X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=fairphone-case.scad;h=e3c28c3c82a62f40f60f3c25b7a0d46558e13d41;hp=7bcbec3f32739203454ec5af52ff703b5ac92a66;hb=ed7c1d5e31810755d0f6c6d2f96d0ca2566f204b;hpb=9f04d00b692084d041d49bf5639f8a91cc24cd94 diff --git a/fairphone-case.scad b/fairphone-case.scad index 7bcbec3..e3c28c3 100644 --- a/fairphone-case.scad +++ b/fairphone-case.scad @@ -1,11 +1,15 @@ // -*- C -*- +include + phone = [ 75.0, 145.0 ]; 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; @@ -24,11 +28,16 @@ jack_dia = 9.1 + .5; // some jack I had lying around noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs noisecancelmic_dia = 1.75; -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; @@ -50,17 +59,27 @@ 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 = 0.25; + foldover_gap = 0.50; -foldover_hinger_gap = 0.50; +foldover_lever_gap = 0.50; +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 -hinger_th = 2; +hingescrew_head_th = 1.38 + 0.75; +hingescrew_head_dia = 3.92; +lever_cover_th = 0.75; +hingemount_th = 2.5; $fa = 5; $fs = 0.1; @@ -68,10 +87,27 @@ $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; +hinge_x_arms_gap = 0.35; +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]; @@ -127,29 +163,65 @@ bppK = [ bppL[0], bppN[1] ]; bppJ = [ bppN[0], bppL[1] ]; // hinge plan -hp_rn = hingescrew_nut_dia; -hp_r2 = hp_rn + hinger_th; +hp_rn = hingescrew_nut_dia/2; +hp_r2_min = hp_rn + lever_cover_th; +hp_rs = hingescrew_shaft_dia/2; +hp_r1_min = hp_rs + hingemount_th; + +hp_r1 = max(hp_r1_min, hp_r2_min); +hp_r2 = hp_r1; hppU = lpp13; -hppS = epp2o[1] + [0,-1] * case_th_bottom; +hppS = epp2o + [0,-1] * case_th_bottom; hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap); -hppM = [ epp4[0] - foldover_hinger_gap - hp_r2, +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; - -module rectfromto(a,b) { - ab = b - a; - translate([min(a[0], b[0]), min(a[1], b[1])]) - square([abs(ab[0]), abs(ab[1])]); -} -module circleat(c,r) { translate(c) circle(r); } -module linextr(z0,z1) { - translate([0,0,z0]) - linear_extrude(height=z1-z0) - children(); -} +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, + kppd[0] + hingescrew_head_th + keeper_gap_x_holes); +hex21 = hex20 + 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){ use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope; @@ -242,7 +314,32 @@ module ButtonPlan(l, deep, cut){ } } -module CaseBase_rhsflip(yn=[0,1]) { +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]) mirror([$rhsflip,0,0]) @@ -251,7 +348,7 @@ module CaseBase_rhsflip(yn=[0,1]) { } } -module CaseBase_botflip(yn=[0,1]) { +module Flip_bot(yn=[0,1]) { for ($botflip=yn) { translate([0, -phone_height/2, 0]) mirror([0, $botflip, 0]) @@ -262,14 +359,14 @@ module CaseBase_botflip(yn=[0,1]) { module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ // sides - CaseBase_rhsflip(){ + Flip_rhs(){ translate([0, -phone_cnr_rad, 0]) rotate([90,0,0]) linear_extrude(height = phone_height - phone_cnr_rad*2) children(0); } // corners - CaseBase_rhsflip() CaseBase_botflip() { + Flip_rhs() Flip_bot() { translate([+1,-1] * phone_cnr_rad) intersection(){ rotate_extrude() @@ -284,7 +381,7 @@ module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ } } // top and bottom - CaseBase_botflip(){ + Flip_bot(){ translate([ phone_width - phone_cnr_rad, 0,0 ]) rotate([90,0,-90]) linear_extrude(height = phone_width - phone_cnr_rad*2) @@ -317,7 +414,7 @@ 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(); } @@ -328,11 +425,11 @@ module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) { } module Buttons(){ - CaseBase_rhsflip([1]) SideButton(15.580, +1, 8.9) children(); // power - CaseBase_rhsflip([1]) SideButton(48.700, -1, 8.920) children(); // camera - CaseBase_rhsflip([0]) SideButton(30.800, +1, 21.96) children(); // volume - CaseBase_rhsflip( ) LidButtonishLeg(20, -1) children(); -// CaseBase_rhsflip([0]) LidButtonishLeg(20, +1, 20) children(); + 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(14, -1) children(); +// Flip_rhs(0) LidButtonishLeg(20, +1, 20) children(); } module Struts(x_start, z_min, th){ @@ -354,13 +451,24 @@ module Struts(x_start, z_min, th){ } module OrdinaryRearAperture(rhs,bot, pos){ - CaseBase_rhsflip(rhs) CaseBase_botflip(bot) + Flip_rhs(rhs) Flip_bot(bot) linextr(-20, 20) mirror([0,1]) translate(pos + bumper) 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) @@ -368,14 +476,15 @@ 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 ); } module RearCameraAperture(){ - CaseBase_rhsflip([1]) + Flip_rhs(1) mirror([0, 0, 1]) linear_extrude(height = 20) mirror([0, 1, 0]) @@ -383,6 +492,70 @@ module RearCameraAperture(){ rectfromto(camera_pos_tl, camera_pos_br); } +module HingeLidProfile(){ + hull(){ + circleat(hppT, hp_r1); + circleat(lpp12, lp_r12); + polygon([lpp10, + lpp13 + [2,0], + lpp12, + hppT]); + } +} + +module HingeBaseProfile(){ + difference(){ + hull(){ + circleat(hppB, hp_r1); + circleat(hppE, hp_r1); + circleat(epp2o, case_th_bottom); + circleat(hppB + [10,0], hp_r1); + } + polygon([epp5, epp1, epp2i, epp3, bppL]); + } +} + +module HingeLeverOuterProfile(){ + hull(){ + circleat(hppT, hp_r2); + circleat(hppB, hp_r2); + } +} + +module HingeLeverInnerProfile(){ + for (c = [hppT, hppB]) { + hull() + 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]) + mirror([1,0,0]) + rotate([90,0,-90]) + linear_extrude(height=x1-x0) + 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(); @@ -394,7 +567,7 @@ 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); @@ -403,14 +576,16 @@ module Case(){ ////toplevel translate([0,0, -25]) linear_extrude(height = 50) hull() - // CaseBase_rhsflip() // actually, we only care about the LH - CaseBase_botflip() + Flip_bot() circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2); } + + // hinge + HingePortion(hex20, hex21) HingeBaseProfile(); } // slot for keeper - CaseBase_rhsflip(1) + Flip_rhs(keeper_side) translate([0, -phone_cnr_rad, 0]) rotate([90, 0, 0]) linear_extrude(height = phone_height + phone_cnr_rad * 2) @@ -429,6 +604,7 @@ 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) @@ -436,7 +612,13 @@ 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) @@ -446,10 +628,27 @@ module Case(){ ////toplevel // apertures along top edge CaseAperture(jack_pos, jack_dia, 8); - CaseBase_rhsflip([1]) + Flip_rhs(1) CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20); 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(); } } @@ -472,16 +671,62 @@ 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(); + } +} + +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]); +} + module TestLength(){ ////toplevel intersection(){ Case(); - translate([-30, -200, -20]) - cube([30 + 15, 250, 40]); + TestSelectLength(); + } +} + +module TestLengthRight(){ ////toplevel + intersection(){ + Case(); + Flip_rhs(1) + TestSelectLength(); } } @@ -589,22 +834,58 @@ module TestFrameCase(){ ////toplevel } module TestFrameLidPrint(){ ////toplevel - rotate([0,0,180]) intersection(){ + rotate([0,180,0]) intersection(){ Lid(); TestSelectFrame(); } } -module Keeper(){ ////toplevel - CaseBase_rhsflip() - 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(); TestSelectFrame(); } + color("black") HingeScrews(); + %HingeLever(); +} + +module DemoHingedFrame(){ ///toplevel + color("red") TestFrameCase(); + translate([0,0, -2*hp_k]) + color("blue") intersection(){ Lid(); TestSelectFrame(); } + + Flip_hinge(){ + color("orange") HingeLever(); + color("black") HingeScrews(); + } +} + +module DemoHinge(){ ////toplevel + DemoFrame(); + translate([0,0, -hp_k*3]) + DemoHingedFrame(); +} + module DemoProfiles(){ ////toplevel LidEdgeProfile(); %EdgeProfile(); @@ -629,6 +910,23 @@ module DemoProfiles(){ ////toplevel color("red" ) ButtonPlanForDemo(-4, 1,1); color("blue") ButtonPlanForDemo(-6, 1,0); } + + translate([0, -30]) { + %LidEdgeProfile(); + %EdgeProfile(); + color("blue") HingeLidProfile(); + color("red") HingeBaseProfile(); + 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();