How to replace 3 x AAA battery pack with Lithium

Hello!

I’ve acquired several headlamps that have 20 LEDs in a band that stretches across your forehead. Loving the great after-dark visibility!

However, I’d like to replace the 3 x AAA battery pack (includes a pwr switch) with a Lithium pack that could be recharged in-place (would need to add USB or other connector to the plastic battery box for charging, or replace with something else low-profile).

I’ve been poking around looking for a good battery pack and charger ready-to-go, but I’m not finding anything (could be I’m being blind, of course!). Wondering if anyone here either knows of a solution already available, or if not, components I could use from SparkFun to build what I need.

Many thanks!

Deb

(Networking Engineer, good solderer, basic electronics knowledge, nowhere near EE-land!)

I’d look into simply using an off-the-shelf USB charger bank.

They’re nominally 5 volts out which isn’t too far off from the 3x AAA series voltage and will have all the recharging provisions built in.

Thanks for the reply, Brow.

  • I wasn’t sure if sending 5V rather than ~4.5 from 3 x AAAs would cause an issue with the LEDs (short- or long-term). Wasn’t sure if I’d need to add something to drop the voltage. If that .5V difference will not be a problem, that is good to know…thanks.

  • Ideally I’d use a battery that’s about the same footprint as 3 x AAAs side-by-side, so it could be carried in the same position / holder as the AAAs. Hadn’t found one so far…but I was looking for ~4.5V. if 5V is safe, then that will expand my search options, obviously.

  • Also ideally, the charging circuitry would be inside the box with the battery, so any USB connection could be used for charging. Not sure if there’s a small foot-print Sparkfun component ready-to-go to do this. If not, I’m 100% up to build one.

Thanks,

Deb

I can’t promise that the extra half volt will work and without consequence, just that a USB power bank is where I’d start. A lot of battery powered devices (like your headlamp, probably) are necessarily flexible with regard to input voltage. If you wish to build some packs and can’t find anything suitable [from Sparkfun, here’s a vendor with a large assortment of lithium-polymer cells: [Powerstream LiPo.

I think you’ll have a difficult time finding and assembling the cells & charging circuit to be the same size as a three AAA holder while maintaining satisfactory performance. In other words, when it’s all said and done, you may wish you’d simply used three NiMH AAAs to begin with.](Rechargeable lithium polymer battery catalog from PowerStream, lithium polymer batteries and cells in stock with specifications)](https://www.sparkfun.com/categories/54)