Modern batteries for Sony Discman players
The author purchased and repaired two vintage Sony Discman players - D9 and D15. The batteries were not attached to both (one “completely dead” sample for the photo shoot was still found), and listening to it only on the PSU is not interesting. I had to make new ones - lithium-polymer, in a 3D-printed case, with a built-in charge controller and a Micro USB connector.
And it works:
Actually the batteries are taken from 2003 iPod Video players. Initially, they had a capacity of 850 mAh, while Sony batteries had a capacity of 550 mAh. Even with a worn-out iPod battery, you can listen to three 40-minute albums at low or medium volume. That is, as much as on the original Sony battery when it was new.
In addition to the battery from the iPod, the design will require two 3D-printed parts - the case ( source ) and the cover ( source ), which must be printed with PLA at a layer height of 0.2 mm, a board with contact pads ( source ), ordered in JLCPCB , a thickness of 0.8 mm, the coverage of the pads is ENIG, but HASL is also possible, as well as a standard LiPo charge controller with a Micro USB input.
This is followed by a simple assembly, and the first step to the aforementioned usdglander “Theseus ship” is taken: