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I'm trying to find the dimensions of a 9V (PP3?) battery (no specific chemistry). For some reason it's giving me a lot of trouble. I've been able to find most of the information (I checked a bunch of sources and they've all got these same values):

enter image description here

However, I can't figure out the allowable range for the terminal diameters and depths. So my question is, what are the min/max values of these dimensions:

enter image description here

Where:

  • M = min/max outer diameter of positive male terminal
  • F = min/max inner diameter of negative female terminal
  • H = min/max depth of negative female terminal

The min/max height of the positive male terminal I assume is linked to the female depth and also the 0.1mm - 2.1mm minimum range implied (A - D) by the first image above.

Also, there's the lip on the terminals to provide the snap action, so, that too.

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    \$\begingroup\$ There's nothing crazy about the lower end of the A-D range. Many 9V batteries have the face with the contacts somewhat recessed below the edges of the metal shell (the metal shell overhangs the plastic piece carrying the contacts, just like on the battery in your picture). The 0.1 mm minimum just tells you that the contacts may be recessed as much to be almost flush with the metal shell. \$\endgroup\$ – TooTea Mar 20 at 12:47
  • \$\begingroup\$ @TooTea Ah, that makes a lot more sense. \$\endgroup\$ – Jason C Mar 20 at 13:26
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They're specified in the relevant standards, such as IEC 60086-1, which are not free. Fortunately, our friends at the Kenyan Bureau of Standards published a public review copy of the standard:

enter image description here

The relevant size for the 9V battery is the "Minature".

The male post is of specified dimensions, the female merely has to fit the male (OC render).

enter image description here

And, for completeness, here are the overall battery dimensions

If you are going to be signing off on tooling to make 1,000,000 snaps, it might be wise to double check against the actual latest standards, but as this battery design is >60 years old probably not much has changed other than conversion to metric.

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