X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=fairphone-case.scad;h=bdde9ad932fbd42847e6bbbc7920683a62713df1;hp=7739a1e5b9fdfe678b831ecf3e4df4dadae6bfb1;hb=8263f4e484f4fc931f300d34c1e154cd7661a988;hpb=3c84fe4beac2b8cd217cd5e6e4cbc69da2c7ce42 diff --git a/fairphone-case.scad b/fairphone-case.scad index 7739a1e..bdde9ad 100644 --- a/fairphone-case.scad +++ b/fairphone-case.scad @@ -4,10 +4,14 @@ include phone = [ 75.0, 145.0 ]; +prop_lid_posns = [ 58, 140 ]; // measured from bottom of phone + bumper = [ 0.250, -0.025 ]; // ^ One side. Overall size is increased by twice this. // If no bumpers, is the gap around the phone. +enable_support = 1; + phone_cnr_rad = 6.0; button_cutout_depth = 9; @@ -20,17 +24,22 @@ phone_backside_slope_outer = 1.0; // larger means shallower camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back -jack_pos = [ 13.92, 7.96 ]; -jack_dia = 9.1 + .5; // some jack I had lying around +jack_pos = [ 14.38, 7.96 ]; +jack_dia = 10.64 + .5; // some jack I had lying around noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs -noisecancelmic_dia = 1.75; +noisecancelmic_dia = 4.00; -fingerpushhole_dias = [ 14, 17 ]; +//fingerpushhole_dias = [ 15, 18 ]; +fingerpushhole_dias = []; -rearspeaker_pos_bl = [ 14.92, 18.72 ]; +rearspeaker_pos_bl = [ 12.64, 18.72 ]; rearspeaker_size = [ 3.76, 7.36 ]; +microusb_above = 3.27 - 0.25; +microusb_below = 0.0; +microusb_width = 16.12 + 1.25; + case_th_bottom = 2.5; case_th_lid = 2.5; case_th_side = 2; @@ -52,12 +61,16 @@ keeper_gap_z_bot = 0.75; keeper_gap_x = 0.25; keeper_gap_x_holes = 0.75; +keeper_side = 0; // 0 = lhs; 1 = rhs + case_lip = 1.25; lid_gap_x = 0.25; lid_gap_z = 0.25; lid_lip = 1.75; +catch_slop = 0.50; + foldover_gap = 0.50; foldover_lever_gap = 0.50; @@ -65,6 +78,8 @@ hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw hingescrew_shaft_len = 12; hingescrew_nut_thick = 1.93 + 0.20; // incl. washer hingescrew_nut_dia = 4.72 + 0.50; // washer, actually +hingescrew_head_th = 1.38 + 0.75; +hingescrew_head_dia = 3.92; lever_cover_th = 0.75; hingemount_th = 2.5; @@ -74,12 +89,37 @@ $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; hinge_x_postscrew_gap = 0.75; - -rearspeaker_gap = [ 1.0, 1.0 ]; // each side +hinge_x_arms_gap = 0.35; +hinge_r_arms_gap = 0.55; + +rearspeaker_gap = [ 2.0, 2.0 ]; // each side + +catch_len = 7.5; +catch_width = 15; +catch_thickness = 1.0; +catch_side_gap = 0.75; // each side + +catch_depth = 0.75; +catch_height = 0.35; +catch_finger_height = 1.5; +catch_finger_depth = 2.5; + +prop_main_width = 3; +prop_main_th = 3; +prop_wing_len = 3; +prop_nose_slope = 1.5; // bigger means pointier +prop_side_gap = 0.75; // each side +prop_fin_height = 1.5; +prop_fin_width = 0.75; +prop_max_angle = 45; // bigger means at worse angle +prop_recess_under = 0.30; +prop_backfwd_gap = 1.0; // total // ---------- calculated ---------- @@ -97,6 +137,11 @@ lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top; phone_backside_slope_thick = phone_total_thick - phone_edge_thick; +prop_nose_len = case_th_lid - prop_recess_under; +prop_recess_slope = tan(prop_max_angle); // bigger means steeper +prop_recess_depth = case_th_lid - prop_recess_under; +prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap; + //lid_lip_overlap_width xxx bad name = ; //lid_lip_inner_slope = [ 5, 5 ]; // xxx @@ -137,9 +182,12 @@ 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; @@ -147,19 +195,57 @@ hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap); hppM = [ epp4[0] - foldover_lever_gap - hp_r2, 0.5 * (hppU + hppS)[1] ]; -hppT = hppM + 0.5 * [0,+1] * hp_k; -hppB = hppM + 0.5 * [0,-1] * hp_k; +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 = 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap); -hex20 = max(epp2o[0], phone_cnr_rad); +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; -hex24 = hex23 + hinge_x_postscrew_gap; +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] ]; + +// prop recess + +prp1 = [0,0]; // by definition +prp2 = prp1 + [ -prop_recess_slope, -1 ] * prop_recess_depth; +prp4 = prp1 + [1,0] * prop_recess_width; +prp3 = [ prp4[0], prp2[1] ]; +prp5 = prp4 + [1,0] * prop_recess_depth; // ---------- modules ---------- @@ -254,6 +340,31 @@ 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]) @@ -329,7 +440,7 @@ module SideButton(y, y_ref_sign, l){ eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 : y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 : y; - echo(eff_y); + //echo(eff_y); translate([0, eff_y, 0]) children(); } @@ -343,7 +454,7 @@ 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(); } @@ -373,6 +484,17 @@ module OrdinaryRearAperture(rhs,bot, pos){ children(); } +module MicroUSB(){ + Flip_bot(1){ + rotate([90,0,0]) + mirror([0,0,1]) + linextr(-epp2i[0], 60) + translate([0.5 * phone_width, 0, 0]) + rectfromto([-microusb_width/2, epp2i[1] + microusb_below], + [+microusb_width/2, epp0[1] + -microusb_above]); + } +} + module OrdinaryRearApertures(){ // rear speaker OrdinaryRearAperture(1,1, rearspeaker_pos_bl) @@ -380,8 +502,9 @@ module OrdinaryRearApertures(){ rearspeaker_size + rearspeaker_gap); // finger hole to remove phone - OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0], - phone[1]/2 ]) + if (len(fingerpushhole_dias)) + OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0], + phone[1]/2 ]) scale(fingerpushhole_dias) circle(r= 0.5 ); } @@ -410,6 +533,7 @@ module HingeBaseProfile(){ difference(){ hull(){ circleat(hppB, hp_r1); + circleat(hppE, hp_r1); circleat(epp2o, case_th_bottom); circleat(hppB + [10,0], hp_r1); } @@ -427,13 +551,21 @@ 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); } } +module Flip_hinge(){ + hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]]; + translate(hinge_origin) + rotate([180,0,0]) + translate(-hinge_origin) + children(); +} + module HingePortion(x0,x1){ Flip_rhs() Flip_bot(1) translate([x0,0,0]) @@ -443,6 +575,34 @@ 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 PropRecess(){ + // origin and orientation are nonstandard + hwd345 = 0.5*prop_main_width + prop_side_gap; + hwd35 = 0.5*prop_fin_width + prop_side_gap; + linextr(-hwd345, +hwd345) + polygon([ prp1, + prp2, + prp3, + prp4, + prp4 + [0,10], + prp1 + [0,10], + ]); + linextr(-hwd35, +hwd35) + polygon([ prp1, + prp3, + prp5, + prp5 + [0,10], + prp1 + [0,10], + ]); +} + module CaseBase(){ AroundEdges(epp3[1], case_th_bottom, 1) EdgeProfile(); @@ -454,7 +614,7 @@ module Case(){ ////toplevel CaseBase(); // ledge (fixed keeper) - intersection(){ + Flip_rhs(1-keeper_side) intersection(){ rotate([90, 0, 0]) linear_extrude(height = phone_height + phone_cnr_rad * 2) KeeperProfile(1); @@ -463,7 +623,6 @@ module Case(){ ////toplevel translate([0,0, -25]) linear_extrude(height = 50) hull() - // Flip_rhs() // actually, we only care about the LH Flip_bot() circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2); } @@ -473,7 +632,7 @@ module Case(){ ////toplevel } // slot for keeper - Flip_rhs(1) + Flip_rhs(keeper_side) translate([0, -phone_cnr_rad, 0]) rotate([90, 0, 0]) linear_extrude(height = phone_height + phone_cnr_rad * 2) @@ -492,6 +651,7 @@ module Case(){ ////toplevel Buttons(){ mirror([1,0,0]) rotate([90,0,90]) { + if (!($button_leg_only && enable_support)) intersection(){ translate([0,0,-10]) linear_extrude(height= 20) @@ -499,7 +659,13 @@ module Case(){ ////toplevel if ($button_leg_only) rotate([-90,90,0]) translate([phone_width/2, -400, kppe[1]]) - mirror([$rhsflip,0,0]) cube([400, 800, 50]); + mirror([1-abs($rhsflip - keeper_side),0,0]) + cube([400, 800, 50]); + if (enable_support) + rotate([-90,90,0]) + translate([-400, -400, kppd[1]]) + mirror([0,0,1]) + cube([800,800,100]); } translate([0,0, -bppR[0]]) linear_extrude(height= 20) @@ -510,9 +676,26 @@ module Case(){ ////toplevel // apertures along top edge CaseAperture(jack_pos, jack_dia, 8); Flip_rhs(1) - CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20); + CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8); OrdinaryRearApertures(); + + MicroUSB(); + + // gaps for the lid's hinge arms + HingePortion(hex20 - hinge_x_arms_gap, + hex21 + hinge_x_arms_gap) + minkowski(){ + HingeLidProfile(); + circle(r= hinge_r_arms_gap, $fn= 8); + } + + // screw holes in the hinge arms + HingeScrews(); + + // catch striker + CatchPortion(catch_width + catch_side_gap*2) + CatchCutProfile(); } } @@ -535,11 +718,52 @@ module Lid(){ ////toplevel ButtonCoverProfile(); } } + + // hinge arms + HingePortion(hex20, hex21) HingeLidProfile(); + + // catch + CatchPortion(catch_width) + CatchCatchProfile(); } Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid); + + // screw holes in the hinge arms + HingeScrews(); + + // prop recesses + Flip_bot(1) + for (y = prop_lid_posns) + translate([ phone_width/2, -y, lpp13[1] ]) + rotate([90,0,90]) + PropRecess(); } } +module HingeLever(){ ////toplevel + difference() { + // outer body, positive + HingePortion(hex22, hex22 + phone_width/2) + HingeLeverOuterProfile(); + + // space for the screws + HingePortion(hex23, hex24) + HingeLeverInnerProfile(); + + // bores for the screws + HingeScrews(); + + // space for the charging cable + MicroUSB(); + Flip_hinge() MicroUSB(); + } +} + +module HingeLeverPrint(){ ////toplevel + rotate([90,0,0]) + HingeLever(); +} + module TestSelectLength(){ translate([-30, -200, -20]) cube([30 + 15, 250, 40]); @@ -641,6 +865,19 @@ module LidPrint(){ ////toplevel Lid(); } +module TestSelectPropRecesses(posns){ + linextr(-100,100){ + translate([phone_width/2, -phone_height]){ + square([ 3, 500 ], center=true); + for (y=posns) + hull() + for (dy=[ -prp5[0], -prp2[0] ]) + translate([0,y+dy]) + square([prop_main_width+5, 5], center=true); + } + } +} + module TestSelectFrame(){ include = [1,-1] * (epp2i[0] + 4); @@ -652,6 +889,11 @@ module TestSelectFrame(){ } } +module TestSelectLidFrame(){ + TestSelectFrame(); + TestSelectPropRecesses(prop_lid_posns); +} + module TestFrameCase(){ ////toplevel intersection(){ Case(); @@ -664,22 +906,58 @@ module TestFrameCase(){ ////toplevel } module TestFrameLidPrint(){ ////toplevel - rotate([0,0,180]) intersection(){ + rotate([0,180,0]) intersection(){ Lid(); - TestSelectFrame(); + TestSelectLidFrame(); } } -module Keeper(){ ////toplevel - Flip_rhs() - OneKeeper(); -} - module ButtonPlanForDemo(z, deep, cut){ translate([0,0,z]) ButtonPlan(8, deep, cut); } +module HingeScrews(){ + Flip_rhs() Flip_bot(1){ + for (c= [ hppT, hppB ]) + translate([ hex20, + -c[0], + c[1] ]){ + rotate([0,90,0]) + translate([0,0,-.2]) + cylinder( r= hingescrew_shaft_dia/2, + h = hingescrew_shaft_len+0.2 ); + rotate([0,-90,0]) + translate([0,0,+.1]) + cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th ); + } + } +} + +module DemoFrame(){ ////toplevel + color("red") TestFrameCase(); + color("blue") intersection(){ Lid(); TestSelectLidFrame(); } + color("black") HingeScrews(); + %HingeLever(); +} + +module DemoHingedFrame(){ ///toplevel + color("red") TestFrameCase(); + translate([0,0, -2*hp_k]) + color("blue") intersection(){ Lid(); TestSelectLidFrame(); } + + Flip_hinge(){ + color("orange") HingeLever(); + color("black") HingeScrews(); + } +} + +module DemoHinge(){ ////toplevel + DemoFrame(); + translate([0,0, -hp_k*3]) + DemoHingedFrame(); +} + module DemoProfiles(){ ////toplevel LidEdgeProfile(); %EdgeProfile(); @@ -713,6 +991,14 @@ 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(); @@ -723,3 +1009,4 @@ module DemoProfiles(){ ////toplevel //LidEdgeProfile(); //KeeperProfile(); //DemoProfiles(); +//PropRecess();