I more or less started by experimenting with that approach but I
found the two sides got forced apart all too quickly.
Just to be clear, can I explain exactly what I am trying to
achieve. It's a bit detailed!
Let's suppose I have a product (such as an MP3 player) and I
want to see what the current consumption is in various states
such as play, record, low volume, high volume, etc. I want to
be able to attach my multimeter leads to a pair of leads about 6
to 10 sinches long which go to my "insertion device". This
"device" is what I am posting about. It needs to be thin and to
have a conductor on each side; it also has to be strong because
sometimes there is precious little movement available to push
the cell or cells back.
I have found if the "insertion device" is not strongly made then
it will start to split. My preference is for a thin PCB or
flexible cable which is already made with conductor on each
side. Having to use adhesives can add problems especially if
there is any extruded adhesive from the two parts being squeezed
together while it is setting. I had initially used some thin
tin-coated steel strips from a food can and glued those onto
each side of a thin plastic base. Good adhesion has not been
easy to achieve.
Of course I could use da fanned out pair of wires with an
insulating sheet in between but that is fiddly and slow and
never quite so easy because the way some battery compartments
are designed seems particularly perverse. Sometimes the cells
spring out because the supports are not in line with the cell's
axis, at other times the shoulder of the cell prevents the small
cap easily reaching the connector, etc I'm sure you know what I
The purpose of building this is to be able to quickly and easily
take a current reading