UPDATE:
I have started to replace a dead battery for a friend.
So I took the old one out to see what it is.
The battery dimensions are ( 64mm X 34mm X 14mm ) if anybody is interested - nothing bigger would fit!
It is 7.4V 1650mAh.
It is comprised of two flat Lipo batteries ( Model 653465G ).
Operating temperature Charging: 0°C ~ 45°C Discharging: -20°C ~60°C
Charging voltage is 8.4V.
The only heat sources are two large chips in the centre.
In case anyone was interested.
2nd Update:
Recently I asserted that :
we are not clever enough to re-engineer this device!
I am about to tell you what I have done in stark contrast to that statement, just for fun and for the heck of it.
While I had the Mojo opened up, I thought I do something about the Heat management within Mojo.
So with the circuit board loose on a towel, I connect everything up to see from where the heat comes from.
While playing most of the heat comes from the two large chips in the centre (the system/input chip and the FPGA gate array)
Warning first ; Be really carefull if you open it up, specially the click-buttons as their metal caps are only held in place with a tiny tape - I almost lost mine.
These chips are stuck to the underside of the battery, so they heat up, they transfer their heat to the battery, which is not a good idea - specially that their centers are the hot spots, so they heat up two spots on one side of one of the batteries. I thought I do something about that.
Next I connected the charger, to get the thing really hot!
Incidentally, the battery remains cool as a cucumber discharging or charging, so none of the heat is due to the batteries.
While charging, the circuit components on the underside of the board near the charging socket get really hot! enough to burn your finger if you keep it on it more than a few seconds. These components are sitting in an airgap (about 1-3 mm) above the bottom shell. They were next on my list.
The cluster of components on the left and centre can get really hot while charging.
Also the underside of the board where the large hot chips from otherside sit, also get hot - next item on the list.
So I carefully located these hot sections, and stuck 1.5mm and 2.5mm heat conducting pads on the bottom shell. these pads are widely used for cooling in computer systems.
This would thermally bond the hot components to the bottom shell, fairly easy.
To take the heat from the two large chips on the top away from the battery and to the shell to dissipate out, needed more effort.
So I cut a strip of pure copper sheet (17mm X 100mm X 0.5mm thick) and bent it into this shape.
It is so shaped so it would touch the tops of the chips, but avoid anything else on the circuit, the end wings have thin thermal pads attached to them, because ultimately they would be touching the inside of the top shell to pass the heat on. The two black pieces of sponge would press the copper to the chips to make a good contact.
Thermal pads are attached to the chips (0.5mm thick), and the copper heatsink is inserted on the top shell.
Lastly, a tiny amount of heatsink compound is applied to the top shell contact areas with the bottom shell, and the shells are brought together gently.
The foam inserts on the strip cause the shells to sit apart a few mm's - as I tighten the screws gently and in sequence, the shell would close up, squeezing a little paste out. no worries, it cleans up easily with white spirit and tissue paper.
The strip of copper is now sitting with a small airgap to the battery, hopefully it is cooling the chips and conducting the heat to the outer shells.
So what did it achieve?
- Mojo is a few grams heavier, not by much, but you can tell!
- Within a minute of switching on, the entire case starts to get warm, much faster than before, it may even feel like it is warming more, but it is not.
- Charging and listening at the same time, causes the case to warm up really quickly, I take this as a good sign. It means the heat is getting out quickly so it can dissipate faster, causing the final temperature equilibrium to be a few degrees lower.
Provided you don't use a case, as it would nullify all this effort.
- Wonderfully the
initial fizzing noise while charging is gone! I assume the thermal pads stop the buzzing components from vibrating. Mojo just goes into charge mode without making any noise.
- The entire shell is at same temperature, no hot spots.
- As I write this it has been playing for 3 hours straight, it is just warm to touch - Just!
- I believe the battery lasts a little longer, but I have not actually tested this.
Well I had fun doing it.
BTW - this is my DIY interconnect from my phone to Mojo.
It is about 750mm long, has a tiny USB hub and a MicroSD card reader soldered in the middle, two small ferrite cores at ends. The MicroSD card is 512GB, it holds my music. The phone detects both the card and Mojo through the same cable. Cable is super flexible 3mm X 2mm.