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95-watt Laptop PSU Adaptor

12 V in, 19 V at 5 A out!

95-watt Laptop PSU Adaptor
Anyone who regularly uses a laptop or notebook computer while they are away from the home or office knows that sooner or later they will need to plug into a mains outlet to top up the batteries. The car cigarette lighter socket in the car is also an electrical outlet but it can only supply 12 V. That’s no problem for the Laptop PSU Adaptor described here; it can deliver ample voltage and current for today’s portable computers from a car battery. It’s also simple to build and has excellent efficiency. Modellers will also be interested in this design to recharge their battery packs in the field.
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Gerber file

CAM/CAD data for the PCB referred to in this article is available as a Gerber file. Elektor Members can exclusively download these files for free as part of their Membership. Gerber files allow a PCB to be produced on an appropriate device available locally, or through an online PCB manufacturing service. Elektor recommends its business partner Eurocircuits as the company of choice for its own prototypes and volume production in selected cases.

R1 = 5k6
R2 = 51k (51k1)
R3 = 9k1 (9k?09)
R4 = 1M
R5 = 4k7
R6,R8 = 15k
R7 = 27k
R9,R10 = 6,8
R11 = 10k
R12 = 100
P1 = 5k preset
C1-C4 = 3300µF 16V, radial, low ESR, diam. 12.5 mm, e.g. Panasonic EEUFC1C332 (Farnell)
C5,C10 = 1µF MKT, lead pitch 5mm or 7.5mm (larger version preferred)
C12 = 1µF MKT, lead pitch 5 mm
C6-C9 = 2200µF 25V radial, low ESR, diam. 12.5mm, e.g., EEUFC1E222 (Farnell)
C11 = 22nF, lead pitch 5mm
C13 = 2nF2, lead pitch 5mm
C14,C15 = 100nF ceramic, lead pitch 5mm
C16 = 10µF 63V radial
L1 = 56µH, 21 turns 10 x 0.5 mm ECW, parallel
1 x ETD 29 coil forner, vertical mounting, Epcos B66359X1014T1 (Schuricht # 331622)
2 x ETD 29 clamp, Epcos B66359-A2000 (Schuricht # 333862)
2 x ETD 29 core half, material # N67, air gap 0.5mm, Epcos B66358-G500-X167 (Schuricht # 333840)
D1 = MBR1645 (International Rectifier) (e.g. Reichelt, Segor)
T1 = IRL2505 (International Rectifier) TO-220AB case, (e.g., RS Components)
T2 = BD139
T3 = BD140
IC1 = UC3843N (Texas Instruments) (e.g. Reichelt, Segor)
K1-K4 = 2-way spade terminal, vertical, PCB mount
F1 = fuse, 10A/T (slow) 6.3 x 32 mm (¼ x 1¼ inch) + 2 fuse holders for 6.3 mm diameter and PCB mounting
2 x heatsink type SK104-STC (or STS) TO220 38.1mm, 11K/W (Fischer Electronic) Isolating washers for T1 and D1 (TO-220AB) + isolating bushes
PCB, order code 050039-1
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