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[Chameo]

Hi,
I've got my Pleo a few days ago and it's really fun to play with her. But unfortunately a battery life of 2 hours is quite short. So I'd like to built additional battery packs myself. I've already constructed a 3D model of the case to print with my 3D printer (I will publish it on thingiverse when it is finished and tested).

More details...

The question is what to put inside this case? Rechargeble AA cells are difficult to connect (no, I don't like this DIY AA holder mod), rechargeble AA cells with solder connectors are quite expensive (compared to the ones without), AA shaped 14500 LiIon cells are even more expensive. The best solution would be a set of 4 LiPo cells, but I can't find cells with dimensions that would fit into the case.
Has anyone opened up an original Pleo lithium battery and knows what's inside? Or does anyone know a good solution to my problem?

Thanks, Chameo

[mweed]

Another member, pintokitkat, has some battery case parts on thingiverse he did a while back: http://www.thingiverse.com/thing:31721
It doesn't have side walls like your model, but it might be of some help to you.

The insides of the original green NiMH pleo battery is just simply six 1.2v AA size rechargeable batteries with a thermistor.  I believe it's either a 10kΩ or 15kΩ (I've seen posts stating both sizes).
The two topics you may have already seen on this issue in the Pleo Hardware board are listed below, but they're both for the NiMH:
TUTORIAL: How to make a Pleo battery pack for a third the cost of a real one
TUTORIAL: HOW TO REFURBISH A BATTERY PACK.

I have not seen anything on a disassembled white or brown LiPo, so not much help on what's inside them, other than they have the same dimensions, same three contacts, so presumably  have similar insides.  RedWoodsMama is our "in-house" battery sales for the white LiPo.  She may have some dead batteries she's seen inside.

The white LiPo batteries were never officially made or sold by Ugobe or Innvo Labs, but by the Taiwan distributor.   As such, the classic pleo (Ugobe, Innvo 2009, and Merlin Edition) wasn't really designed with the LiPo battery in mind, so there's no LiPo related circuitry in the classic pleo.  The RB, however, was designed for the LiPo battery and may have circuitry or programming designed to protect/manage the LiPo batteries.  Most of the circuitry is in the charger for both the white and brown LiPo batteries, so I don't think there's anything else in the battery itself other than the cells and the thermistor.

I know pleos are pretty picky about voltage, and seem to want to shut down as soon as the voltage starts to drop even when there is still power available.

Also, whe you design your model, please note that the rectangular pin on the bottom faces a different direction depending on if the battery is for a classic style pleo or an RB.  So if you come up with a good solution, there will probably be other members who would be interested in your model for both types of pleos.

[Chameo]

@mweed
Thanks for your reply. I know pintokitkats case and I've already printed it, but I'm not very happy with it. That's the reason I did one myself. I've measured the thermistor on my lithium pack and it seems to be a 10k type.

Of course I've read all the threads about battery packs but didn't find a solution that satisfies me completely.

Pleo rb seems to have a recognition of the battery type based on that rectangular pin. There's a L-shaped cut in the battery compartement which allows to use both battery types. I guess the switch off voltage is determined by that, although 6V should be a good value for both types. My case construction will be available in both versions.

I'm still looking for some cheap LiPo cells (maybe out of camcorder batteries) which will fit into the case. But maybe I'll try a 6 AA rechargeble battery version first because the batteries are much more easy to get.