I have requirement to create a device which works on 3AA battery and uses a small enclosure. When all the items are put inside the enclosure, only about 31x31x60 space is left.
So all the readily available 3xAA battery case were out. They are mostly linear and are of sizes 57x48x20 or so. I have the metal contacts needed to create the battery holder:
The idea I have is to make something like this:
The case would be open from top side, and would have side walls and bottom wall. Its almost like a "U" shaped case. The easiest way to prototype this would be to get acrylic sheet cut but once the walls are all made, I've the next step to "fasten" the metal spring contacts. I have following options:
- Make another thin wall parallel to the end of the U shaped side wall, to "hold" the plates.
- Make holes made on the metal spring contacts and then screw them via m1.5/m2 to the U wall.
In terms of ease, 1>3>2. However I dont know if option 1 to glue using araldite is going to work well - will it cause any leakage current to go higher (I doubt, just double checking). And I'm not too sure if araldite is stable and strong enough for this metal/acrylic bonding for 3-4 years life. Option 3 is definitely a possiblity but asthetically not pleasing. And option 2 is lot of extra work, but would just work.
Please let me know what you guys think.