a silver ion-containing solution. It safeguards copper lines against corrosion and enhances pottery.

Immersion Tin

Immersion Tin is a RoHS surface finish which is an excellent solution for flat ground needs and for fine-tone charger PCB parts. Immersion Tin is a light coating of Tin deposited on a circuit’s copper layer.

What Is A Wireless Charger PCB And What Is Its Working Principle?

With the wireless charger PCB, you can charge your gadgets without connecting them to an external adapter or a socket board.

Wireless charger PCB mainly operates on the mutual inductance theory. Current from the sender circuit to the receiver circuit is transmitted on the air without interconnecting any wire on the basis of an “inductive connection” mechanism.

Wireless Charger for Phone

Inductance is the function of conductors where a power or electromagnet power is inducted to conductors through the electromagnetic flows into conductors. Self Inductance and Mutual inductance are the two types of inductance that are available.

How To Design A Wireless Charger PCB?

When the fact comes about the designing of a wireless charger PCB, basically two things come. You have to design a transmitter and a receiver actually.

Transmitter wireless charger PCB designing

The transmitter is the origin of power that induces the wireless transmission of electricity. The main transmitter components are the DC power source, the transmitter coil, and an oscillator. The n-channel MOSFETS and 4148 diodes are used in an oscillator circuit building.

4148 Diodes

The signal goes via the transistor and the spiral when the input voltage is implemented to the oscillator. You may also insert a voltage stream into the port of the transistor gate whenever this occurs. One is powered by the transistor while another is disabled.

Let’s check here how does a wireless charger works:

Receiver wireless charger PCB designing

You must now create a receiver. The receiver is made up of components such as a rectifier PCB, a regulator, and a receiving coil. The receiver circuit is separated by a distance from the inductor to induce power transmission. It will cause an AC current to flow through the coil.

This AC current isn’t suitable for use in wireless power systems. until you rectify the circuit. A capacitor and a diode are used in this circuit. After that, you’ll need to use a regulator to convert this AC to DC 5v. For wireless transmission, you may now link the regulator’s charging origin to the battery.

What Are The Advantages Of Wireless Charger PCB?

• It is safe to use, no electrical short circuit or shock possibilities here
• No hassle of using a cable, just put the device on the charging pad
• Reduces the amount of pressure on your device’s charging port.

Wireless charger PCB Circuit Board

• If you run out of energy and don’t have a cord, you may yet charge your devices using Qi wireless charging pads that are being put in various locations across the world.
• No overheating issues with wireless chargers to the devices

What Are The Limitations Of Wireless Charger PCBs?

• Wireless charging is slower than the wired charging method
• Has power loss possibilities
• Features between short distance
• Not all devices facilitate wireless charging

What Are The Features Of USB Charger PCB?

• The USB charger PCBis fully featured with MCP73832, a highly advanced charge management controlling system that is powered by MICROCHIP.
• Fully integrated with Lithium-Ion and Lithium polymer batteries
• Facilitates direct charging from a USB port, no hassles of having an extra adaptor

USB Charger

How To Control The Quality Of Charger PCB?

There are several ways of controlling your charger PCB’s quality during the manufacturing till the final production.

They are:

• IPC certification
• Expertise in Components
• Ensuring manufacturability
• Controlling the process
• During the production process, there should be frequent checks.
• Controls for assembly
• Examination and testing
• Practical functional testing

Who Are Top Charger PCB Manufacturers In China?

How do you determine a good manufacturer for manufacturing quality charger PCBs? There are several criteria you should consider while declaring a manufacturer as a top PCB manufacturer.

• They should have wide experience in the industry
• Must provide good customer services
• Can meet the deadline strictly
• Provides quality products with less cost
• The capability of meeting requirements
• Ensures the best material for the charger PCBs

These are the criteria to take place among the top manufacturer list. Considering these, you may choose PCBMay, one of the best charger PCB Manufacturers in China. We are experienced, time-concerned, efficient. We understand your demand for building quality PCBs.

Conclusion

Finally, the Charger PCB is one of the most important parts of the PCB industry. And the fact is, most digital devices will be immobile without chargers. And for sure, the demand for the charger PCB will increase day by day.

When you are looking for the best quality charger PCB as a merchant, you should consult the top PCB manufacturers like PCBMay.