DIY Recycled Soda Can Battery Pack

Welcome to this exciting Instructables guide where we'll show you how to transform everyday items into a functional battery pack! By repurposing a soda can, springs from a pen, and an old pair of earbuds, you can create a portable power source for your small electronic devices. This DIY project not only helps you reduce waste but also demonstrates the creative potential of upcycling. So, gather your materials and let's get started on this fun and eco-friendly adventure!

Note: Before we begin, please exercise caution and ensure proper safety measures are followed when working with batteries and electrical components.

1. Empty soda can (cleaned and dried)
2. Springs from a pen (2-3 springs, depending on the size)
3. Old pair of earbuds (with intact wires)
4. Small wire cutter or scissors
5. Small pliers
6. Soldering iron and solder (optional)
7. Hot glue gun and glue sticks (optional)

1. Safety goggles and gloves (for protection)
2. A well-ventilated workspace
3. 
   

A soda can is primarily made of aluminum, which is generally considered a non-conductive material. Aluminum has a thin layer of oxide on its surface, which acts as an insulator, preventing the flow of electricity. Therefore, a standard soda can itself is not conductive and cannot be directly used for electrical purposes.

However, the tab on a soda can lid is a different story. The tab is typically made of a more conductive metal, such as steel. Steel is known for its ability to conduct electricity, allowing it to serve as a conductor in various applications. The tab is attached to the can lid using a metal rivet, which also contributes to its conductivity.

The reason the tab is conductive while the rest of the can is not lies in the difference in the metal composition. The tab is specifically designed to provide a point of contact for opening the can and, incidentally, can be repurposed as a conductor in DIY projects like battery packs or simple electrical circuits.

By leveraging the conductive nature of the soda can tab, we can incorporate it into our battery pack project and use it as a connection point for electrical components, creating a pathway for the flow of electricity.

1. Ensure you have put on your safety goggles and gloves to protect yourself during the process.
2. Take the empty soda can and make sure it has been thoroughly cleaned and dried.
3. With a marker or pen, draw a clear line around the top third of the soda can lid. This line will serve as a cutting guide.
4. Carefully position a small screwdriver or sharp object, such as a craft knife, at any point along the marked line on the lid.
5. Apply gentle pressure and rotate the screwdriver or knife in a circular motion to create a small puncture hole on the marked line. Take care to keep the tool aligned vertically with the can lid.
6. Gradually increase the pressure as you continue rotating the screwdriver or knife along the circumference of the lid. This will create a cut line.
7. Slowly and carefully follow the marked line, maintaining a steady hand as you rotate the tool. The goal is to create a clean and even cut, separating the top third of the soda can lid from the rest of the can.
8. If needed, you can make multiple puncture holes along the marked line to guide your cutting process more accurately.
9. Once you have completed the cut, inspect the edge to ensure it is smooth and even. Use a wire cutter or scissors to trim any sharp or uneven areas, creating a safe surface.

By following these steps, you have successfully cut off the top third of the soda can lid. This allows you to proceed with the next stages of your DIY battery pack project

After cutting off the lid of a soda can as described earlier, the next step involves using pliers to remove the tab from the lid. Pliers provide a firm grip and make it easier to detach the tab without damaging it.

1. Take the pliers and position the tips around the base of the tab, where it is attached to the lid.
2. Apply gentle pressure and slowly wiggle the pliers back and forth to loosen the tab from the lid. Take care not to apply excessive force that could deform or break the tab.
3. Once the tab is loosened, continue gripping it with the pliers and gently pull it away from the lid until it separates completely.

By removing the tab from the lid, we create a standalone conductive component that can be incorporated into our battery pack project.

Now, to ensure safety and prevent any sharp edges from causing harm, we will proceed to crease the edges of the lid inward using the pliers.

1. Position the edge of the lid between the jaws of the pliers, closer to the cut edge.
2. Apply moderate pressure and carefully bend the metal inward, creating a crease along the entire circumference of the lid. This process helps fold the sharp edges inward, reducing the risk of accidental cuts or injuries.
3. Repeat this creasing process multiple times, gradually working your way around the lid until the edges are securely folded inward.

By creasing the lid edges, we create a safer and more user-friendly surface, ensuring that there are no sharp parts that could potentially cause harm during handling or assembly.

Remember to exercise caution and take your time while using the pliers to remove the tab and crease the lid. This will help ensure that you achieve a clean, well-prepared component for your DIY battery pack project.

1. Select a pen that has a retractable mechanism and a spring inside. Ensure that the pen is no longer in use and has no ink remaining.
2. Hold the pen firmly with one hand while keeping a secure grip on the barrel.
3. With your other hand, locate the end of the pen where the retractable mechanism is situated. This is typically the opposite end from the pen tip.
4. Gently apply pressure to the end of the pen and start retracting the mechanism by clicking or twisting, depending on the design of the pen.
5. As you retract the mechanism, you will notice the spring becoming visible between the barrel and the retracted mechanism. Continue retracting until the spring is fully exposed.
6. Once the spring is visible, carefully grasp it with your fingers or use a pair of pliers to grip it near one end.
7. While maintaining a firm grip on the spring, gently pull it out of the pen barrel, taking care not to damage the spring or the pen.
8. If the spring does not come out easily, you may need to wiggle it slightly or use the pliers to exert gentle pulling force.
9. Once the spring is removed, inspect it to ensure that it is intact and free from any damage.

1. Grab a pair of pliers, ensuring they are clean and in good working condition.
2. Take the soda can tab that you previously removed from the lid and hold it securely with one hand.
3. With the other hand, hold the pliers and position the jaws around the base of the tab, where it is attached to the main curved portion.
4. Apply gentle pressure and carefully bend the tab at a 90-degree angle, away from the main curved portion of the tab. This creates a perpendicular section that will serve as a contact point in your battery pack.
5. While bending, ensure that you do not apply excessive force that could cause the tab to snap or become deformed. Take your time and maintain control over the bending process.
6. Once the tab has been bent at a 90-degree angle, inspect it to ensure that the bend is clean and secure. If needed, you can use the pliers to make any minor adjustments or straighten any uneven portions.

By bending the soda can tab at a 90-degree angle, you have created a distinct contact point that can be utilized for electrical connections in your battery pack. This perpendicular section provides a convenient surface for attaching wires or other components, allowing for the flow of electricity.

1. Use your pliers to stretch the spring on both ends
2. Once you have the end stretched, you can screw it onto each side of the tab
3. Once it is in place on both sides you can either use hot glue or what I recommend is solder for a direct connection and better conductivity

For my wires I am using an old pair of headphones you can use any wire you have

1. Take your wire and cut it
2. Strip your wires to expose about 1-2 centimeters

1. Ensure you have a soldering iron, solder, and the wires you want to connect to the soda can tab. Make sure your soldering iron is heated up and ready for use in a well-ventilated area.
2. Take the soda can tab with the 90-degree bend and place it on a heat-resistant surface, such as a ceramic tile or metal plate.
3. Prepare the wires by stripping a small portion of insulation from the ends, typically around 1/4 to 1/2 inch (6 to 12 mm).
4. Hold the soldering iron in one hand and the solder in the other. Allow the soldering iron to reach its operating temperature.
5. With the soldering iron, gently heat the soda can tab where you want to make the connections. This helps ensure good thermal contact between the tab and the wires.
6. Once the tab is heated, quickly touch the soldering iron tip to the heated area and melt a small amount of solder onto it. This creates a small solder pool or mound on the tab.
7. While the solder is still molten, carefully place the stripped end of the positive wire onto the positive side of the tab, ensuring good contact between the wire and the solder pool. Hold it in place for a few seconds to allow the solder to solidify.
8. Once the solder has solidified and the connections are secure, gently tug on the wires to ensure they are firmly attached to the tab.
9. Allow the soldered connections to cool down before handling them. Avoid touching the soldered area until it has cooled completely.

By following these steps, you have successfully soldered the wires to the soda can tab, creating reliable electrical connections for your battery pack. Remember to exercise caution while working with a soldering iron to prevent burns or other accidents. Additionally, ensure you are working in a well-ventilated area to avoid inhaling any fumes.

Use hot glue to attach everything together

1. Hot glue each tab on opposing sides of the lid
2. Lead the wires out of the drink hole in the lid
3. Place your battery inside

You now have your own DIY upcycled portable battery pack