epaper_door_case/lid.scad

// Sliding lid for EE04 case — integrates epd_case as ceiling
// z=0 = bottom of flanges; ceiling at z=LID_T (epd_case backplate) or z=FLANGE_H (flat test plate)
include <params.scad>
use <epd_case.scad>
use <GDEY0583T81.scad>

/* [Preview] */
SHOW_DISP = true;

// Hinge drum — EPD_ANGLE-swept partial cylinder filling the gap between the flat
// plate and the tilted epd_case back. Radius reaches WALL past the Y- edge of the
// flat-plate FPC slot so a cable path can later be cut inside it.
FPC_SLOT_Y0 = LID_Y_LEN - 3 - FPC_U_DEPTH + FPC_U_T;
HINGE_R     = (OUT_W - WALL) - FPC_SLOT_Y0 + WALL;

// ============================================================
//  LID  (slide-on; enters from Y- face, closes toward Y+)
//  Flanges sit inside cavity and ride on base retention flange hypotenuses.
// ============================================================
module lid() {
  // Flanges: right triangles in XZ; hypotenuse at reciprocal angle to base retention flanges.
  // Wide vertical face at x=WALL+FLANGE_W (inner), tip at bottom-wall-face — same
  // (-FLANGE_W, -FLANGE_H) hypotenuse slope as base flanges so they mate when lid slides in.
  color("#2C3863") {
    // Left (X-) flange
    hull() {
      translate([WALL + FLANGE_W - SLIDE_CLEAR - 0.01, 0, 0])
        cube([0.01, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, FLANGE_H - SLIDE_CLEAR]);
      translate([WALL + SLIDE_CLEAR, 0, -0.005])
        cube([0.01, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, 0.01]);
    }
    // Right (X+) flange
    hull() {
      translate([OUT_L - WALL - FLANGE_W + SLIDE_CLEAR, 0, 0])
        cube([0.01, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, FLANGE_H - SLIDE_CLEAR]);
      translate([OUT_L - WALL - SLIDE_CLEAR - 0.01, 0, -0.005])
        cube([0.01, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, 0.01]);
    }

    // Interior ribs — 2 mm wide
    translate([WALL + FLANGE_W - SLIDE_CLEAR, 0, 0])
      cube([2.0, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, FLANGE_H]);
    translate([OUT_L - WALL - FLANGE_W + SLIDE_CLEAR - 2.0, 0, 0])
      cube([2.0, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, FLANGE_H]);

    // Y+ locking flange — single angled wedge matching side-flange profile.
    // Spans the whole face (the old FPC notch split is no longer needed thanks
    // to the Y- clearance) and shields the cable from pinching during assembly.
    _ypf_x0 = FLANGE_W - SLIDE_CLEAR + 2.0;
    _ypf_w  = OUT_L - FLANGE_W + SLIDE_CLEAR - 2.0 - _ypf_x0;
    hull() {
      translate([_ypf_x0, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR - 0.01, 0])
        cube([_ypf_w, 0.01, FLANGE_H - SLIDE_CLEAR]);
      translate([_ypf_x0, LID_Y_LEN - SLIDE_CLEAR - 0.01, -0.005])
        cube([_ypf_w, 0.01, 0.01]);
    }
    // Backing rib — 2 mm deep on cavity face of flange, matches side-rib style
    translate([_ypf_x0, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR - 2.0, 0])
      cube([_ypf_w, 2.0, FLANGE_H]);

    // Y+ corners — intersection of the X-prism and Y-prism in the corner region.
    // Equivalent to: cube with the X-flange relief cut AND the Y-flange relief cut applied.
    // Result tapers to zero height along both wall faces, producing a single shared edge.
    // Left corner (X-)
    intersection() {
      hull() {
        translate([WALL + FLANGE_W - SLIDE_CLEAR - 0.01, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, 0])
          cube([0.01, FLANGE_W - 2*SLIDE_CLEAR, FLANGE_H - SLIDE_CLEAR]);
        translate([WALL + SLIDE_CLEAR, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, -0.005])
          cube([0.01, FLANGE_W - 2*SLIDE_CLEAR, 0.01]);
      }
      hull() {
        translate([WALL + SLIDE_CLEAR, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, 0])
          cube([FLANGE_W - 2*SLIDE_CLEAR, 0.01, FLANGE_H - SLIDE_CLEAR]);
        translate([WALL + SLIDE_CLEAR, LID_Y_LEN - SLIDE_CLEAR - 0.01, -0.005])
          cube([FLANGE_W - 2*SLIDE_CLEAR, 0.01, 0.01]);
      }
    }
    // Right corner (X+)
    intersection() {
      hull() {
        translate([OUT_L - WALL - FLANGE_W + SLIDE_CLEAR, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, 0])
          cube([0.01, FLANGE_W - 2*SLIDE_CLEAR, FLANGE_H - SLIDE_CLEAR]);
        translate([OUT_L - WALL - SLIDE_CLEAR - 0.01, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, -0.005])
          cube([0.01, FLANGE_W - 2*SLIDE_CLEAR, 0.01]);
      }
      hull() {
        translate([OUT_L - WALL - FLANGE_W + SLIDE_CLEAR, LID_Y_LEN - FLANGE_W + SLIDE_CLEAR, 0])
          cube([FLANGE_W - 2*SLIDE_CLEAR, 0.01, FLANGE_H - SLIDE_CLEAR]);
        translate([OUT_L - WALL - FLANGE_W + SLIDE_CLEAR, LID_Y_LEN - SLIDE_CLEAR - 0.01, -0.005])
          cube([FLANGE_W - 2*SLIDE_CLEAR, 0.01, 0.01]);
      }
    }
  }

  difference() {
    union() {
      // Flat ceiling plate for EPD_ANGLE > 0
      color("#2C3863")
      translate([0, -WALL, FLANGE_H])
        rounded_box(OUT_L, OUT_W, LID_T, CORNER_R);
      if (EPD_IS_LID) {
        translate([OUT_L/2 - epd_case_w/2, OUT_W - WALL, LID_T + LIP])
          rotate([-EPD_ANGLE, 0, 0])
            translate([0, -epd_case_d, 0])
              epd_case();

        // Hinge drum — axis along X at the epd_case pivot line; swept from the
        // flat-plate plane up through EPD_ANGLE to sit flush against the case back.
        // Inset CORNER_R from each end so it stays clear of the corner rounding.
        if (EPD_ANGLE > 0)
          color("#004B49")
          translate([OUT_L/2 - epd_case_w/2 + CORNER_R, OUT_W - WALL, LID_T + LIP])
            rotate([0, 90, 0])
              pie_slice(ang=EPD_ANGLE, l=epd_case_w - 2*CORNER_R, r=HINGE_R,
                        spin=270 - EPD_ANGLE, anchor=BOT, $fn=96);
      }

      // Y- lip — same rounded_box profile clipped to the Y- wall zone so the
      // lip corners match the base exterior corners
      color("#004B49")
      intersection() {
        translate([0, -WALL, FLANGE_H - LIP_H - SLIDE_CLEAR])
          rounded_box(OUT_L, OUT_W, LIP_H + SLIDE_CLEAR, CORNER_R);
        translate([-0.1, -WALL - 0.1, FLANGE_H - LIP_H - SLIDE_CLEAR - 0.1])
          cube([OUT_L + 0.2, WALL + 0.2, LIP_H + SLIDE_CLEAR + 0.2]);
      }
    }

    // FPC cable slot — through flat ceiling plate (test-fit lid only; EPD_IS_LID uses epd_case slot)
    translate([PCB_OX + FPC_CX - FPC_NOTCH_W/2,
               FPC_SLOT_Y0,
               FLANGE_H - 0.1])
      cube([FPC_NOTCH_W, FPC_SLOT_W, LID_T + 0.2]);

    // Cable channel through hinge drum — straight tapered passage hulled between
    // the flat-plate slot mouth and the epd_case backplate slot exit on the tilted
    // face. Both mouths share the same X extent; the hull stays >1.9 mm inside the
    // drum's curved surface.
    if (EPD_IS_LID && EPD_ANGLE > 0)
      hull() {
        translate([PCB_OX + FPC_CX - FPC_NOTCH_W/2, FPC_SLOT_Y0, FLANGE_H + LID_T - 0.1])
          cube([FPC_NOTCH_W, FPC_SLOT_W, 0.2]);
        translate([OUT_L/2 - epd_case_w/2, OUT_W - WALL, LID_T + LIP])
          rotate([-EPD_ANGLE, 0, 0])
            translate([_fpc_x1, BEZEL_Y + DISP_D + DISP_Y_EXTRA - epd_case_d, -0.1])
              cube([_fpc_xw, FPC_SLOT_W, 0.2]);
      }
  }
}

// ============================================================
//  RENDER
// ============================================================
lid();