User Manual
ENGINEERING SPECIFICATION CONFIDENTIAL
mophie spacestation Page 1 of 13 Last Update: 6/27/2014 5:51 PM
spacestation
2014
Revision 0.4 Drafted: 06/27/2014
Author: Steven Chou
mophie Inc. Proprietary
All data and information contained in or disclosed by this document is proprietary, confidential and privileged
information of mophie Inc, and all rights therein are expressly reserved. By accepting this material, the recipient
agrees that this material and the information contained therein is held in confidence and in trust and will not be used,
copied, reproduced in whole or in part, nor its contents revealed in any manner to others without the express written
permission of mophie Inc.
ENGINEERING SPECIFICATION CONFIDENTIAL
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Table of Contents 1
Changes/Revision History 3
Approvals 3
1.0 PURPOSE AND SCOPE 4
1.1 Product Marketing Requirements – An Overview 4
2.0 INDUSTRIAL DESIGN REQUIREMENTS 6
2.1 Design Requirements 6
3.0 MECHANICAL DESIGN REQUIREMENTS 7
3.1 Hardware System Design 7
3.2 Mechanical Design Requirements 8
4.0 ELECTRICAL DESIGN REQUIREMENTS 9
4.1 Electrical Design Requirements 9
4.2 Battery Cell Requirements 10
5.0 QUALITY CONTROL PLAN 12
5.1 Quality Design Requirements 12
5.2 Environmental Test Requirements 12
5.4 Critical Dimension Requirements 12
6.0 STANDARD COMPLIANCE 13
6.1 Certifications required for this product: 13
6.2 ESD Protection 13
6.3 EMC Compliance 13
6.4 RoHS Compliance (Restriction of Hazardous Substances) 13
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CHANGES/REVISION HISTORY
Rev
Date
Author
Page(s)
Change Description
0.1
06/10/2014
Steven Chou
First draft
0.2
06/23/2014
Charles Kim
7, 8
Updated ME section and added Figure 3.1
Mechanical Design Control (DC)
0.3
06/23/2014
Steven Chou
9, 10, 11
Updated Battery Cell spec
0.4
06/27/2014
Steven Chou
All
Incorporated comments from CN team
APPROVALS
Date
Title
Name
Signature
Product Development
Manager
Tyson Mackjust
Director of Product
Development
Charlie Quong
Director of Hardware
Engineering
Vannin Gale
VP of Marketing
Ross Howe
SVP of Sales and
Business Development
Darren Shimkus
Principle
Shawn
Dougherty
or
Daniel Huang
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1.0 PURPOSE AND SCOPE
1.1 Product Marketing Requirements – An Overview
Concept:
The mophie spacestation combines the functionality of a mophie space pack and a
mophie powerstation. The two major features are power and storage with the added
benefits of the powerstation form factor (portability and universal compatibility). The
product will ship with a 6000 mAH battery @ 2.4A output in variants of 32, 64, and
128GB of additional storage. As a premium product the design will be similar, yet, more
premium than the powerstation w/cables 2014 line. The product will ship with BLE as
well accompanying free iOS and Android apps. The current iOS “Space” app will be
redesigned to work with the spacestation and a new “Space” android app will be ready
at launch.
Use cases
The mophie spacestation has the following use cases:
Supplies up to an additional 60% battery capacity for the iPad Air, 85% battery
capacity for the iPad mini retina and 300% battery capacity for iPhone 5/5s
Supplies additional memory capacities of 32, 64 and 128GB for tablets and
smartphones
Pass-through charging with priority for the connected device
File transfer from the spacestation to the connected device and vice versa
File management via included Application – allows for content management
between devices (space pack, tablet/smartphone, PC/Macs, iOS/third party apps,
cloud solutions via API)
Compatible with iOS and Android tablets and smartphones
Features:
The following list of key features defines the basic functions of the product:
Housing:
Color/finish: Metal top and bottom plates/PMS Process Black Pantone Black C.
mophie logo lasered
Single Female USB port
Single female Lightning or microUSB port (depends on SKU)
LED indicator light button (to double as data on button a la space pack)
May use 2x64GB microSD cards to achieve 128GB capacity (multiple slots for
higher capacity) to save cost.
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Battery:
6,000 mAh Li-ion polymer battery delivers 100% additional battery (5000 mAH is
stated battery size; will actually be closer to 6000)
Charge indicator button
4 white LED indicators and the charge button will function as described below:
o When the battery button is pressed, the white LEDs will show charge level
of the device.
4 LEDs light up: 100% ~ 76%
3 LEDS light up: 75% ~ 51%
2 LEDS light up: 50% ~ 26%
1 LED: 25% ~ 11%
0 LED: 10% ~ 0%
o When Unit is charged via charging port and included cable, the White
LEDs will indicate level of charge. The LED duty cycle is 50% @ 1S
(500mS ON and 500mS off)
4 LEDs light up: 100% ~ 76%
3 LEDS light up: 75% ~ 51%
2 LEDS light up: 50% ~ 26%
1 LED: 25% ~ 11%
0 LED: 10% ~ 0%
Firmware:
Approximately 10% of battery reserved for the spacestation for data only
Over the air (OTA) firmware updates available (on the App)
Data transfer – must be able to play HD video and audio
Auto-notification to download App when spacestation is initially attached to a
tablet/smartphone
Files able to be viewed on tablet/smartphone directly from space station without
transferring or saving of files from the space station to the tablet/smartphone
When connected to a computer, it must be automatically recognized as a
removable drive. If passcode feature is turned ON in the space pack firmware,
when connecting to a computer, SS will not automatically recognized as a
removable drive unless the user has entered the correct password.
Auto-charge and auto-data connection. When a device is connected to the
space station via female USB port, charging and data to be activated. Data to
have 3 minute timeout period if not accessed via iOS or Android app
Charging to be controllable from app. Charging can be turned on or off via the
app.
Pairing BLE to tablet/smartphone via app
Auto-reconnect of BLE when back in range of previously connected device
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Hard button use of Power indicator light button to put spacestation in pairing
mode
Other:
BLE to turn on spacestation data access when the app is opened up
Pass-through charging with priority for tablet/smartphone
Input Charging Rating:
Voltage: 5V +/- 5% with Current: 1.8A
Output Charging Rating:
During Pass through: Voltage: 5V +/- 5% with Current: 1A
During regular charging: Voltage: 5V +/- 5% with Current: 2.4A
Kit contents:
Gift box style packaging with window and flap with hero shot
USB to Micro USB 2.0 cable
Quick start guide with legal info and online link for full user manual (user manual
not included in box. To be online only)
spacestation
One global packaging SKU for Apple and ROC (See Appendix A for languages
supported)
2.0 INDUSTRIAL DESIGN REQUIREMENTS
2.1 Design Requirements
Description
Requirement
Detailed CMF (Color/Material/Finishes)
See Figure 1
Multiple CMF Options or SKU’s?
TBD
Secondary Process Required?
Yes
a) Process Black Pantone Black C.”
b) Anodize
Mophie LOGO (size)
Laser mark on Aluminum
Device label and marking size
Laser etching on bottom plate
Power button
Stainless polish
LED indicator
4 white
Figure1:
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3.0 MECHANICAL DESIGN REQUIREMENTS
3.1 Hardware System Design
Number
Descriptions
1
Main Body
2
Cover Top & Bottom, Aluminum (1.0mm 6061-T6)
3
Power button
4
VHB tape for adhesion
5
2 X 3000 mAh battery
6
2 PCBA
7
Screws (mount PCBA)
8
Thermal transfer material
9
Conformable thermal conductive pad
NOTE
Refer to 3D CAD for detail
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Figure 3.1 Mechanical Design Control (DC)
3.2 Mechanical Design Requirements
Descriptions
Requirement
Power button
TBD. 0.5 to 1 lbf
LED brightness
Cool white at 1000 lux intensity
Light leakage
Must not be seen through nearby opening
Ultra Sonic Weld (USW)
Must pass Drop Test (Refer to test plan)
UV paint
Must pass 2H hardness @500gf and chemical test
(Refer to test plan)
Housing construction
Must pass probe test of 20Kg for 1 minute (Refer to
test plan)
Housing construction
Must with stand drop test and still functional.
Minor crack may occur less than 1mm wide.
Housing Plastic
Must meet Flame retardant 94-V1 minimum (Refer to
test spec)
All metal parts and hardware’s
Must pass salt spray test (Refer to test spec)
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All adhesive and glue
Must pass thermal cycle test (Refer to test spec)
Housing Plastic
Must meet Flame retardant 94-V1 minimum (Refer to
test plan)
All metal parts and hardware’s
Must pass salt spray test (Refer to test plan)
All adhesive and glue
Must pass thermal cycle test (Refer to test plan)
4.0 ELECTRICAL DESIGN REQUIREMENTS
4.1 Electrical Design Requirements
Description
Requirement
Battery Output Voltage
3.8V/cell; 6000mAh Li-ion (polymer) battery
Input Charging
Voltage: 5.1V +/- 0.5% with Current: 1.8A
Output Charging
Voltage: 5.1V +/- 0.1% with Current: 2.4A
Charging (general)
Pass through charging with priority for connected
device
Syncing
Yes, data path must be allowed from input to the
applicable charging device (ex. phone and
tablets)
Compatibility
Compatible with charging outlets: BC1.2,
Samsung wall chargers, computer, wall and Car
charger (500mA or greater)
Hardware Interface
Input: USB-A connector
Output: Lightning or MicroUSB Connector
PCB Type (Single Sided, Double Sided
Silver thru hole, Double Sided Plated thru
hole, Double Sided Carbon)
Double Sided Silver thru hole; 4-layer
Power Converter Type (Input/output)
Buck/Boost; DC-DC
ESD Protection (e.g. USB Receptacle)
Yes; SMD diode(s)
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LED Power indictors
4 White LED indicators and the charge button will
function as described below:
When the battery button is pressed, the
White LEDs will show charge level of the
device.
o 4 LEDs light up: 100% ~ 76%
o 3 LEDS light up: 75% ~ 51%
o 2 LEDS light up: 50% ~ 26%
o 1 LEDS light up: 25% ~ 11%
o No LED: 10% ~ 0%
When Unit is charged via charging port
and included cable, the white LEDs will
indicate level of charge. The LED duty
cycle is 50% @ 1S (500mS ON and
500mS off)
o 4 LEDs light up: 100% ~ 76%
o 3 LEDS light up: 75% ~ 51%
o 2 LEDS light up: 50% ~ 26%
o 1 LEDS light up: 25% ~ 11%
o No LED: 10% ~ 0%
4.2 Battery Cell Requirements
The table below outlines baseline requirements for the battery cell used in this product:
Description
Requirement
Appearance
The surface is clear and no scratch
Maximum Cell Dimensions
74.35*51.5*11.8 mm
Max Cell Dimensions(after swell)
TBD
Weight
TBD
Nominal Capacity
6000mAh
Marked Capacity(Minimum Rated)
6000mAh (0.5C)
Typical Rated capacity
6000mAh (0.5C)
Charge time
Approx.4 hours from input of 5V at 1.8A
Nominal Cell Charge Voltage
4.35V±0.05V
Nominal Cell Discharge (Operating) Voltage
3.8V
Nominal Cell Discharge Cut-Off Voltage
3.1V
Nominal Cell Charge Current
3A
Nominal Cell Discharge Current
4.6A
Basic Charging Characteristics
Charging shall consist of charging at a
constant current rate of 3A until the cell
voltage reaches 4.35V. The cell shall then be
charged at constant voltage of 4.35V while
tapering the charge current. Charging shall
be terminated when the charging current has
tapered to 250mA. These characteristics
should stay consistent when charging the
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call between 0°C and 40°C
Basic Discharging Characteristics
Cells shall be able to discharge at a constant
current of 4600mA, 3.1 V, at 23±2°C and
humidity of 65±20%.
Nominal Cell Cycle Life
500 0.5C-discharging cycles (residue ≥ 80%
of initial capacity)
Overcharge Protection?
Yes
Overcharge Detection
Yes
Over-Discharge Protection?
Yes
Over-Discharge Detection
Yes
Over-Current Protection?
Yes
Over-Current Detection
Yes
Overcharge Protection Test Criteria
TBD
Over-Discharge Protection Test Criteria
TBD
Short-Circuit Protection Test Criteria
TBD
PCM Input Voltage’s Dynamic Range
2.7V – 4.5V
Active Protection Components (Or Equivalent)
Seiko S8211CAM-M5T1S (SOT23-5);
Panasonic MTMC8E2A0LBF (WMini8-F1);
Panasonic FC8V22040L (WMini8-F1);
Analog Power AMCC920NE (DFN3x3-8L).
Ex-Factory Cell Capacity
100%
Minimum Remaining Capacities. Shelf Time
1-month in 20±5°C& 70-80% RH Storage:
90%;
6-monthsin 20±5°C& 70-80% RH Storage:
70%;
12 months in 20±5°C &70-80% RH Storage:
50%.
Relative Cell Capacity vs. Temperature
-10°C (70%); 0°C (80%); 25°C (100%); 45°C
(95%); 60°C (90%)
Leakage Shutdown Capability?
Required
Minimum Required Declarations/Certifications
Directive 2006/66/EC, MSDS, UN38.3
See Battery Pack Specification for more detail.
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5.0 QUALITY CONTROL PLAN
5.1 Quality Design Requirements
Must meet mophie General Workmanship Standard
Descriptions
Requirement
Gap between Cap and Main Body
0.2 mm max
Part mismatch
0.1 mm max
Part flash
.05 mm max
Paint scratch / durability
See Test Plan for testing
USW gap
0.1 mm
Sink Mark
See Standard
Color match
Match approved sample
CMF match
Match approved sample
5.2 Environmental Test Requirements
Description
Requirement
Operating temperature range
0°C to + 40°C
Storage (Non-operating)
temperature range
-20°C to +60°C
Temperature Shock
will be subjected from 0°C to 50°C for 4 cycles at a rate of 1°C
per minute with a dwell time of 1 hour at high and low
temperature (as shown below). Functional tests will be
randomly performed while unit is inside the chamber
Humidity (operating)
40±3°C, 95% relative humidity, and non-condensing for 96
hours with batteries or power. Functional tests will be
randomly performed while unit is inside the chamber.
Altitude
Must withstand a 10,000-feet altitude test (by simulation).
Packaged products must withstand a 20,000-feet altitude test
(by simulation)
Vibration
Must withstand the vibration/stress test. The test is performed
at amplitude of 3.15 mm and frequency of 7-500 Hz, for 10
minutes (per axis)
Unit Drop test (transit drop)
Must withstand multiple free-fall drops on a hardwood floor
(e.g. a 1.00" thick oak layer) with the surface(s) or edge(s)
without obstruction. See Test Plan for details
Chemical resistance
See Test Plan for list of chemicals and test methods
5.3 Functional Test Requirements
Description
Requirement
Refer to test plan
N/A
5.4 Critical Dimension Requirements
Description
Requirement
2D drawings for plastic parts
See part prints and Incoming Quality Control (IQC)
Finish notes for secondary process
See part prints and IQC
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Assembly notes and Checklist
See part prints and IQC
6.0 STANDARD COMPLIANCE
6.1 Certifications required for this product:
Certification
Requirement
RoHS
Yes
FCC
Yes
CE
Yes
C-Tick
Yes
IEC60950-1
Yes
UL1642
Yes
WEEE
Yes
Prop 65 (CA), KC, PSE, TISI
Yes
UN38.3
Yes
6.2 ESD Protection
Standard products must meet 8kV air discharge. Products that have metal casing must
meet 4kV contact discharge, as well as 8kV air. All ESD tests shall be performed using the test
systems as specified by the IEC 61000-4-2 2001 standard.
6.3 EMC Compliance
All EMC tests shall be performed by following the IEC 61000-4-2 2001 standard.
6.4 RoHS Compliance (Restriction of Hazardous Substances)
The product should be RoHS compliant. The product shall not contain any of the following
six harmful substances:
Lead
Mercury
Hexavalent Chromium
Cadmium
PBB (Polybrominated Biphenyl)
PBDE (Polybrominated Diphenyl Ether
FCC Notice
This device complies with Part 15 of the FCC Rules. Operation is
subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) this device must accept any
interference received, including interference that may cause undesired operation.
NOTE 1: This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference in a residential installation. This equipment generates, uses
and can radiate radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation. If this equipment does cause
harmful interference to radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the interference by one or more of
the following measures:
- Reorient or relocate the receiving antenna.
- Increase the separation between the equipment and receiver.
-Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
-Consult the dealer or an experienced radio/TV technician for help.
NOTE 2: Any changes or modifications to this unit not expressly approved by the party
responsible for compliance could void the user's authority to operate the equipment.