From c9e34f298b058864dcf23965ed46975d6101be57 Mon Sep 17 00:00:00 2001
From: "Jan \"Yenya\" Kasprzak" <kas@fi.muni.cz>
Date: Tue, 9 Dec 2014 08:26:27 +0100
Subject: [PATCH] case.scad: alternative lid clips

Also higher holes for battery contacts, bigger grabbing holes,
and holes for battery contacts also in the lid.

Thicker outer wall of the case above the PCB.
---
 case.scad | 39 ++++++++++++++++++++++++---------------
 1 file changed, 24 insertions(+), 15 deletions(-)

diff --git a/case.scad b/case.scad
index 43583c4..653a79a 100644
--- a/case.scad
+++ b/case.scad
@@ -53,7 +53,9 @@ clip_pretension = 0.5;
 plus_width = 4.5; // width of the + sign
 
 batt_contact_w = 12;
-clip_cyl_r = 1;
+batt_contact_h = 14;
+batt_contact_h_lid = batt_contact_h-2;
+clip_cyl_r = 0.7;
 batt_end_h = body_top_h - 4*clip_cyl_r;;
 
 
@@ -70,9 +72,9 @@ module case_body() {
 			translate([-infty/2, -infty/2, eps]) cube(infty);
 		};
 		translate([-front_flat_len/2,
-			batt_diam/2 - pcb_width,
+			batt_diam/2 - pcb_width-0.5*wall,
 			-batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall])
-			cube([front_flat_len, pcb_width+wall, eps]);
+			cube([front_flat_len, pcb_width+1.5*wall, eps]);
 	};
 	// mounting cylinders
 	for (x = [-1, 1]) translate([x*(batt_len/2-mounthole_w/2),
@@ -102,20 +104,21 @@ module case() {
 		// upper cube-shaped part
 		// rotate([20, 0, 0])
 		translate([-batt_len/2, -batt_diam/2, 0])
-			cube([batt_len, batt_diam, batt_diam]);
+			cube([batt_len, batt_diam, batt_end_h+eps]);
 		// upper longer cube-shaped part
 		difference() {
 			translate([-batt_len/2-cable_sep-wall, -batt_diam/2, batt_end_h])
 				cube([batt_len+2*cable_sep+2*wall, batt_diam, batt_diam]);
-			for (x = [-1,1]) scale([x, 1, 1])
-				translate([batt_len/2 + wall + cable_sep, -infty/2, batt_end_h + 3*clip_cyl_r])
-				rotate([-90, 0, 0])
-				cylinder(r = clip_cyl_r, h = infty, $fn=4);
+			// clips
+			for (x = [-1,1]) scale([1, x, 1])
+				translate([batt_len/6, batt_diam/2, batt_end_h + 3*clip_cyl_r])
+				rotate([0, -90, 0])
+				cylinder(r = clip_cyl_r, h = batt_len/3, $fn=4);
 		}
 		// grabbing holes
 		for (x=[-1,1]) scale([x,1,1])
 		translate([batt_len/2 + 2*wall + cable_sep+10-wall, 0, 0])
-			cylinder(r1 = 7, r2 = 10-wall/4, h = body_top_h + eps);
+			cylinder(r1 = 7, r2 = 10, h = body_top_h + eps);
 		// battery cylinder for the lower part
 		translate([-batt_len/2, 0, 0])
 			rotate([0, 90, 0])
@@ -180,12 +183,12 @@ module case() {
 		// holes in front of battery contacts
 		for(x=[-1,1]) scale([x, 1, 1])
 		translate([batt_len/2-eps, wall/2-batt_contact_w/2,
-			wall/2-batt_contact_w/2])
+			wall/2-batt_contact_h/2])
 			cube([wall+2*eps, batt_contact_w-wall, infty]);
 		// holes for battery contacts
 		for(x=[-1,1]) scale([x, 1, 1])
 		translate([batt_len/2+wall-eps, -batt_contact_w/2,
-			-batt_contact_w/2])
+			-batt_contact_h/2])
 			cube([cable_sep+2*eps, batt_contact_w, infty]);
 		// internal plus sign - vertical line
 		translate([-batt_len/2 + 0.5*wall+plus_width/2, -plus_width/2, -batt_diam/2-wall])
@@ -219,10 +222,11 @@ module lid_body() {
 	translate([-batt_len/2 - wall - cable_sep + lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
 		cube([batt_len + 2*wall + 2*cable_sep - 2*lid_sep, batt_diam-2*lid_sep, batt_diam/2 - batt_end_h + wall - lid_sep]);
 	// clips
-	for (x = [-1, 1]) scale([x, 1, 1])
-	translate([batt_len/2 + wall + cable_sep - lid_sep, batt_diam/2 - lid_sep, -batt_end_h-lid_sep-clip_cyl_r])
-		rotate([90, 0, 0])
-		cylinder(r = clip_cyl_r, h = batt_diam-2*lid_sep, $fn = 4);
+	for (x = [-1, 1]) scale([1, x, 1])
+		translate([batt_len/6, batt_diam/2-lid_sep, - batt_end_h - clip_cyl_r - lid_sep])
+		rotate([0, -90, 0])
+		cylinder(r = clip_cyl_r, h = batt_len/3, $fn=4);
+	// translate([batt_len/2 + wall + cable_sep - lid_sep, batt_diam/2 - lid_sep, -batt_end_h-lid_sep-clip_cyl_r])
 }
 
 module lid() {
@@ -230,6 +234,11 @@ module lid() {
 		lid_body();
 		translate([-batt_len/2-lid_sep, 0, 0]) rotate([0, 90, 0])
 			cylinder(r=batt_diam/2 + lid_sep, h=batt_len+2*lid_sep);
+		// holes for battery contacts
+		for(x=[-1,1]) scale([x, 1, 1])
+		translate([batt_len/2+wall-eps, -batt_contact_w/2,
+			-batt_contact_h_lid/2])
+			cube([cable_sep+2*eps, batt_contact_w, infty]);
 	};
 };
 
-- 
2.39.3