Small, lightweight battery charger?

I recently plugged in one of my Chinese plastic chargers only to have it go *pop* as they are inclined to do every so often. I’ve been using a Cycle Satiator and a MeanWell HLG-240H-54A for my at-home charging needs, but I carry with me on each of my e-bikes a cheap and lightweight plastic cased 48V/4A charger. These have proven to be so unreliable that I keep more of them than I need, so I can have one available when I need it.

While cheap Chinese plastic chargers are lightweight (and cheap), they are somewhat bulky considering what’s inside. And crappy.

My question: Is there a small, lightweight charger available that’s optimized for carrying along? Where can I get the charger version of the Phaserunner controller?

You know about Luna, and rebranding but the keyword being "MINI" charger but 1A less then your 4A.
https://lunacycle.com/48v-3amp-luna-mini-charger/

Here's one Meanwell HEP-320, for Harsh Enviroments, right on its title.
$130usd mouser.com
https://www.meanwell.com/productPdf.aspx?i=456
43-52V, 3.3-6.7A, 252x90x44mm, 1.88lbs
https://endless-sphere.com/forums/viewtopic.php?f=14&t=42169&p=1546811&hilit=Meanwell+HEP#p1546811
https://endless-sphere.com/forums/viewtopic.php?f=14&t=73459&p=1109236&hilit=Meanwell+HEP#p1108924

MW HLG, 54V model. Some MW's I've noticed give you an extra 0.50V for your 48V fully charged 54.60V.
https://www.meanwell.com/productPdf.aspx?i=327
https://endless-sphere.com/forums/viewtopic.php?f=14&t=52529&p=971152&hilit=Meanwell+HEP#p1028976

I consider both the HLG and Satiator small and reliable.

john61ct said:

I consider both the HLG and Satiator small and reliable.

Click to expand...

They're not too large and heavy to carry, but they're larger and heavier than I think is necessary or convenient. I mean, they're both bigger and heavier than speed controllers that handle much more power and have a much more complex job to do. They're heavy enough to bash up their own cable strain reliefs and whatever else is riding in the basket with them. Cycle Satiator is like a box full of chargers in one; it makes sense that it would be bigger and more massive than a similarly well-designed charger that delivers a single fixed voltage and current.

Satiator and HLG are also bigger and lots heavier than the cheap Chinese ones that do the job until they suddenly don't. When I've opened plastic chargers up to do voltage trim adjustments or to resolder rattly heat sinks and capacitors, it's clear that they don't really need as much volume as they have in the case either.

I think there's a market opportunity here that I'm not enough of an electrical engineer to exploit.

Chalo said:

I recently plugged in one of my Chinese plastic chargers only to have it go *pop* as they are inclined to do every so often.

Click to expand...

If they fail in the same manner how about opening up and finding/repairing the failed component? Replace w/ more robust item. Now you have a bunch of spares that should be more reliable as well, in a form factor you favor. I really dislike the market economy throwaway mentality.

99t4 said:

Chalo said:

I recently plugged in one of my Chinese plastic chargers only to have it go *pop* as they are inclined to do every so often.

Click to expand...

If they fail in the same manner how about opening up and finding/repairing the failed component? Replace w/ more robust item. Now you have a bunch of spares that should be more reliable as well, in a form factor you favor. I really dislike the market economy throwaway mentality.

Click to expand...

This latest one I think I'll do a postmortem on. But I reckon whether it's a FET or a cap that went pop, the voltage transient may well have taken out other stuff.

Chalo said:

john61ct said:

I consider both the HLG and Satiator small and reliable.

Click to expand...

They're not too large and heavy to carry, but they're larger and heavier than I think is necessary or convenient.
…
I think there's a market opportunity here that I'm not enough of an electrical engineer to exploit.

Click to expand...

I meant within the reality of the current market.

Of course smaller but still reliable would be better, I'm sure will emerge in years to come.

Personally I think the controller should include precision charging functionality

perhaps with an add-on DC-DC / AC-DC module to feed what it needs, from all the common inputs a rider would come across worldwide.

Eventually all built into the bike frame 8-D