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1.2

Minor Versionm

by Procheta Mallik

Introduction

A quick primer on how to connect two AA batteries together to make a 3-volt power source for powering various projects and experiments.

    • Scissors have functional sharp edges. Contact may result in injury. Always keep blades away from fingers and body. Handle with care.

    • Please realise that batteries might cause damages like leaking, fire or explode when misused or defective. Refrain from mechanically damaging them.

    • Be careful not to short the terminals of the batteries.

  1. Take the printed template and foam piece Paste the template over the foam with the help of tape. The bold lines show where the pockets will be carved out.
    • Take the printed template and foam piece

    • Paste the template over the foam with the help of tape.

    • The bold lines show where the pockets will be carved out.

  2. Cut along the bold lines to create pockets for holding the AA cells. Remove the cut foam pieces . Remove the cut foam pieces .
    • Cut along the bold lines to create pockets for holding the AA cells.

    • Remove the cut foam pieces .

  3. Cut 8 strips of copper/aluminium tape tape (you may use any other metallic strip), each of length 5 cm. Divide one of the 5 cm strips into two equal parts. These will be used for making the foam springs as shown in the next step. Divide one of the 5 cm strips into two equal parts. These will be used for making the foam springs as shown in the next step.
    • Cut 8 strips of copper/aluminium tape tape (you may use any other metallic strip), each of length 5 cm.

    • Divide one of the 5 cm strips into two equal parts. These will be used for making the foam springs as shown in the next step.

  4. Take 2 foam pieces of 1 mm thickness of the size 2 cm x 1 cm. Fold them from the middle as shown. Now take the 2.5 cm copper/aluminium strips and wrap around the folded foam pieces. Cut out any protruding bits of the foam and the foam springs are ready.
    • Take 2 foam pieces of 1 mm thickness of the size 2 cm x 1 cm. Fold them from the middle as shown.

    • Now take the 2.5 cm copper/aluminium strips and wrap around the folded foam pieces.

    • Cut out any protruding bits of the foam and the foam springs are ready.

  5. Take the foam with slots made in 'Step 1' and wrap the 5 cm copper/aluminium strip around the  shorter edge of the foam piece. Now take another strip and connect two terminals on one side. Consider this to be Side 2 (marked with a red arrow) and the other side as Side 1. Now take another strip and connect two terminals on one side. Consider this to be Side 2 (marked with a red arrow) and the other side as Side 1.
    • Take the foam with slots made in 'Step 1' and wrap the 5 cm copper/aluminium strip around the shorter edge of the foam piece.

    • Now take another strip and connect two terminals on one side. Consider this to be Side 2 (marked with a red arrow) and the other side as Side 1.

  6. Now take two wires of 15  cm each, strip off 4 cm and 1 cm insulation on either side of each wire. Wind the 4 cm over the metal tape on Side 1 of the foam. Repeat the same for both the terminals on Side 1.
    • Now take two wires of 15 cm each, strip off 4 cm and 1 cm insulation on either side of each wire.

    • Wind the 4 cm over the metal tape on Side 1 of the foam.

    • Repeat the same for both the terminals on Side 1.

    • Now cover the wire hence wound with another copper/aluminium tape.

  7. Apply glue to a piece of cardboard that has the same dimensions as the foam piece. Also put some glue on the underside of the foam. Now take the foam and paste it over the cardboard. Now take the foam and paste it over the cardboard.
    • Apply glue to a piece of cardboard that has the same dimensions as the foam piece. Also put some glue on the underside of the foam.

    • Now take the foam and paste it over the cardboard.

  8. Now place the foam springs made in Step 4 at diagonally opposite corners of the slots, as shown. Your DIY battery holder is ready to  be used. Fix two AA cells in the slots such that negative terminal of the cell is towards the foam spring.
    • Now place the foam springs made in Step 4 at diagonally opposite corners of the slots, as shown.

    • Your DIY battery holder is ready to be used. Fix two AA cells in the slots such that negative terminal of the cell is towards the foam spring.

    • Use an LED to test. The orientation of the LED is important. The longer lead is the positive pin and should connect to the positive terminal of the battery holder.

  9. Here is a circuit diagram of the holder. We are connecting the cells in series to get a total output of 3 volts.
    • Here is a circuit diagram of the holder. We are connecting the cells in series to get a total output of 3 volts.

    • If the battery holder refuses to light an LED, check the contact between the pins and battery terminals.

    • Be careful not to short the terminals of the cells. If the cells heat up while in the holder, this could indicate an electrical short circuit. Remove the cells and check your connections.

    • Scissors have functional sharp edges. Contact may result in injury. Always keep blades away from fingers and body. Handle with care.

    • Please realize that batteries might cause damages like leaking, fire or explode when misused or defective. Refrain from mechanically damaging them.

    • Be careful not to short the terminals of the batteries.

  10. As you may already know, a battery has two terminals - a positive (+) and a negative (-). On a AA Battery, the positive is indicated by a nub on one side. While the other flat side is the negative. Stretch the elastic band over each battery from positive side to negative side. Stretch the elastic band over each battery from positive side to negative side.
    • As you may already know, a battery has two terminals - a positive (+) and a negative (-). On a AA Battery, the positive is indicated by a nub on one side. While the other flat side is the negative.

    • Stretch the elastic band over each battery from positive side to negative side.

  11. Insert a safety pin (head-first) in between the battery and the elastic band. This pin should be inserted near the positive side of the battery. Pull the safety pin along the battery till the head sits flat on the positive nub. Take care that the pin doesn't slip out from under the elastic band. You should end up with a battery with the safety pin sticking out from the positive end.
    • Insert a safety pin (head-first) in between the battery and the elastic band. This pin should be inserted near the positive side of the battery.

    • Pull the safety pin along the battery till the head sits flat on the positive nub. Take care that the pin doesn't slip out from under the elastic band.

    • You should end up with a battery with the safety pin sticking out from the positive end.

  12. Insert the battery assembly into the space between the elastic band and the other cell (in the elastic band). This time towards the negative end. Drag up the cell so that the safety pin is flat on the negative terminal as well. You should end up with two cells connected positive to negative by the safety pin and two free terminals.
    • Insert the battery assembly into the space between the elastic band and the other cell (in the elastic band). This time towards the negative end.

    • Drag up the cell so that the safety pin is flat on the negative terminal as well.

    • You should end up with two cells connected positive to negative by the safety pin and two free terminals.

  13. Now insert one of the safety pins in between the free positive terminal and the elastic band. Now insert a safety pin under the elastic band over the free negative terminal as well. You will end up with two safety pins sticking out in opposite directions, one being positive and the other negative. Now, use the scissors to cut the ice cream sticks into two lengths of 3.5 - 4 cms each.
    • Now insert one of the safety pins in between the free positive terminal and the elastic band.

    • Now insert a safety pin under the elastic band over the free negative terminal as well. You will end up with two safety pins sticking out in opposite directions, one being positive and the other negative.

    • Now, use the scissors to cut the ice cream sticks into two lengths of 3.5 - 4 cms each.

  14. Insert one of the ice cream stick pieces in between the elastic bands and across both cells. Use the other piece to secure the other side. Use the other piece to secure the other side.
    • Insert one of the ice cream stick pieces in between the elastic bands and across both cells.

    • Use the other piece to secure the other side.

  15. Our battery holder is now finished! You can test its functionality by attaching an LED across the safety pins.
    • Our battery holder is now finished! You can test its functionality by attaching an LED across the safety pins.

  16. Here is a circuit diagram of the holder. We are  connecting  the  batteries in series for at total of 3 volts.
    • Here is a circuit diagram of the holder. We are connecting the batteries in series for at total of 3 volts.

    • If the battery holder refuses to light an led, check the contact between the pins and battery terminals. Also check the tension on the elastic bands and add spacers with ice cream stick pieces.

    • Be careful not to short the terminals of the batteries. If the batteries heat up while in the holder, this cloud indicate an electrical short circuit. Remove the batteries and check your connections.

Finish Line

Kailash NR

Member since: 05/02/2017

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