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OpenSCAD source code: Sony NP-BX1 battery holder with SMT pogo pin contacts
// Holder for Sony NP-BX1 Li-Ion battery
// Ed Nisley KE4ZNU January 2013
// 2018-11-15 Adapted for wire leads from 1.5 mm test pins, added upright wire bases
// Layout options
Layout = "Show"; // Show Build Fit Case Lid Pins
//- Extrusion parameters - must match reality!
// Print with +2 shells and 3 solid layers
ThreadThick = 0.25;
ThreadWidth = 0.35;
HoleWindage = 0.2;
function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
Protrusion = 0.1; // make holes end cleanly
inch = 25.4;
BuildOffset = 3.0; // clearance for build layout
Gap = 2.0; // separation for Fit parts
//- Battery dimensions - rationalized from several samples
// Coordinate origin at battery contact face with key openings below contacts
Battery = [43.0,30.0,9.5]; // X = length, Y = width, Z = thickness
Contacts = [[-0.75,6.0,6.2],[-0.75,16.0,6.2]]; // relative to battery edge, front, and bottom
KeyBlocks = [[1.75,3.70,2.90],[1.75,3.60,2.90]]; // recesses in battery face set X position
//- Pin dimensions
ID = 0;
OD = 1;
LENGTH = 2;
PinShank = [1.5,2.0,6.5]; // shank, flange, compressed length
PinFlange = [1.5,2.0,0.5]; // flange, length included in PinShank
PinTip = [0.9,0.9,2.5]; // extended spring-loaded tip
PinChannel = PinFlange[LENGTH] + 0.5; // cut behind flange for solder overflow
PinRecess = 3.0; // recess behind pin flange end for epoxy fill
echo(str("Contact tip dia: ",PinTip[OD]));
echo(str(" .. shank dia: ",PinShank[ID]));
OverTravel = 0.5; // space beyond battery face at X origin
//- Holder dimensions
GuideRadius = ThreadWidth; // friction fit ridges
GuideOffset = 7; // from compartment corners
WallThick = 4*ThreadWidth; // holder sidewalls
BaseThick = 6*ThreadThick; // bottom of holder to bottom of battery
TopThick = 6*ThreadThick; // top of battery to top of holder
ThumbRadius = 10.0; // thumb opening at end of battery
CornerRadius = 3*ThreadThick; // nice corner rounding
CaseSize = [Battery.x + PinShank[LENGTH] + OverTravel + PinRecess + GuideRadius + WallThick,
Battery.y + 2*WallThick + 2*GuideRadius,
Battery.z + BaseThick + TopThick];
CaseOffset = [-(PinShank[LENGTH] + OverTravel + PinRecess),-(WallThick + GuideRadius),0]; // position around battery
LidOverhang = 2.0; // over top of battery for retention
LidSize = [-CaseOffset.x + LidOverhang,CaseSize.y,TopThick];
LidOffset = [0.0,CaseOffset.y,0];
//----------------------
// Useful routines
module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
FixDia = Dia / cos(180/Sides);
cylinder(r=(FixDia + HoleWindage)/2,h=Height,$fn=Sides);
}
//-------------------
//-- Guides for tighter friction fit
module Guides() {
translate([GuideOffset,-GuideRadius,0])
PolyCyl(2*GuideRadius,(Battery.z - Protrusion),4);
translate([GuideOffset,(Battery.y + GuideRadius),0])
PolyCyl(2*GuideRadius,(Battery.z - Protrusion),4);
translate([(Battery.x - GuideOffset),-GuideRadius,0])
PolyCyl(2*GuideRadius,(Battery.z - Protrusion),4);
translate([(Battery.x - GuideOffset),(Battery.y + GuideRadius),0])
PolyCyl(2*GuideRadius,(Battery.z - Protrusion),4);
translate([(Battery.x + GuideRadius),GuideOffset/2,0])
PolyCyl(2*GuideRadius,(Battery.z - Protrusion),4);
translate([(Battery.x + GuideRadius),(Battery.y - GuideOffset/2),0])
PolyCyl(2*GuideRadius,(Battery.z - Protrusion),4);
}
//-- Contact pins
// Rotated to put them in their natural oriention
// Aligned to put tip base / end of shank at Overtravel limit
module PinShape() {
translate([-(PinShank[LENGTH] + OverTravel),0,0])
rotate([0,90,0])
rotate(180/6)
union() {
PolyCyl(PinTip[OD],PinShank[LENGTH] + PinTip[LENGTH],6);
PolyCyl(PinShank[ID],PinShank[LENGTH] + Protrusion,6); // slight extension for clean cuts
PolyCyl(PinFlange[OD],PinFlange[LENGTH],6);
}
}
// Position pins to put end of shank at battery face
// Add wire exit channel between pins
// Does not include recess access
module PinAssembly() {
union() {
for (p = Contacts)
translate([0,p.y,p.z])
PinShape();
translate([-(PinShank[LENGTH] + OverTravel) + PinChannel/2,
(Contacts[1].y + Contacts[0].y)/2,
Contacts[0].z])
cube([PinChannel,(Contacts[1].y - Contacts[0].y),PinFlange[OD]],center=true);
}
}
//-- Case with origin at battery corner
module Case() {
difference() {
union() {
difference() {
translate([(CaseSize.x/2 + CaseOffset.x), // basic case shape
(CaseSize.y/2 + CaseOffset.y),
(CaseSize.z/2 - BaseThick)])
hull()
for (i=[-1,1], j=[-1,1], k=[-1,1])
translate([i*(CaseSize.x/2 - CornerRadius),
j*(CaseSize.y/2 - CornerRadius),
k*(CaseSize.z/2 - CornerRadius)])
sphere(r=CornerRadius,$fn=8);
translate([-OverTravel,-GuideRadius,0])
cube([(Battery.x + GuideRadius + OverTravel),
(Battery.y + 2*GuideRadius),
(Battery.z + Protrusion)]); // battery space
}
Guides(); // improve friction fit
translate([-OverTravel,-GuideRadius,0]) // battery keying blocks
cube(KeyBlocks[0] + [OverTravel,GuideRadius,0],center=false);
translate([-OverTravel,(Battery.y - KeyBlocks[1].y),0])
cube(KeyBlocks[1] + [OverTravel,GuideRadius,0],center=false);
}
translate([(-OverTravel), // battery top access
(CaseOffset.y - Protrusion),
Battery.z])
cube([CaseSize.x,(CaseSize.y + 2*Protrusion),(TopThick + Protrusion)]);
translate([(CaseOffset.x - Protrusion), // battery insertion allowance
(CaseOffset.y - Protrusion),
Battery.z])
cube([(CaseSize.x + 2*Protrusion),(CaseSize.y + 2*Protrusion),(TopThick + Protrusion)]);
translate([(Battery.x - Protrusion), // remove thumb notch
(CaseSize.y/2 + CaseOffset.y),
(ThumbRadius)])
rotate([90,0,0])
rotate([0,90,0])
cylinder(r=ThumbRadius,
h=(WallThick + GuideRadius + 2*Protrusion),
$fn=22);
PinAssembly();
translate([CaseOffset.x + PinRecess/2 + Protrusion/2,(Contacts[1].y + Contacts[0].y)/2,Contacts[0].z])
cube([PinRecess + Protrusion,
(Contacts[1].y - Contacts[0].y + PinFlange[OD]),
2*PinFlange[OD]],center=true);
}
}
// Lid position offset to match case
module Lid() {
translate([-LidSize.x/2 + LidOffset.x + LidOverhang,LidSize.y/2 + LidOffset.y,0])
difference() {
hull()
for (i=[-1,1], j=[-1,1], k=[-1,1])
translate([i*(LidSize.x/2 - CornerRadius),
j*(LidSize.y/2 - CornerRadius),
k*(LidSize.z - CornerRadius)]) // double thickness for flat bottom
sphere(r=CornerRadius,$fn=8);
translate([0,0,-LidSize.z/2])
cube([(LidSize.x + 2*Protrusion),(LidSize.y + 2*Protrusion),LidSize.z],center=true);
cube([LidSize.x/4,0.75*LidSize.y,4*ThreadThick],center=true); // epoxy recess
}
}
//-------------------
// Build it!
if (Layout == "Case")
Case();
if (Layout == "Lid")
Lid();
if (Layout == "Pins") {
color("Silver",0.5)
PinShape();
PinAssembly();
}
if (Layout == "Show") { // reveal pin assembly
difference() {
Case();
translate([(CaseOffset.x - Protrusion),
Contacts[1].y,
Contacts[1].z])
cube([(-CaseOffset.x + Protrusion),
CaseSize.y,
(CaseSize.z - Contacts[0].z + Protrusion)]);
translate([(CaseOffset.x - Protrusion),
(CaseOffset.y - Protrusion),
0])
cube([(-CaseOffset.x + Protrusion),
Contacts[0].y + Protrusion - CaseOffset.y,
CaseSize.z]);
}
color("Silver",0.15)
PinAssembly();
translate([0,0,Battery.z + Gap])
Lid();
}
if (Layout == "Build") {
translate([-(CaseSize.x/2 + CaseOffset.x),-(CaseOffset.y - BuildOffset),BaseThick])
Case();
translate([CaseSize.y/2,(CaseOffset.x/2 - BuildOffset),0])
rotate([0,0,90])
Lid();
}
if (Layout == "Fit") {
Case();
translate([0,0,(Battery.z + Gap)])
Lid();
color("Silver",0.25)
PinAssembly();
}
@ednisley

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ednisley commented Nov 18, 2018

More details on my blog at https://wp.me/poZKh-7RT

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