sleepphone-cable-box: reinforce keeper

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

diff --git a/fairphone-case.scad b/fairphone-case.scad
index bc0cef0062460d5c596fed1c65c6c4d6709b1c17..d83c53474f4b548972d672539cecb5210bf28c8b 100644 (file)
--- a/fairphone-case.scad
+++ b/fairphone-case.scad
@@ -169,7 +169,8 @@ noisecancelmic_dia = 4.00;
 fingerpushhole_dias = [];
 
 lanyard_half_dia = 1.15;
-
+lanyard_entry_rel_breadth = 2;
+lanyard_channel_len = 15;
 rearspeaker_pos_bl = [ 12.64, 18.72 ];
 rearspeaker_size   = [  3.76,  7.36 ];
 
@@ -254,13 +255,14 @@ rearspeaker_gap    = [ 2.0, 2.0 ]; // each side
 
 catch_len = 7.5;
 catch_width = 15;
-catch_thickness = 1.0;
+catch_thickness = 1.3;
 catch_side_gap = 0.75; // each side
 
-catch_depth = 0.75;
+catch_depth = 1.25;
 catch_height = 0.35;
 catch_finger_height = 1.5;
 catch_finger_depth = 2.5;
+catch_catch_slope = 0.25;
 
 catch_topcurve_r = 5.0;
 
@@ -435,7 +437,7 @@ 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;
+cppT = cppS + [1, -catch_catch_slope] * catch_depth;
 cppU = cppT + [0,-1] * catch_height;
 cppV = [ cppS[0], cppU[1] - catch_depth ];
 
@@ -449,6 +451,19 @@ cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
 // lanyard
 
 ly_r = lanyard_half_dia / 2;
+ly_rc = ly_r * 2;
+
+ly_theta = -atan2vector(epp2i - epp1);
+ly_o = epp2i + 3 * ly_r * unitvector2d(epp1 - epp2i);
+
+max_case_bottom_edge_thickness =
+  case_th_bottom
+  + sin(ly_theta) * (epp2i-epp2o)[0];
+
+ly_q_z = -(ly_rc + ly_r);
+ly_re = max_case_bottom_edge_thickness - (-ly_q_z);
+
+ly_oec_y = lanyard_entry_rel_breadth * ly_r;
 
 // prop recess in case
 
@@ -527,15 +542,23 @@ module EdgeProfile(){
 
 module LanyardLanyardProfile(entry=false){
   hull(){
-    for (xs=[-1,+1] * (entry ? 2 : 1))
+    for (xs=[-1,+1] * (entry ? lanyard_entry_rel_breadth : 1))
       translate(xs * 0.5 * lanyard_half_dia * [1,0])
        circle(r= lanyard_half_dia/2);
   }
 }
 
-module LanyardMainChannelProfile(){
+module LanyardCurveChannelProfile(){
   translate([0, -ly_r])
     LanyardLanyardProfile();
+}  
+
+module LanyardEntryChannelProfile(){
+  LanyardLanyardProfile(true);
+}  
+
+module LanyardMainChannelProfile(){
+  LanyardCurveChannelProfile();
   difference(){
     square(center=true, ly_r * [6, 2]);
     for (xs=[-1,+1])
@@ -544,6 +567,81 @@ module LanyardMainChannelProfile(){
   }
 }
 
+module LanyardEntryOuterProfile(){
+  circleat([ly_re + ly_r, 0], ly_re);
+}
+
+module LanyardEntry(){
+  q_z = ly_q_z;
+  oec_y = ly_oec_y;
+
+  d_x = -ly_rc;
+
+  translate([d_x, 0, q_z]) {
+    intersection(){
+      rotate([90,0,0])
+       rotate_extrude(convexity=10)
+       rotate(90)
+       translate([0, -q_z])
+       LanyardCurveChannelProfile();
+      translate([0,-10,0])
+       cube([20,20,20]);
+    }
+  }
+
+  mirror([0,0,1])
+    translate([0,0,-1])
+    linear_extrude(height=20)
+    rotate(-90)
+    LanyardEntryChannelProfile();
+
+  translate([0, ly_r*2, 0])
+    rotate([90,0,0])
+    linear_extrude(height = ly_r*4){
+    difference(){
+      rectfromto([d_x, q_z], [ly_r, 0]);
+      circleat([d_x, q_z], ly_rc);
+    }
+  }
+
+  translate([0,0,q_z]){
+    for (my=[0,1])
+      mirror([0,my,0]){
+       translate([0, oec_y, 0]){
+         difference(){
+           translate(ly_re * [-1,0,-2])
+             cube(ly_re * [2,1,2]);
+           rotate_extrude(convexity=10)
+             LanyardEntryOuterProfile();
+         }
+       }
+      }
+    difference(){
+      translate([-ly_re, -(oec_y + 0.01), -2*ly_re])
+       cube([ly_re*2, 2*(oec_y + 0.01), 2*ly_re]);
+      for (mx=[0,1])
+       mirror([mx,0,0])
+         rotate([90,0,0])
+         translate([0,0,-10])
+         linear_extrude(height=20)
+         LanyardEntryOuterProfile();
+    }
+  }
+}
+
+module LanyardCutout(l){
+  rotate([0,-90,0])
+    linear_extrude(height=l)
+    rotate(-90)
+    LanyardMainChannelProfile();
+
+  for (ee=[0,1]){
+    translate(ee * l * [-1,0])
+      mirror([ee,0,0])
+      LanyardEntry();
+  }
+}
+
 module LidEdgeProfile(){
   polygon([ lpp10,
            lpp11,
@@ -954,7 +1052,7 @@ module PropProfileAssignments(gamma){
   children();
 }
 
-module PropProfile(gamma, cut=0, rot=0){ ////toplevel
+module PropProfile(gamma, cut=0, rot=0){
   PropProfileAssignments(gamma){
 
     //#circleat($prpp3,1);
@@ -1102,6 +1200,13 @@ module Case(){ ////toplevel
     CatchPortion(catch_side_gap*2, epp4[1])
       CatchCutProfile();
 
+    // lanyard
+    Flip_bot(1)
+      translate([ly_o[0], -(phone_cnr_rad + ly_re), ly_o[1]])
+      rotate([0, ly_theta, 0])
+      rotate([0,0,90])
+      LanyardCutout(lanyard_channel_len);
+
     // prop recess
     Flip_rhs(1)
       translate([prop_x_pos,0,0])
@@ -1539,6 +1644,10 @@ module DemoFrame(){ ////toplevel
   %HingeLever();
 }
 
+module DemoLanyardCutout(){ ////toplevel
+  LanyardCutout(25);
+}
+
 module DemoHingedFrame(){ ///toplevel
   color("red") TestFrameCase();
   translate([0,0, -2*hp_k])
@@ -1563,17 +1672,25 @@ module DemoProfiles(){ ////toplevel
   %EdgeProfile();
   KeeperProfile();
   translate([0,0,-1]) color("black") KeeperProfile(1);
-  color("purple") translate(epp2i)
-    rotate(atan2vector(epp2i - epp1)) {
-    translate(lanyard_half_dia * 0.5 * [-3,-1])
-      LanyardLanyardProfile();
-    translate(lanyard_half_dia * 0.5 * [-3,+1])
-      translate([0,-1] * case_th_side)
-      LanyardLanyardProfile(true);
+  translate(ly_o){
+    rotate(-ly_theta){
+      translate([0,0,+1]) color("purple") LanyardMainChannelProfile();
+      translate([0,0,+2]) color("red") LanyardCurveChannelProfile();
+      translate([0, ly_q_z]){
+       translate([0,0,-1]) color("blue") LanyardEntryChannelProfile();
+       translate([ly_oec_y,0,-2]) color("black") LanyardEntryOuterProfile();
+      }
+    }
   }
+  translate([0,0,-5]) color("white") translate(epp2i)
+    rotate(-ly_theta)
+    rectfromto([-15, 0],
+              [+15, -max_case_bottom_edge_thickness]);
 
   translate([0,20]) {
     LanyardMainChannelProfile();
+    translate([0,0,1]) color("purple") LanyardCurveChannelProfile();
+    translate([0,0,-1]) color("red") LanyardEntryChannelProfile();
   }
 
   translate([20,0]) {