fairphone-battery-case.scad

   1 // -*- C -*-
   2
   3 include <utils.scad>
   4
   5 mainwall_th = 3.0;
   6 smallwall_th = 2.0;
   7
   8 seal_th = 0.3 + 0.6 + 0.6 - 0.4 - 0.4 + 0.2; // total gap for seal etc.
   9 behind_recess = 1.5;
  10
  11 recess_gap_end = 0.4;
  12
  13 lid_edge_th = 0.5;
  14
  15 battery_len = 66.55 + 1.25 -.55;
  16 battery_th = 6.55 + 0.75 - .60;
  17 battery_wdth = 44.38 + 0.75 -.55;
  18
  19 battery_base_indent = 0.94 + 0.50;
  20 battery_base_indent_fromside_outside = 4;
  21 battery_base_indent_fromside_inside = 10;
  22
  23 handle_height = 3.5;
  24 handle_inward = 10;
  25 handle_len = 5;
  26
  27 pushhole_ell_sz = 4.75;
  28 pushhole_ell_th = 1.75;
  29 pushhole_circle_dia = 4.0;
  30
  31 // for testing:
  32 //battery_len = 3;
  33 //battery_wdth = 15;
  34 //battery_base_indent_fromside_inside = 6;
  35
  36 // calculated
  37
  38 bpp0 = [0,0];
  39 bpp1 = bpp0 + [ 0, mainwall_th - behind_recess ];
  40 lppA = bpp1 + [ seal_th, -recess_gap_end ];
  41 lppB = lppA + [ lid_edge_th, 0 ];
  42 bpp2 = [ lppB[0], bpp1[1] ];
  43 bpp3 = [ bpp2[0] + (bpp1 - bpp0)[1], bpp0[1] ];
  44 bpp4 = [ bpp3[0], bpp0[1] + mainwall_th ];
  45 lppC = bpp3 + [ 0, -recess_gap_end ];
  46
  47 lppF = lppC + [ handle_height, 0 ];
  48
  49 s0 = battery_wdth/2;
  50 s0i = s0 - battery_th/2;
  51 s1 = s0 + smallwall_th;
  52
  53 l1 = s1 - handle_inward;
  54 l0 = l1 - handle_len;
  55
  56 echo(
  57      bpp0,
  58      bpp1,
  59      bpp2,
  60      bpp3,
  61      bpp4,
  62      bpp5,
  63      bpp6,
  64      bpp7,
  65      bpp8
  66 );
  67
  68 echo(
  69      lppA,
  70      lppB,
  71      lppC,
  72      lppD,
  73      lppE
  74 );
  75
  76 bpp8 = bpp0 + [ -battery_len,0 ];
  77 bpp5 = [ bpp8[0] - smallwall_th, bpp4[1] ];
  78 bpp9 = [ bpp0[0], bpp0[1] - battery_th/2 - 1.0 ];
  79 bpp7 = [ bpp8[0], bpp9[1] ];
  80 bpp6 = [ bpp5[0], bpp9[1] ];
  81 lppE = [ lppA[0], bpp9[1] ];
  82 lppD = [ lppC[0], bpp9[1] ];
  83
  84 module BaseHalfPlan(indent=0){
  85   polygon([ bpp0,
  86             bpp1,
  87             bpp2,
  88             bpp3,
  89             bpp4,
  90             bpp5,
  91             bpp6,
  92             bpp7 + indent * [1,0],
  93             bpp8 + indent * [1,0]
  94             ]);
  95 }
  96
  97 module SideHalfPlan(){
  98   polygon([ bpp5,
  99             bpp6,
 100             bpp9,
 101             bpp1
 102             ]);
 103 }
 104
 105 module LidHalfPlan(){
 106   polygon([ lppA,
 107             lppE,
 108             lppD,
 109             lppC,
 110             lppB
 111             ]);
 112 }
 113
 114 module HandleHalfPlan(){
 115   translate(lppE)
 116     square(lppF - lppE);
 117 }
 118
 119 module ExtrudePlan(from,to){
 120   rotate([0,-90,0])
 121   for (mj=[0,1]) {
 122     mirror([0,0,mj]) translate([0,0,from]){
 123       linear_extrude(height= to-from, convexity=5){
 124         for (mi=[0,1]) {
 125           mirror([0,mi])
 126             translate([0, battery_th/2])
 127             children(0);
 128         }
 129       }
 130     }
 131   }
 132 }
 133
 134 module PushHolePlan(){ ////toplevel
 135   translate(-(pushhole_ell_th * 0.10 +
 136               pushhole_ell_sz * 0.10) * [1,1]) {
 137     for (r=[0,90])
 138       rotate(r)
 139         translate(-pushhole_ell_th * 0.5 * [1,1])
 140         square([ pushhole_ell_sz, pushhole_ell_th ]);
 141   }
 142   circle(pushhole_circle_dia/2, $fn=40);
 143 }
 144
 145 module PlanDemo(){ ////toplevel
 146   color("blue") BaseHalfPlan();
 147   color("red") LidHalfPlan();
 148   translate([0,0,-1]) color("lightblue") SideHalfPlan();
 149 }
 150
 151 module Base(){ ////toplevel
 152   difference(){
 153     ExtrudePlan(0,s1) BaseHalfPlan();
 154     linextr(-(10+battery_len), battery_len+10, convexity=5) PushHolePlan();
 155   }
 156   difference(){
 157     union(){
 158       ExtrudePlan(s0i, s1) SideHalfPlan();
 159       ExtrudePlan(s0 - battery_base_indent_fromside_inside,
 160                   s0 - battery_base_indent_fromside_outside
 161                   ) BaseHalfPlan(indent = battery_base_indent);
 162     }
 163     for (m=[0,1])
 164       mirror([m,0,0])
 165         translate([s0i, 0, bpp7[0] - 0.1])
 166         cylinder(r= battery_th/2, h=100, $fs=0.5);
 167   }
 168 }
 169
 170 module BaseHalfTest(){ ////toplevel
 171   intersection(){
 172     Base();
 173     translate([-100,0,-100])
 174       cube([200,200,200]);
 175   }
 176 }
 177
 178 module Lid(){ ////toplevel
 179   ExtrudePlan(0,s1) LidHalfPlan();
 180   ExtrudePlan(l0,l1) HandleHalfPlan();
 181 }
 182
 183 module Demo(){ ////toplevel
 184   %Base();
 185   Lid();
 186 }
 187
 188 //PlanDemo();
 189 //Demo();
 190 //Base();