chiark / gitweb /
sleepphone-cable-box: reinforce keeper
[reprap-play.git] / fairphone-case.scad
index d77e7b9..d83c534 100644 (file)
 //  this case will meet your needs.
 
 include <utils.scad>
+include <funcs.scad>
 
 phone = [ 75.0, 145.0 ];
 
@@ -167,6 +168,9 @@ noisecancelmic_dia = 4.00;
 //fingerpushhole_dias = [ 15, 18 ];
 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 ];
 
@@ -176,7 +180,7 @@ 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 +208,8 @@ 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;
 
@@ -249,13 +255,16 @@ 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;
 
 prop_recess_under = 0.50;
 prop_recess_slop = 0.200; // each side
@@ -270,6 +279,8 @@ 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 +327,7 @@ 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 +349,7 @@ 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 +362,8 @@ 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 +421,12 @@ 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] ];
@@ -418,7 +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 ];
 
@@ -429,6 +448,23 @@ cppQ = [ cppR[0],
         cppV[1] - (catch_finger_height - cp_rQ) ];
 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
 
 prop_x_pos = phone_width/2;
@@ -504,6 +540,108 @@ module EdgeProfile(){
   }
 }
 
+module LanyardLanyardProfile(entry=false){
+  hull(){
+    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 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])
+      translate(ly_r * [3 * xs, -1])
+       circle(r = ly_r);
+  }
+}
+
+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,
@@ -521,6 +659,16 @@ 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 ],
@@ -824,14 +972,31 @@ module HingePortion(x0,x1){
     mirror([1,0,0])
     rotate([90,0,-90])
     linear_extrude(height=x1-x0)
-    children(0);
+    children();
 }
 
-module CatchPortion(width){
-  translate([phone_width/2, 0,0])
-    rotate([90,0,-90])
-    linextr(-width/2, width/2)
-    children(0);
+module CatchPortion(xwidth, ztop){
+  width = catch_width + xwidth;
+  w = width + catch_topcurve_r*2 + 1;
+  translate([phone_width/2, 0,0]){
+    difference(){
+      rotate([90,0,-90])
+       linextr(-w/2, w/2)
+       children(0);
+      translate([0, 50, 0])
+       rotate([90,0,0])
+       linear_extrude(height=100){
+       for (m=[0,1]) mirror([m,0,0]) {
+         hull(){
+           translate([w/2, ztop - catch_topcurve_r])
+             circle(catch_topcurve_r);
+           translate([w/2, -50])
+             square(catch_topcurve_r*2, center=true);
+         }
+       }
+      }
+    }
+  }
 }
 
 module CaseBase(){
@@ -887,7 +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);
@@ -1032,9 +1197,16 @@ module Case(){ ////toplevel
     HingeScrews();
 
     // catch striker
-    CatchPortion(catch_width + catch_side_gap*2)
+    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])
@@ -1055,19 +1227,27 @@ 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(){
-      intersection_for(skew=[0,1]){
+      intersection(){
+       LidAroundEdges()
+         LidEdgeProfile();
+
        translate(skew_centre)
          multmatrix([[ 1, 0, 0, 0 ],
-                     [ 0, 1, 0, 0 ],
+                     [ 0, 1, -lid_fold_clearance_skew, 0 ],
                      [ 0, 0, 1, 0 ],
                      [ 0, 0, 0, 1 ]])
          translate(-skew_centre)
-         AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
-         LidEdgeProfile();
+         LidAroundEdges()
+         LidEdgeFoldClearanceProfile();
       }
 
       // button covers
@@ -1085,10 +1265,13 @@ module Lid(){ ////toplevel
       }
 
       // hinge arms
-      HingePortion(hex20, hex21) HingeLidProfile();
+      HingePortion(hex20, hex21) {
+       LidEdgeProfile();
+       HingeLidProfile();
+      }
 
       // catch
-      CatchPortion(catch_width)
+      CatchPortion(0, lpp12[1])
        CatchCatchProfile();
     }
     Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
@@ -1461,6 +1644,10 @@ module DemoFrame(){ ////toplevel
   %HingeLever();
 }
 
+module DemoLanyardCutout(){ ////toplevel
+  LanyardCutout(25);
+}
+
 module DemoHingedFrame(){ ///toplevel
   color("red") TestFrameCase();
   translate([0,0, -2*hp_k])
@@ -1485,6 +1672,26 @@ module DemoProfiles(){ ////toplevel
   %EdgeProfile();
   KeeperProfile();
   translate([0,0,-1]) color("black") KeeperProfile(1);
+  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]) {
     LidEdgeProfile();