fairphone-case: thicken buttoncovers (since one broke)

[reprap-play.git] / fairphone-case.scad

diff --git a/fairphone-case.scad b/fairphone-case.scad
index d7d064cba2d1348f23a9429b1576ac9228d3e430..96cdbf74de305759e9a4227ee59d08f06832e218 100644 (file)
--- a/fairphone-case.scad
+++ b/fairphone-case.scad
@@ -176,7 +176,7 @@ microusb_width = 16.12 + 1.25;
 
 case_th_bottom = 2.5;
 case_th_lid = 3.0;
-case_th_side = 2;
+case_th_side = 2.3;
 case_th_lip = 1.2;
 
 lid_screen_gap_extra = .66;
@@ -204,6 +204,8 @@ case_lip = 1.25;
 lid_gap_x = 0.25;
 lid_gap_z = 0.25;
 lid_lip = 1.75;
+lid_edgepart_width = 5.0;
+lid_buttoncover_thick = 1.3;
 
 catch_slop = 0.50;
 
@@ -270,6 +272,8 @@ prop_caserecess_taper = 0.45; // one side only
 prop_prop_gap = 0.5;
 prop_prong_heel_slope = 0.5;
 
+lid_fold_clearance_antislop = 0.5;
+
 // ---------- calculated ----------
 
 phone_width =  (phone + bumper*2)[0];
@@ -316,7 +320,7 @@ kppa = [ kppb[0], kppf[1] ];
 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
 lpp11 = [ lpp10[0],            epp5[1] + lid_gap_z ];
 
-lpp14 = lpp10 + [1,0] * keeper_inner_width;
+lpp14 = lpp10 + [1,0] * max(keeper_inner_width, lid_edgepart_width);
 // exact x posn not very important; must extend past end of keeper
 
 lpp15 = [ lpp14[0],
@@ -338,7 +342,7 @@ case_bottom_z = epp2o[1] - case_th_bottom;
 
 // button profile
 bppM = epp4 + [0,5];
-bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
+bppN = [ bppM[0] + lid_buttoncover_thick, bppM[1] ];
 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
 bppS = [ epp1[0], bppR[1] ];
 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
@@ -351,6 +355,8 @@ bppU = [ bppJ[0], lpp12[1] ];
 bppV = lpp11;
 bppW = lpp10;
 
+echo("BUTTON COVER TH", bppO[0] - bppP[0]);
+
 // notification led aperture
 
 nla_r0 = led_aperture/2;
@@ -408,6 +414,12 @@ chk(hex22, 10.9975);
 chk(hex23, 13.74);
 chk(hex24, 18.75);
 
+lid_fold_clearance_skew =
+  (lpp10[1] - hppB[1]) /
+  (lpp10[0] - hppB[0]);
+
+echo("SK",lid_fold_clearance_skew);
+
 // catch
 
 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
@@ -521,6 +533,16 @@ module LidEdgeProfile(){
   }
 }
 
+module LidEdgeFoldClearanceProfile(){
+  translate([-lid_fold_clearance_antislop, 0])
+    polygon([ lpp10,
+             lpp11,
+             lpp11 + [-20,  0],
+             lpp11 + [-20, 20],
+             lpp11 + [+20, 20],
+             lpp10 + [+20,  0] ]);
+}
+
 module ButtonCoverProfile(){
   intersection(){
     polygon(concat([ bppM, bppP, bppO, bppJ ],
@@ -824,7 +846,7 @@ module HingePortion(x0,x1){
     mirror([1,0,0])
     rotate([90,0,-90])
     linear_extrude(height=x1-x0)
-    children(0);
+    children();
 }
 
 module CatchPortion(width){
@@ -1055,11 +1077,28 @@ module LidAdhocMultiprintFrame(phase){
   }
 }
 
+module LidAroundEdges(){
+  AroundEdges(lpp15[1], lpp13[1] - lpp15[1], 0)
+    children();
+}
+
 module Lid(){ ////toplevel
+  skew_centre = [0, lpp11[0], lpp11[1]];
   difference(){
     union(){
-      AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
-        LidEdgeProfile();
+      intersection(){
+       LidAroundEdges()
+         LidEdgeProfile();
+
+       translate(skew_centre)
+         multmatrix([[ 1, 0, 0, 0 ],
+                     [ 0, 1, -lid_fold_clearance_skew, 0 ],
+                     [ 0, 0, 1, 0 ],
+                     [ 0, 0, 0, 1 ]])
+         translate(-skew_centre)
+         LidAroundEdges()
+         LidEdgeFoldClearanceProfile();
+      }
 
       // button covers
       Buttons(){
@@ -1076,7 +1115,10 @@ module Lid(){ ////toplevel
       }
 
       // hinge arms
-      HingePortion(hex20, hex21) HingeLidProfile();
+      HingePortion(hex20, hex21) {
+       LidEdgeProfile();
+       HingeLidProfile();
+      }
 
       // catch
       CatchPortion(catch_width)
@@ -1399,7 +1441,7 @@ module DemoPropAngles(){ ////toplevel
 
 module DemoHingeAngle(ang1,ang2){
   hL = [0, -(phone_height - hppT[0]), hppT[1]];
-  hC = [0, -(phone_height - hppB[0]), hppB[1] - hp_k*2];
+  hC = [0, -(phone_height - hppB[0]), hppB[1]];
 
   translate(hL)
     rotate([ang2,0,0])
@@ -1412,17 +1454,26 @@ module DemoHingeAngle(ang1,ang2){
 
   color("blue") intersection(){
     Case();
-    translate([bppJ[0], -400, -200])
-      mirror([1,0,0])
-      cube([400, 800, 400]);
+    union(){
+      translate([bppJ[0], -400, -200])
+       mirror([1,0,0])
+       cube([400, 800, 400]);
+      translate([10, -400, -200])
+       cube([10, 800, 400]);
+    }
   }
 }
 
 module DemoHingeAngles(){ ////toplevel
-  DemoHingeAngle(0,45);
-//  for (i=[0 : len(prop_angles)-1])
-//    translate(i * [0, -100, 100])
-//    DemoHingeAngle(prop_angles[i]);
+  angles = [ 0, 4, 8, 12 ];
+  echo("angles",angles);
+  for (i=[0 : len(angles)-1]) {
+    translate(i * [0, 0, 30]) {
+      DemoHingeAngle(0,angles[i]);
+      translate([0, 200, 0])
+       DemoHingeAngle(angles[i],0);
+    }
+  }
 }
 
 module DemoSelectAdhocLeftRight(right=0) {