TP5100-Charging Module

TP5100 Micro Li-Ion Battery Charging Module (V2 — Micro Redesign)

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An ultra-compact, high-efficiency lithium-ion battery charging module based on the TP5100 synchronous buck switching controller, designed in KiCad with full schematic, layer plots, and 3D photorealistic visualization.

[!NOTE] Project Context (V2 Micro Redesign)
This board represents the Micro Module redesign (August 2026) of the author's original TP5100 charging board. It achieves an aggressive 66% reduction in surface area (down to just 20.0 mm × 16.5 mm) compared to the original TP5100 1S Learning Design (V1), while adding selectable 1S (4.2V) or 2S (8.4V) cell configuration, rounded corner edge cuts, and high-density double-sided SMD placement.

3D Renders

Top View	Bottom View

Evolution & Version Comparison

Features

• Ultra-Compact Micro Form Factor:
  • Footprint reduced to only 20.0 mm × 16.5 mm with rounded corners, suitable for embedding inside tight handheld enclosures, RC models, and modular battery packs.
• Selectable 1S / 2S Charging:
  • Configurable for 1-cell (4.2V) or 2-cell series (8.4V) lithium-ion / lithium-polymer chemistry via onboard solder jumper.
• Synchronous Buck Switching Architecture:
  • High switching frequency (~400 kHz) allows use of small surface-mount power inductors while maintaining cool operation at up to 2A charge current.
  • Multi-stage Constant Current (CC) / Constant Voltage (CV) charging with trickle pre-charging for over-discharged cells.
• Wide Input Supply Range:
  • 5V to 18V DC input capability, compatible with USB supplies, 12V DC power adapters, and small solar panels.
• Dual Status Indication & Telemetry:
  • Onboard dual LED indicators for active charging state and charge completion / battery standby.
• Comprehensive Visual Documentation:
  • Multi-layer vector assembly plots (pcb.pdf, TP5100_Charging_Module-F_Cu.pdf, TP5100_Charging_Module-B_Cu.pdf).
  • High-resolution schematic diagrams (Schematic.pdf, Schematic.png).
  • Front and back photorealistic 3D board renders (Front.png, Back.png).

Hardware Specification

Project Structure

TP5100-Charging-Module/
├── Front.png                         # 3D PCB top surface render
├── Back.png                          # 3D PCB bottom surface render
├── Schematic.pdf                     # High-resolution vector schematic
├── Schematic.png                     # Raster schematic preview
├── pcb.pdf                           # Complete board outline and trace plots
├── TP5100_Charging_Module.kicad_sch  # KiCad schematic design file
├── TP5100_Charging_Module.kicad_pcb  # KiCad PCB board layout
├── TP5100_Charging_Module.kicad_pro  # KiCad project file
├── TP5100_Charging_Module-F_Cu.pdf   # Front copper layer plot
├── TP5100_Charging_Module-B_Cu.pdf   # Back copper layer plot
├── .gitignore                        # Git ignore patterns
└── README.md                         # Project documentation

License

Open hardware design. All rights reserved by Kausthubh Viswanath.