Portable power station
An LFP pack on rails in an extruded shell, with AC and battery kept apart.
- Process
- Aluminium extrusion + molded end caps
- Quantity
- 300
- Region
- US 120 V
- Environment
- Home and camping
- Image
- Concept image, not to scale
Example brief · not client workWe wrote this brief ourselves; it is not client work. The 3D model, drawings and inspection results are in production and will replace the placeholders below.
The request, as a client would send it
We're designing a 1.3 kWh LFP power station for home backup and camping in the US; 300 units for a first crowdfunding batch. Battery: a 4S pack of EVE LF105 prismatic cells (each 130.3 x 36.35 x 200.5 mm, about 2 kg) with the BMS board on top; the pack envelope is about 175 x 140 x 215 mm including busbars. We want it to slide into an extruded aluminium shell on rails, so it can be serviced. Inverter: a 1200 W board, 200 x 120 x 45 mm with a finned heatsink, cooled by a 60 mm fan, air in on one side and out the other. Front panel: two US AC outlets, two USB-C PD ports, one 12 V car socket, a power button and a small display. Injection-molded end caps and a carry handle. Size and feel: something like the Anker SOLIX C1000, but ours is lighter and must have its own look. We plan to certify to UL 2743 later, so keep the AC outputs and the battery wiring apart and tell us what we would need to change. Our concept sketch is attached.
Attached by the client
Links in the request
- EVE LF105 LFP cell (opens in a new tab)130.3 x 36.35 x 200.5 mm, 1980 g
- Anker SOLIX C1000 (size reference) (opens in a new tab)37.6 x 20.5 x 26.7 cm, 12.9 kg; do not copy the look
- UL 2743 Portable Power Packs (opens in a new tab)standard the client plans to certify to
Product names are their owners' trademarks and are used only to describe size or parts.
Highlighted numbers came with the request; they are the values we would design to.
What we considered
| No. | Consideration | How it is checked |
|---|---|---|
| 01 | One extrusion does three jobs The shell profile carries the pack rails, screw channels for the end caps, and the outer skin. | Profile cavities and rail fit against the pack envelope. |
| 02 | The inverter gets its own air Intake, heatsink, fan and exhaust line up in a path the battery doesn't block. | Clear path from intake to exhaust; vent openings sized. |
| 03 | Real plugs fit the front panel Room in front of each outlet for a US plug body and a USB-C plug, side by side. | Clear zones in front of each port at the same time. |
| 04 | AC and battery wiring kept apart AC output wiring and the battery zone sit on opposite sides of a barrier, with the reason recorded for the UL 2743 review. | Zones and barrier present; distances listed. |
The question we would ask you
Folding handle or fixed handle?
A folding handle needs pivots in the end caps and a recess in the top; a fixed one changes the stacking height and the extrusion length.
What we do not claim
- UL 2743 or any certification
- Capacity, output or thermal performance
- Thermal-runaway safety
CAD, drawings and inspection
Model, drawings, parts list and inspection report
The 3D model, dimensioned drawings, parts list, and the first-try and final inspection results will appear here after the first build. First-try failures stay visible.