Dry cell battery monitor adaptor - ultra thin PCB.

[aargee]

Hi all,

I'm looking to build or buy a super thin, flexible, strong double sided PCB that can slide between dry cells (AA, AAA, alkaline, etc) and can bring out two conductors to banana sockets for measuring the current draw of battery operated devices.

Firstly, does anyone know of such a thing available now? If not I would want to construct something with long lasting contacts that is reasonably robust. The physical material to slide between the batteries is the key here.

Any thoughts?

- Rob.

[Muttley Snickers]

HI aargee,

Funny that you mentioned this, as it is another project on both my bench and list of thing's to finish.

Not so much as a PCB/ribbon style device but " dummy " batteries that I have made out of PTFE and Delrin with a brass centre conductor.

I have already made a few in CR123a size for my Cree torches, they came with 18650 batteries but I have a stack of CR123A's that I want to use up, so I made spacer dummy batteries on the lathe. I now want to finish the AA  AAA  C  D sizes for general testing with removable flying leads and my variable power supply for a variety of devices.

And for those that may have concern's, the torches are brighter with the 18650's, but I have other evil plans for these batteries.

I end up with lot's of slightly used CR123A's from the type of work that I do and have been putting them to good use in other gadget's.

I can knock these up in very little time at all, material is at hand, I'm just pondering over the best method for the lead connection, I may just internally thread the brass rod on a couple for attachment .

Muttley

[aargee]

I'm actually looking for something that could slide in between two batteries or the end of a battery and the terminal. I do see where you're coming from, Muttley, but the problem with dummy cells is having a smaller substitute battery in the dummy and having a 'dummy' of every size.

This device would work for any removable battery regardless of size, just pop the battery cover off and insert the gadget and measure. I thought about flexible PCB, I have seen some pretty robust stuff used for multi-way connectors.

[Muttley Snickers]

I see what you are doing, I initially looked at this option and then changed course, but my requirement's will differ from yours.

I wanted a solution for not just current testing but also to power up gadgets for testing without having to take them apart if the battery connection's were out of reach of a clip lead, it would be handy for just quick Go - NoGo types of testing.

I never seem to buy C or D cell's, but friend's and family bring crap around ( toy's and the like ) for me to fix, bloody nightmare.

I'm making full size solid dummies not enclosure's or step up housing's.

Muttley

[T3sl4co1l]

If nothing else, you can take two bits of metal foil (doesn't have to be copper just for testing) and some plastic film or double stick tape.

Tim

[ModemHead]

I'm looking to build or buy a super thin, flexible, strong double sided PCB that can slide between dry cells (AA, AAA, alkaline, etc) and can bring out two conductors to banana sockets for measuring the current draw of battery operated devices.

This is one I made a while back, from 0.01" double-sided copper clad like this:
http://www.goldmine-elec-products.com/prodinfo.asp?number=G19339

edit: added extra photo

[Rufus]

If nothing else, you can take two bits of metal foil (doesn't have to be copper just for testing) and some plastic film or double stick tape.

You can get self adhesive copper tape (useful stuff to have anyway). Cut a bit of plastic (from a blister pack or something) into a disc with a suitable tail, stick tape on both sides and solder wires to the tail.

I could make one in 10 minutes.

[Muttley Snickers]

ModemHead,

Good job, nice handy device,

I'm going to make a set now even though I previously decided to expand upon the concept with " The No Battery " monster, which I will still do.

It never stops, alway's something else that you think you need.

Muttley

[IconicPCB]

Rob,

we make PCB prototypes.

We have 1.6, 0.7 and 0.2mm double side FR4 in stock.

www.iconicpcb.com in Brisbane