Active Cooled USB-C Charger Enclosure for 2S–4S Li-ion Modules (with 40mm Fan Support)

by jacopotofani

This upgraded enclosure is designed for USB-C charging modules for lithium-ion batteries ranging from 2S to 4S, with current ratings between 1A and 4A. It has been tested with this AliExpress module: 👉 https://it.aliexpress.com/item/1005007556867979.html (Similar modules from other brands should have the same dimensions.) 🔧 Main features: - Dedicated space for a 40mm 5V cooling fan - Enlarged interior for better airflow and heat dissipation - Visible window for charging LED - Cable lock system with dedicated clip and slot - Space for a flat 2-wire power cable - 4 mounting holes for M2.5 heat-set inserts (Ø4×4mm) - Fits flat head M2.5 screws (7–10 mm recommended) 🛠️ Hardware required: - 4x M2.5 heat-set inserts - 10x M2.5 screws (4 for the enclosure, 4 for the fan, 2 for lock the module in place) - 4x M2.5 nuts (for securing the fan) - 2x small self-tapping screws (for securing the cable clip) If inserts or screws aren’t available, the two halves can still be glued—but this will make future access harder. ⚠️ Warning: Always monitor while charging. Never leave the charger unattended. Ensure the module does not overheat. Lithium batteries can be dangerous if mishandled. This enclosure helps, but proper precautions and supervision are essential.