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Aluminium foil - carry voltage? Enough for this?
SOAPboy:
So.. can you explain the part where just hooking the fan up to some kind of normal switch is an issue?
Maybe i missed that part..
I mean, its not hard to make a quick clip for the fan, like on a case side for a PC.. and wouldnt be so "unsafe"
Xiaou2:
Foil is not very sturdy, and being so thin, in time, may cause it to catch on fire.
Use a cabinet switch is better ;)
But for cheapness, maybe a coke can would at least be better than foil.
Or maybe better , use a couple of large steel washers.
Bones:
--- Quote from: missioncontrol on December 03, 2005, 06:37:26 am ---I think I understand. the fans are on the back panel and you have wires wining to the conections and when the back panels are on they make connection and run.
--- End quote ---
Spot on!
--- Quote from: SOAPboy on December 03, 2005, 06:55:01 am ---So.. can you explain the part where just hooking the fan up to some kind of normal switch is an issue?
--- End quote ---
It is not a switch I am trying to create, it is a connection. (I always want the fans to be turned on.)
If the wires going to the fans are plugged into the power supply they have to be unplugged before the panel can be removed. This means unscrewing the panel and while holding it, trying to remove the connection plug. To attach the panel back to the cab the process has to be repeated.
With this system there is no wiring. It is kind of like an electric slot car with the little spring loaded contact points rubbing the track and powering it as it goes.
I just put the panel back onto the cabinet and the power is returned to this panel when the layers of foil make contact.
--- Quote from: Xiaou2 on December 03, 2005, 07:01:44 am ---Or maybe better , use a couple of large steel washers.
--- End quote ---
Washers were actually my first prototype! Found them difficult to hold down flush once they were wrapped in wire (had to wrap them because I couldn't get solder to stick to them). Coke can would be too thick. I am trying to solve this problem within the raised height of a t-nut which is 2mm. I should also note that to make this thickness the foil needs to be folded about 20 times so it is not one slither of foil that is carrying the 12 volts, it is more like a thick "chunk" of foil.
My test rig has now been running for just over two hours and the foil is still cold with no hot spots, it looks like heat won't be an issue. I also tried setting fire to some foil with a lighter, couldn't get it to burn which is kind of reassuring.
Bones:
I just altered my test rig and now both fans are connected. This should give me a better idea of how the foil will handle the extra power requirements. (Each fan draws 0.28 amps)
I will let it run overnight and examine it in the morning by unwrapping the foil and looking for any damage, hot spots or discoloration.
Matt Berry:
It may seem safe at first but as the foil seperates from removal the power is very likely to start arcing between the layers. Once it starts doing that it doesn't take long for it to heat up and cause a fire.
To get the solder to adhere to a washer you have to get the washer hot enough to melt the solder. While this is safer then the foil idea, it still isn't the best idea. Any space could cause arcing and after that you could easily have a fire.
You'd be better of using a real disconnect such as a molex connector, bullet connectors or quick disconnects. You could also just make the wires longer so that you can set the panel off to the side and not worry about it.