Jay Summet via EV wrote:
Why not pressure fit?  ...Flashlights do it all the time...

Think about how many times you've had bad connections and flickering light, had to shake it or clean the contacts to get it to work.

You can make a good electrical connection with pressure alone, but it takes a *lot* of pressure.

Corrosion is another problem. The contact surface is completely exposed, and subject to moisture, dirt, and the resulting corrosion. It would help to gold plate the connections, but who would want to spend the money?
--
The principal defect in a storage battery is its modesty. It does not
spark, creak, groan, nor slow down under overload. It does not rotate.
It works where it is, and will silently work up to the point of
destruction without making any audible or visible signs of distress.
        -- Electrical Review, 1902
--
Lee Hart's EV projects are at http://www.sunrise-ev.com/LeesEVs.htm
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