June 27, 2024
Description
This insulating spacer cap enables—at least on US airlines, and with TSA/airline acceptance—the lithium battery-powered BLF LT1 lantern to be packed in checked luggage when flying; per 49 CFR 175.10(a)(18):
“Portable electronic devices powered by lithium batteries may be carried in either checked or carry-on baggage. When carried in checked baggage, portable electronic devices powered by lithium batteries must be completely switched off (i.e., not in sleep or hibernation mode) and protected to prevent unintentional activation or damage”
The insulating spacer is installed over the positive battery terminals in the bottom part of the lantern before screwing on the top of the lantern until snug. This prevents the cells from making contact and activating the lantern. When not in use, the spacer can be screwed in to the ¼"-20 threaded hole on the bottom of the lantern (or the one on the side) for easy storage. It's easier, less fussy, and more reliable than using tape on the battery contacts.
It should fit button-top battery cells with positive terminals of various sizes.
The spacer should be easy to remove from the flashlight, but just in case the spacer has holes around the perimeter to make it easier to remove should it get stuck. The threaded portion has a hollow recess at its center with a cross-section that should fit a small Phillips-head screwdriver, to aid in its removal should the threaded portion break off in the ¼"-20 hole of a lantern.
Printed with the threaded rod facing up off the build plate, no supports are needed. In PLA with 25% infill, the spacer should add only ~6g to the total weight of a lantern.
Important: Hopefully obvious, but this should be printed with non-conductive filament.
License:
Creative Commons — Attribution — Noncommercial — Share Alike