JUGEE battery teardown full size video.

[Music] traditionally for rechargeable double-a cells you'd have used nickel metal hydride or in the past nickel cadmium technology and they're they're fine they've got good capacity but they have that slight downside of producing a lower voltage than alkaline batteries so if you've got an application that uses our claimed batteries and it requires that 1.5 volts then a nickel metal hydride cell even a good-quality one like the N on it will quickly drop from 105 down to one point two and it will consistently hold that one point two to the end of the charge but some applications just require that little bit of extra pep particularly camera flashes so I'm these batteries these jugee batteries is it jugee or juggy I'm not really sure but these are these are good quality by the way this charger is dedicated to these batteries and these are for the theme-based batteries and they weren't cheap there were $30 30 American dollars to buy the set batteries but they do seem to be very good quality now if I measure the voltage of this one it's gonna give me 1.5 volt could sell 1.5 volt and the interesting about these is they'll hold that for they're almost the full discharge cycle but to allow equipment to detect the battery's gone you know battery's running down at the end when they approach a certain voltage level in the lithium battery they will deliberately cut the output voltage down a little bit to actually trigger a low battery warnings and have equipment shut down instead of just cutting the power off completely so they come with a dedicated charger that has powered in this instance by a USBC connector and it's interesting it says 5 volts at 3 amps you plug it in a little green light lights and if you look at the end of the batteries you'll see that the ones on the left you can actually see what they're all actually hold on if I tilt rotate this round these ones are very low so that's positive why they're just a little bit dimmer but these ones are pretty much fully charged but once they've been topped up fully these lights at the end will go out it's quite hard they've actually just got i guessing it's down to the size of the circuit board in the end but they've just basic at 4 little dots of light round that I would say disk weight initially when you see it it's not really glaringly obvious it's best view in a sort of darkroom that you can see those little dots the green light I wondered if that showed you when they were charged but in reality the purpose of that is to show you when somebody's stuck in a non rechargeable cell because this thing let me get the meter again let's put it up to a higher voltage like 20 volts a bit across the output of this charger and it's pretty out I thought well let's get the right way around but it does really matter it should the five volts so this thing is pretty much cruising at a street USB supply but there is a little bit of circuiting there we shall explore now take that two bits as well and if you put in a prized eneloop cell obviously that's not going to be great but when you put it in it immediately turns red it shows that perhaps a high current was drawn or the voltage shot up too high and it immediately shuts off it's basically just a warning light but what is inside these cells that is the question in these other ones like this is a nickel metal hydride cell but it's got a little micro USB charging port but the whole black here there is pretty much the electronic circuitry with this one it looks a lot smaller this was sent by air Kim sleep well particular look at these some other time but right now let us open one of these cells I've tested it for capacity and it was very impressive the my little clock tester thing came in at well over 2 and PI R it came in at almost about 2.5 amp hour which is good very good particularly given the ease of recharging these because it's very decisive okay what am I seeing here I'm seeing the metal house am seeing little circuit board on the end it's all kind of welded together is this actually going to come out at all this could be quite destructive right say what I'm going to get the circuit board out and then explore it take some pictures hopefully it won't be destroyed in the process but I think it probably will I can see little recesses for the surface mount ayr LEDs here let me just show you this let me just err in fact hold on that's a focus to here and put this here and then just zoom down on that so we get the metal Pip at the end there that has been used to supply the 5 volts and and also the 1.5 also and then we've got the little indicator LEDs around this aid officer these are all holes that could be probe holes that's interesting or just please I don't think I played it through or don't think they are test pad holes okay right tell you what I am going to go and I'm gonna take one of these two bits and then we'll explore it you guys want me to take it to right now don't you in case it actually blows up let's do that let's there get a pair of pliers this is a good idea no there's my explosion containment pie dish and it makes Fatimid pie dish is nowhere to be seen the exploit containment pie dish is now in chart just in case I have a little incident okay this is there's not much to prise off here this is not you know no matter what I do it's going to actually potentially short this out isn't it I think this is possibly spot welded onto the end of this I'm not sure hmm this is a bit worrying it's actually saved it says it's got a number doesn't actually tell you much information about it okay I think I'm gonna have to pause for this and put it in vases and things that are and what you guys want to see see this yeah this is really well sealed shut that's annoying that is so annoying can i prize that little cap off oh this is not it's not designed to pertain to bits but this isn't really surprising is it what if I nibble there's nothing you can't get your you can't get anything it's so optimized it is impenetrable and if I try and lever it from the side its potentially gonna short over lithium cell but you guys want and let me see if I can just price that down you're like that things you shouldn't do is lithium batteries this is just solid this is going to take a while I don't think this is gonna be easily penetrable at all it is so solidly put together how annoying but good in a way yeah I'm not sure the best way to proceed with this this is a bit this is a bit squirming even by my standards because it is so tightly packed together I don't even know if there's some circuitry under that pip it wouldn't surprise me if there was to actually try and maximize the available space this these are these electricians say cutters are just not going to get in at all I'm gonna have to dremel into that or something like that right one moment I'm gonna try and get this open by maybe dribbling the site a bit and then trying to prise this metal case opening at the circuit board up right one moment please and no one to do that sort of things you shouldn't do with lithium batteries let's [Music] by strong [Music] [Music] [Music] [Music] [Music] [Music] [Music] let's see if I can fill this out of it off to reveal the circuit board is a circuit board still locked into position yes it's it's not budging that is most annoying last aspect I've groaned off most of the outer rim it's the battery getting hotter as that just heat from this abrasion I think is heat from the abrasion but you just never know it lithium cells things I've noted already the two little they're gold-plated pads are actually an indication that this looks as as parted I hate to say are an indication of head the voltages one of them indicates the internal boosted voltage and the other indicates the lithium cell voltage sigan warm I don't think it's getting warm but you just never know you just never know that is the circuit board and prising that that doesn't look like it may be potted in oh they're being very secretive about their circuitry they do not want us opening up I'm not really surprised there is there we go Rachel we're in let's carefully cut the positive connection without bridging it to the positive the negative okay so what we have here is a lithium cell in here that's been rolled up and stuffed and inside it looks there's also fairly Sudan unless they've actually is that sealed is that one of the serve mass Porter to try and open it further I'm not getting the leaky lithium smell this might just be a standard two terminal lithium cell that's been stuffed down then say to that but no this is what we're looking for here so there's a tab this is rezoned and they have gone to great lengths to keep us out unfilled ah Rachel one moment I'm going to see if I can get into this a bit more and take some pictures of it well that took an unusually long time when - the fact that it is so deeply potted in an extremely hard glass like resin that was extremely heat resistant and would not dissolve an acetone or anything else I tried it was extremely frustrating let me give you a description of this unit then so this is looking from the back of that electronic module and here's the resin it's all potted in one side the also turned out to be red another resident other side and there is the circuit board material around the edge slightly chaffed from my dremel this is the lithium battery attachment point couple of spot welds onto this metal tab if I flip this over I can show you the construction of it so here's the circuit board disk of Zuckerberg material and there is a little pip raised it's not actually pressed right onto the circuit board it's actually raised up with a couple of tabs coming down and there is circuitry under here and that's the bit that the positive connection of the lithium battery will get spot welded onto on the other side we the methyl dome on the circuit board is quite clean in relative terms other side but it's got this metal dome with the pepper the positive before the battery but this is all all potted in resin inside it was very very hard to disassemble it was quite destructive its assembly as such that the circuit board is then kind of a dresner's carrot glued in here maybe it's actually all potted in in here with just that little bit sticking out and the lithium battery is got a metal a stainless steel cylinder here and the lithium battery is a typical it's like the inside of say for instance well let's just show you an ordinary battery you know the inside of these batteries tends to have that there old construction but if you get the the standard lithium battery and the foil pack you get the round version of these that's pretty much what it is and sometimes you find their own batteries just have a little foil pouch inside almost like the ones used in electronic dip devices and so it's got a fairly high capacity one ruled in and by it's rolled up and it was physically just rammed into that there I couldn't get out hurtis currently being charged to test its capacity so you end up that little metal cop on top that is presumably glued or spot well didn't the boss of that has a little extra layer of captain tape on drip and I'm guessing then that the lithium battery is spot welded maybe it's a friction fit that the tab off the back of the lithium cell when it's slid into that closed end troop makes a connection to save the trip but the other side of it there is just simply the usual insulating ring which is this placed over the top of the circuit board like this partly to hide all the connections things and then the heat shrink comes out the side and if shrunk over it it's very compact its up it's a very narrow thing most of these batteries is lithium cell let me just dare get one out let you try and get one out there we go yeah okay so the electronic circuitry see the text here the electronic circuitry just stops there oh that's that little module most of this is solid lithium battery inside it's a bit of a miracle of Engineering if we look from the battery side underneath this there is an inductor it's a little box in dr. ipser a fully enclosed ceramic case they have ceramic well farad Kirsten dr. not much left to show I'll show you the the shattered remnants afterwards there's some plated through holes from that match from the output from the inductor and then this metal tab has unusually they're not just straight across that's been shaped a FET it's this raised metal tab soldiers down here and it's sort of down here and there's a plated through hole going through to the other side and a little gold contact pad that tells you you can measure you can probe from the other side the circuit board to actually detect the lithium cell voltage and also there's another point at the other side that detects the bucked voltage there are also one two three four LEDs pointing down the way so they actually shine through from the back of the circuit board and basically they make just the front of it just four little dots of light round I would say ders it's basically they were just trying to squeeze LEDs and really coud to actually show that lighting there is a Schottky diode this is all important and as much of other components under here then these two little tabs here are for securing the other side on this metal plate from the other side of the bit the positive tip if we go to the other side and so this is the back of that circuit board here is the metal pip from the front that I've just shown that says skip on what's that set with the metal tab folded up revealing us matter of small components underneath but the main thing of note in this side is there is an inductor then dr. is actually under here and there is that diode there a Schottky diode the other side you can see this as a metal dish but it is filled with resin and still has the chip in it because unfortunately when I prized it off it everything came off there wasn't any way to get that out the reason I did try burning the resin it just did crumble to degree but it was like flames and black and smoke before it was doing that so connection coming through is going to this little it was that package called its 16-pin qf n package i wonder if this as a standard ship that has been repurposed by clever means or if it's custom it's got quite a few extra components i wouldn't have expected for if it was a custom chip I respect I think to have been done inside so wonder if it's a a chip this design for this application but maybe different voltages a few capacitors came off you can see a capacitor came off here and here and here I would like to take a little closer look at that capacitor but it pinged somewhere so I couldn't but that came well that is actually no I'm talking crap that one is actually in there but it pinged afterwards so these capacitors I'm guessing this big one is probably the main output capacitor let's say tick on it step further down so that's a potted resin that that tells you absolutely nothing more this is more interesting so this is the battery side of again there's the inductor folded out so there was the inductor that is used to drop that voltage and it's folded out but you can see the windings wrap around it this is tiny keep in mind this is absolutely my Newt so err it was quite hard initially to even see it I was scraping and we're just looking for signs of windings the diode is an SM or 3/4 oh there's the LEDs round the edge and I'm guessing that may just be the remnants of the maybe that's why those words didn't tie up because all that's left is the phosphor layer in the front and I did check these I was hoping to get a couple one I've put my probe against one dat lit but the others didn't but I was hoping they were going to be in parallel that was gonna prove that was just maybe one resistor but in reality at all they're all knackered just because there it was a destructive disassembly right let us bring in the notepad and see if we can extrapolate from what we've seen here how this works so I'm gonna guess that that might be accustomed ship let's go with a custom chip approach and we'll call it because there's no number and because it is actually still potted in in resin here and because I can't get the resin off the front without potentially it seems the same to save a resin as a package without damaging the package itself let's just call it at jugee which is the batteries 90 name okay I'll put a question mark in it it may be a standard power trip but I don't really know the negative is common throughout the whole circuit so this is the negative let's call it in the zero volts negative and that is the metal case of the battery pack everything is can it referenced that so I would guess that we've got the lithium cell connected to that and it will pretty much be going straight into that I could be wrong there is an element are there it's in the very close facility to the inductor but you're not going to have them doctor just connected street to that hmm but I'm guessing there'll be a probably local decoupling capacitor Assoc of that there'll be a negative reference for the jugee 99 mystery trip the output will almost certainly be a conventional buck regulator based on a coil where you've got a capacitor I was gonna draw an electrolytic but I can't really draw an electrolytic because there wasn't one it was a high-capacity ceramic one and this will be the 1.5 volts and I'll put in brackets 1 volts because it does drop head down when it's a detecting that the lithium battery is running low there's also that Schottky diode which looks like this I shall draw is a proper Schottky diode and this is a classic buck regulator on my guess is that also be a sense going back but this might actually be much more complicated and it may have a divider resistor network so it can be used for different battery voltages but certainly in this indication that another thing that would be left here would be a resistor and the LEDs to actually show it's charging and that would only require um that would only require one two three four five pins that could have been done worse one of the all five or six pin packages so I'm not sure um why it's got 16 pins unless it is just repurposed maybe as a universal chip and certainly the support component suggests maybe it is however if the duque99 custom chip measured a voltage see above three volts here it knew that lithium battery is capable of supplying power it would provide a pulse to this and basically speaking it would switch the positive to that inductor and current would flow through them dr. and the Lord and charge that capacitor and in running through the inductor would limit the amount of current that fluid because initially a magnetic back EMF against that but it builds up a magnetic field so this is effectively going positive and that end was negative then that turns off this end then goes negative as the field collapses this was positive via this diode the flywheel diode it also then on the collapse the magnetic field also puts current into the capacitor and it would keep pulsing it like that on each cycle it would just boost the voltage up to it reached 1.5 volts if there's no Lord pulling it down it would then sense that through this line and it would shut off and it would just waited keep monitoring that line and then it's saying the voltage drop will of 1.5 volt so to provide more pulses and if there was you know if it was like you had a very heavy load and opened it was struggling to keep up it would just basically be a continuous stream of pulses to the point that you know it could have its maximum current I'm not sure this maximum current was it seemed to handle the 500 milliamps fame I did put it into a load with about that was probably her an amp and it got quite warm but that Lord may have may be getting warm as well so I would guesstimate it maybe a 1 amp capability of Oprah and when it's charging say five volts is connected to this pin and the five volts the sense pin will then detect it's charging and the current will flow either through them doctor but most likely just through a direct line and it will have a current regulator built into this chip that will regulate the froth come in to the lithium cell until it reaches its 4.2 volts and when it reaches the 4.2 volts it will then the LEDs will go out to show its charged and or stop allowing current the five volts will still be there but it just won't allow current to flow into this to charge it any further and when it detects the 5 volts has gone then it will just resume normal operation the other possibility here is maybe this is some fancy chip that does have the ability to it's designed to drive from a lithium cell it's designed to put out random voltages but it may have the facility to detect a low voltage and the fact that as it's a as it runs down as the voltage goes down when it gets don't about just above three volts this output drops that changes the sensing to drop it down to one volt and that's used to indicate to equipment that the battery's running low and it's about to cut out but it's possible that they could have used they could have done something fancy they could have used a voltage divider and sensed a feedback voltage of c of 0.6 volts and it's possible they could have skewed that they could have actually the output could have added another resistor in or something like that change it to give it a different voltage threshold it's hard to say it does seem quite a high number of pins but maybe it is just an early model but that's my guess at how it works it's very well made I think the reason was there not so much to keep people like us out but for strengths because it's I suppose it will be protecting their intellectual property as well it would keep people like me from making videos about it and sticking them on YouTube but it would also have potentially protect it from the pressure these things get because you know when you sum actually holders are really tight and you actually really have to force the batch in and that raisin would reinforce that it would give it extra strength with the metal work and stuff like that it would also seal it against water ingress it's quite rugged and let's break in this image up cause it's a good idea yeah it's good enough let's take the charger apart so I shall zoom out a little bit more for this is this going to open easily or have they applied the same jugee devious tactics to keeping us out it's chewing see I cannot slash myself in the process it's cracking this is one of these things that having spent $30 on it it's just it seems such a shame to bursting it but whatever happens I will improvise a way to charge those batteries oh this is not coming apart cleanly and easily this is why I don't work with their work with their folks the iphones would be pieces of the time i finished with them this isn't just clip together this is delude oh yeah that's that's not nice use the Force this is nothing they were screws holding it shut so there's a connector there's some circuitry on here and there's two LEDs under there there's a metal plate that was the negative and it looks as though it's going straight across to the USB input the other connection is there's a small cluster of components here capacitors maybe is there any current limiting for at one moment please I'm just going to take a closer look at this and resume okay I've drawn drawn a blank on this chip it doesn't help when the glitch such short named one nine D and there's one of these on each output and it does have a decoupling capacitor going from the positive bus here I should I should mark that as being positive positive M but it seems to be switching I'm guessing this as a current sensor and a switch it does seem to have communication back with the main control system there is a common bus running on them all there's also a sense bus which is a diode that if the outputs are shorted me guess it pulls to zero this sense bus will also detect that over in the main circuit board and will turn all these off but there is an inductor which made me wonder if it was a current regulator because there is also resistive divider with a signal going back into this chip and the rest of it is just a coupling or in this case it could be in the case of an inductor it could just be four am a local sub power supply I did stick one these batteries across a five volt supply and it drew about 500 milliamps I stopped a 5 volt supply across this well I'll do that up I actually will measure the voltage across this but anyway this say it's got these sensors and there is a bit of circuitry not an awful lot and the main one that controls the two LEDs and normally the LEDs are at green but if you if you put an aura Bashan it just it charges and it stays at green if you put a wrong battery on it instantly goes red and it shuts power off to all of them I'll show you that and the only way to reset it is to at pillar so I get the feeling a lot of this is protection against M over a current if you put in their own tail batteries and also to stop these batteries exploding let's measure some voltages then let's get these over with and I shall put one even know I put it into this light this is one that was testing at 1 amp and after a while the light went blinked out and then came on again and it was a hot at the end I get the feeling that that's another reason for that resin it's probably for foul coupling but it's also using the metal rod to try and dissipate some of that heat when you're charging it and gets hot and when you're discharging then gets hot with the switching control that the buck regulator but I don't think it's actually rated for sustained current at one amp it could be wrong let's put this one into charge and measure the voltage across that so going from the negative real to the positive the voltage is 4.8 new years up there 4.8 volt see if I stick in one of these non recharge well that is a rechargeable battery for the wrong one instinct was red and the voltage I'm measuring here is the voltage that battery 1.3 volts but the volge this one is now just this standard output voltage of about 1.5 volts of that standard battery because the Power has been shut off to all these outputs so that does suggest that those little squared chips the d1 9d ones possibly are just switches and this 7:03 3 not sure latch maybe it's our proprietary trip maybe they're all proprietary chips because there is a patent on what they called mill bat technology now I could demonstrate this just by stick among these batteries across how can I do this let's bring in a meter let's use this meter so I shall set this to the 20 ampere setting I shall turn it round to DC 20 amps and I'll bring in the bench power supply which I've set for 5 volts and I show hook the positive 2 here and this is a negative from the bench supply going on to the negative of that battery let's bring the meter in let's measure the current just double-check and when I put this on here this is let's turn the post plan on that that would work a lot better aim and I apply the positive and it draws between 400 and 500 milliamps and it depends on the state of charge of battery and also how warm it is initially starts about 500 but then Till's off I wonder if I wonder if part of the suction here is no cuz they're those resistors are definitely detecting voltage and not current I think it's all just safety circuitry I don't think it's trying to currently limit the current out although it could technically limit the current arrows butthole but I don't see a cent resistor change the meter lead back so we don't stick across something set two amps and turn around or more useful setting as well but in summary the juggy or juji or I don't know what you call them they're very well designed the very rugged it's like they look like they take a lot of effort to actually build you know I've just thought something is that other battery charge yet just give me a second and I'll go and see if it's actually finished charging the lithium cell it's not finished charging but I shall open this up and just show you what that's like inside this canister and I'll zoom down in this so you can see it is that is one of the cylindrical foil packed batteries but it's been wedged down in here really tight and they've literally filled up all that space that when this little end cap gets put on here their electronics really is this that tiny little slice at the top it's really really interesting it's a lot of work involved in making them inside it doesn't look like it's easily mass-produced as such particularly with the resin it's so well filled that suggests it's been vacuum potted and resin and how did they inject it they must have injected it from one say the circuit board through to other to actually be able to fill the little cavity in the other side around all the circuitry with actually flooding over onto the side this thing is just intense it just looks like it really must take a lot to actually make it if anything it looks a bit over complicated but the end result is you do get this lithium battery that can be charged at the full voltage of about three to four point two volts at 500 milliamps so it charges quite quickly and then because it's putting at 1.5 volts or last they're effectively it's using less current so it will putto a sizable runtime it's very neat I have to give this more tests I'll have to look up the specifications there is Chinese or Japanese writing on it it says 2000 million 3000 milliwatt over two thousand nine hundred milli whatever so is that two thousand milliamp cell inside I don't know or is it the equivalent I think it's more the equivalent of two thousand milliamp power battery but my test system did and you can't really see that my test system did sure that hair it certainly has more than two amp power capacity it seemed to be unusually high capacity that ran for ages but there we go interesting things quite expensive but ultimately if you need you know a high-capacity rechargeable cell that could say 1.5 volts all the time then it certainly does the job

Channel: bigclivedotcom

Views: 173,662

Keywords: jugee, rechargeable, lithium, cell, battery, AA, 1.5v, teardown

Id: dakm4ra8Xv0

Length: 36min 37sec (2197 seconds)

Published: Wed Jul 29 2020