Site Navigation

Your Account

Choose Language

1.2

Minor Versionm

by Procheta Mallik

Introduction

Using a foam piece, cardsheet and few metal tapes we will design a casing to connect two AA cells in series.

    • 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.

Finish Line

Suhail Ahanger

Member since: 05/02/2017

3,848 Reputation

68 Guides authored

Team

Content Creation Member of Content Creation

Community

2 Members

107 Guides authored

0 Comments