fairphone-case: hinge: really room to get at locknut

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

diff --git a/fairphone-case.scad b/fairphone-case.scad
index e230a769026fc362eb9069840a9e16272ac84df7..5637594a834bc852c7a65bb181b642787567a45f 100644 (file)
--- a/fairphone-case.scad
+++ b/fairphone-case.scad
@@ -31,9 +31,9 @@ fingerpushhole_dias = [ 15, 18 ];
 rearspeaker_pos_bl = [ 12.64, 18.72 ];
 rearspeaker_size   = [  3.76,  7.36 ];
 
-microusb_above = 4.48 + 0.50;
-microusb_below = 1.82 + 0.50;
-microusb_width = 10.60 + 1.00;
+microusb_above = 3.27 - 0.25;
+microusb_below = 0.0;
+microusb_width = 16.12 + 0.25;
 
 case_th_bottom = 2.5;
 case_th_lid = 2.5;
@@ -62,6 +62,8 @@ lid_gap_x = 0.25;
 lid_gap_z = 0.25;
 lid_lip = 1.75;
 
+catch_slop = 0.25;
+
 foldover_gap = 0.50;
 foldover_lever_gap = 0.50;
 
@@ -80,6 +82,8 @@ $fs = 0.1;
 button_l_fudge = 4.4;
 buttonishleg_default_l_is_fudge = 10;
 
+hinge_base_slope = 1.5; // bigger is steeper
+
 strut_min_at_end = 1.5;
 
 hinge_x_gap = 0.125;
@@ -89,6 +93,16 @@ hinge_r_arms_gap = 0.55;
 
 rearspeaker_gap    = [ 1.0, 1.0 ]; // each side
 
+catch_len = 7.5;
+catch_width = 15;
+catch_thickness = 1.0;
+catch_side_gap = 0.75; // each side
+
+catch_depth = 1.25;
+catch_height = 0.35;
+catch_finger_height = 1.5;
+catch_finger_depth = 2.5;
+
 // ---------- calculated ----------
 
 phone_width =  (phone + bumper*2)[0];
@@ -145,9 +159,12 @@ bppJ = [ bppN[0], bppL[1] ];
 
 // hinge plan
 hp_rn = hingescrew_nut_dia/2;
-hp_r2 = hp_rn + lever_cover_th;
+hp_r2_min = hp_rn + lever_cover_th;
 hp_rs = hingescrew_shaft_dia/2;
-hp_r1 = hp_rs + hingemount_th;
+hp_r1_min = hp_rs + hingemount_th;
+
+hp_r1 = max(hp_r1_min, hp_r2_min);
+hp_r2 = hp_r1;
 
 hppU = lpp13;
 hppS = epp2o + [0,-1] * case_th_bottom;
@@ -158,6 +175,10 @@ hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
 hppT = [ hppM[0], hppU[1] - hp_r1 ];
 hppB = hppT + [0,-1] * hp_k;
 
+hppE_y = epp2o[1] - case_th_bottom + hp_r1;
+hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
+hppE = [ hppE_x, hppE_y ];
+
 // hinge elevation x coords
 
 hingescrew_portion_len =
@@ -167,12 +188,34 @@ hex20 = max(epp2o[0],
            phone_cnr_rad,
            kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
 hex21 = hex20 + hingescrew_portion_len;
-hex22 = hex21 - hinge_x_gap;
-hex23 = hex22 + hingescrew_portion_len;
+hex22 = hex21 + hinge_x_gap;
+hex23 = hex22 + hingescrew_portion_len
+  - hingescrew_nut_thick; // bodge, need to divvy this up more sensibly
 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
 echo(hex20, hex21, hex22, hex23, hex24);
 echo(hingescrew_portion_len);
 
+// catch
+
+cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
+cppA = cppJ + [lid_gap_x, -lid_gap_z];
+cppB = [ epp0[0], cppA[1] ];
+cppP = [ epp4[0], cppJ[1] ];
+
+cppS = cppJ + [0,-1] * catch_len;
+cppD = [ cppA[0], cppS[1] + catch_slop ];
+cppC = [ cppB[0], cppD[1] ];
+cppT = cppS + [1,0] * catch_depth;
+cppU = cppT + [0,-1] * catch_height;
+cppV = [ cppS[0], cppU[1] - catch_depth ];
+
+cppR = 0.5*(cppP + cppJ);
+
+cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
+cppQ = [ cppR[0],
+        cppV[1] - (catch_finger_height - cp_rQ) ];
+cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
+
 // ---------- modules ----------
 
 module KeeperProfile(slant=0){
@@ -266,6 +309,31 @@ module ButtonPlan(l, deep, cut){
   }
 }
 
+module CatchCatchProfile(){
+  hull(){
+    for (c=[ cppR, cppQ ])
+      circleat(c, cp_rQ);
+  }
+  hull(){
+    circleat(lpp12, lp_r12);
+    circleat(lpp12 + [5,0], lp_r12);
+    rectfromto(cppP, cppP + [5,0.1]);
+  }
+  polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
+}
+
+module CatchCutProfile(){
+  polygon([ cppB,
+           cppA,
+           cppD,
+           cppF,
+           cppF + [0,-10],
+           cppF + [-10,-10],
+           lpp12 + [-10,0],
+           lpp12 + [10,0]
+           ]);
+}
+
 module Flip_rhs(yn=[0,1]) {
   for ($rhsflip=yn) {
     translate([phone_width/2, 0, 0])
@@ -355,7 +423,7 @@ module Buttons(){
   Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
   Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
   Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
-  Flip_rhs(   ) LidButtonishLeg(20, -1) children();
+  Flip_rhs(   ) LidButtonishLeg(14, -1) children();
 //  Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
 }
 
@@ -433,6 +501,7 @@ module HingeBaseProfile(){
   difference(){
     hull(){
       circleat(hppB, hp_r1);
+      circleat(hppE, hp_r1);
       circleat(epp2o, case_th_bottom);
       circleat(hppB + [10,0], hp_r1);
     }
@@ -450,10 +519,10 @@ module HingeLeverOuterProfile(){
 module HingeLeverInnerProfile(){
   for (c = [hppT, hppB]) {
     hull()
-      for (x=[0,20])
-       translate([x,0])
-         circleat(c, hp_rn);
-       circleat(hppB, hp_rn);
+      for (x=[-20,20])
+       for (y=[0, c[1] - hppM[1]])
+         translate([x,y])
+           circleat(c, hp_rn);
   }
 }
 
@@ -474,6 +543,13 @@ module HingePortion(x0,x1){
     children(0);
 }
 
+module CatchPortion(width){
+  translate([phone_width/2, 0,0])
+    rotate([90,0,-90])
+    linextr(-width/2, width/2)
+    children(0);
+}
+
 module CaseBase(){
   AroundEdges(epp3[1], case_th_bottom, 1)
     EdgeProfile();
@@ -557,6 +633,10 @@ module Case(){ ////toplevel
 
     // screw holes in the hinge arms
     HingeScrews();
+
+    // catch striker
+    CatchPortion(catch_width + catch_side_gap*2)
+      CatchCutProfile();
   }
 }
 
@@ -582,6 +662,10 @@ module Lid(){ ////toplevel
 
       // hinge arms
       HingePortion(hex20, hex21) HingeLidProfile();
+
+      // catch
+      CatchPortion(catch_width)
+       CatchCatchProfile();
     }
     Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
 
@@ -828,6 +912,14 @@ module DemoProfiles(){ ////toplevel
     color("black") translate([0,0,-2]) HingeLeverOuterProfile();
     color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
   }
+
+  translate([20,-30]) {
+    %EdgeProfile();
+    %LidEdgeProfile();
+    //translate([0,0,1]) CatchCutProfile();
+    color("blue") CatchCatchProfile();
+    color("red") difference(){ EdgeProfile(); CatchCutProfile(); }
+  }
 }
 
 //EdgeProfile();