Hello
I have a toy device that uses 2 AA batteries installed end to end with just a battery clip (see image below) at each end. The batteries aren't very securely held in place, often popping loose where the 2 batteries meet when the child drops the toy, requiring that the batteries be reinserted. The device also eats through batteries at a ridiculous rate. I can't use AA rechargeables because they are 1.2 V for a total of 2.4 V, and they just won't allow the device to even turn on. The full 1.5 V from Alkaline batteries is required. Plus the rechargeables also pop out when dropped.
I can't make any changes to the device itself. The battery compartment is much larger than it needs to be. Large enough that I would like to make a PCB with an 18650 battery clip. My plan is to put a 14.5 mm diameter (the diameter of a AA battery) stud at each end of the PCB, an 18650 battery clip between the studs, and possibly a voltage regulator to take the voltage down to 3 V. And potentially even a battery charger circuit - this has not been decided yet and depends partially on space available. This would allow me to just plug my new PCB into the device to act as a battery pack. I believe that this PCB would be held in place more securely than the 2 AA batteries because it would be a single device with no meeting place in the center. The 18650 battery should last longer on each charge. And the 18650 is of course rechargeable. Overall a good solution!
However, I haven't been able to find the studs to put on the end of the PCB. For a proof of concept prototype I just used 1/2 inch long pieces of 1/2 inch diameter copper pipe that I got from a plumber. But that is not an acceptable solution.
Does anyone know where I can find the type if studs that I am describing? 14-16 mm long x 14.5-15.5 mm diameter copper or other conductive studs that can be mounded onto a PCB.
Thank you
Joe
I have a toy device that uses 2 AA batteries installed end to end with just a battery clip (see image below) at each end. The batteries aren't very securely held in place, often popping loose where the 2 batteries meet when the child drops the toy, requiring that the batteries be reinserted. The device also eats through batteries at a ridiculous rate. I can't use AA rechargeables because they are 1.2 V for a total of 2.4 V, and they just won't allow the device to even turn on. The full 1.5 V from Alkaline batteries is required. Plus the rechargeables also pop out when dropped.
I can't make any changes to the device itself. The battery compartment is much larger than it needs to be. Large enough that I would like to make a PCB with an 18650 battery clip. My plan is to put a 14.5 mm diameter (the diameter of a AA battery) stud at each end of the PCB, an 18650 battery clip between the studs, and possibly a voltage regulator to take the voltage down to 3 V. And potentially even a battery charger circuit - this has not been decided yet and depends partially on space available. This would allow me to just plug my new PCB into the device to act as a battery pack. I believe that this PCB would be held in place more securely than the 2 AA batteries because it would be a single device with no meeting place in the center. The 18650 battery should last longer on each charge. And the 18650 is of course rechargeable. Overall a good solution!
However, I haven't been able to find the studs to put on the end of the PCB. For a proof of concept prototype I just used 1/2 inch long pieces of 1/2 inch diameter copper pipe that I got from a plumber. But that is not an acceptable solution.
Does anyone know where I can find the type if studs that I am describing? 14-16 mm long x 14.5-15.5 mm diameter copper or other conductive studs that can be mounded onto a PCB.
Thank you
Joe
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