A battery interrupter lets you use an accessible switch to turn on and off many battery-operated toys and devices. The battery interrupter interrupts the flow of power from the battery until an attached assistive switch is activated. This is a flexible battery interrupter that can be used with AAA, AA, C, or D sized batteries.
Note: This design utilizes a custom PCB, so it is not cost effective for small quantities (< 50). If you need a small quantity of battery interrupters, the Battery Interrupter (Soldered) design is likely a better option.
The flexible battery interrupter is inserted within the battery enclosure either between two batteries or between a battery and a battery terminal. The flexible battery interrupter can be trimmed with scissors to match the size of battery. The wires to the jack are routed to the outside of the battery enclosure.
An assistive switch is connected to the battery interrupter switch jack. If there a power switch on the electronic device or toy, it is placed into the on position. Activating the assistive switch should then activate the electronic device or toy.
Bill of Materials
1X Battery Interrupter Flexible PCB ($2 – $126)
1X 3.5 mm Jack (https://www.digikey.ca/en/products/detail/cui-devices/SJ1-3513/738683, ~$2 CAD + $11 Shipping)
1X 3D Printed Jack Case (~ 1.1 g of filament, $0.03)
1X 3D Printed Jack Case Spacer (~ 0.4 g of filament, $0.01)
- Soldering Iron
This design requires a custom flexible printed circuit board (PCB). All of the information and files required to have the PCB fabricated are within the GitHub repository.
The price will vary widely depending on the fabricator, the quantity of boards, and the selected shipping option.
A detailed assembly guide is available on GitHub or within the zipped release.
- Solder the jack to the flexible PCB.
- Insert the jack with the spacer into the jack case.
- Thread the retainer ring onto the jack.
Initial concept and design: Dale Grover
V1.0 Design and Assembly Instructions: Makers Making Change