Comprising a flexible hinge device for weakening the hinge opening in the folding area of the device

Abstract

This specification relates to flexible hinges and articulated devices. A flexible hinge of a foldable device (102) includes a hinge region (210) between wing regions (212), wherein the flexible hinge material of the hinge region (210) defines a plurality of linearly arranged through-holes (104) that weaken the flexible hinge material to define a hinge axis (HA), and the lightened flexible hinge bends along the hinge axis (HA) as a first portion and a second portion rotate through a series of orientations.

Description

Background Art

[0001] Flexible hinges are employed in many device scenarios. Flexible hinges are typically made of a single material or a composite material. For example, a fabric can be impregnated with a resin (or otherwise coated) to form a composite flexible hinge. Several parameters affect the characteristics of these flexible hinges. Examples of such parameters can include: the type of fiber, the modulus / strength of the fiber, the type of matrix resin, the modulus / strength of the resin, the type of fabric, and / or the layering of woven layers. These parameters affect the mechanical characteristics of the composite hinge, thereby defining hinge performance. In a traditional manner, hinge performance is optimized by running complex design of experiments (DOE), which is time-consuming, costly, and labor-intensive. Additionally, deviations in the composite material itself and / or the manufacturing process can result in deviations in hinge performance. However, after the composite layup is cured, it is impossible to change the mechanical characteristics of the composite hinge and adjust the hinge performance back to the design specifications. The present inventive concept addresses these and other problems by allowing a single flexible hinge to be customized for different use case scenarios. Brief Description of the Drawings

[0002] The various drawings illustrate implementations of the concepts conveyed herein. The features of the illustrated implementations can be more readily understood by reference to the following description in conjunction with the drawings. Wherever possible, the same reference numerals are used in the various drawings to refer to the same elements. Additionally, the leftmost digit of each reference numeral conveys the drawing and associated discussion in which that reference numeral is first introduced. Where space permits, for the convenience of the reader, both the element and its associated reference numeral are shown on the drawing page. Otherwise, only the reference numeral is shown.

[0003] Figure 1 A perspective view of an example device showing some implementations in accordance with the present inventive concept is shown.

[0004] Figures 2A - 2D 4A - 4C and 6 - 10 show elevation views of an example device showing some implementations in accordance with the present inventive concept.

[0005] Figures 3A - 3C 4D, 5A, 5B, 11A - 11B, and 12A - 12B show cross-sectional views of an example device showing some implementations in accordance with the present inventive concept. Detailed Description

[0006] The present inventive concept relates to devices such as computing devices that employ a flexible hinge to rotatably secure a first device portion and a second device portion. The flexible hinge can be selected based on various criteria. This flexible hinge can be customized for various different device applications by reducing the hinge material to facilitate the desired hinge performance for a single device application.

[0007] Introductory Figure 1Shows three different configurations of an example flexible hinge material (“hinge material”) 100 and an articulated device 102. This flexible hinge material 100 can be a single-piece material, such as a rubber material, a fabric, or a composite material, such as a fabric impregnated with resin (e.g., fabric-resin composite), and other configurations. The hinge material 100 may have been widely tested and exhibit desired properties, such as durability and resistance to curling or creasing, etc.

[0008] Different hinge applications for two devices 102(1) and 102(2) may have different hinge design characteristics, such as stiffness, hinge radius, etc. The hinge material 100 can be customized to produce these different hinge design characteristics. Customization of the hinge material 100 can include lightening the hinge material with through-holes 104 to form a lightened hinge material 106. The lightened hinge material can contribute to a lightened flexible hinge 108 rotatably fixing device parts 110.

[0009] In this case, the hinge material 100 intended for a specific hinge application on a single device 102 can be lightened in a manner that provides the desired design characteristics for rotatably fixing device part 110. In this example, relative to device 102(1), the first part 110(1) is shown as a keyboard 112, the second part 110(2) is shown as a tablet 114, and the third part 110(3) is shown as a stand 116.

[0010] For the hinge application between the keyboard 112 and the tablet 114 of device 102(1), the lightened hinge material 106(1) can include three rows of parallel linearly arranged through-holes 104 formed penetrating the hinge material 100 along the hinge axis. As used herein, the term “through-hole” refers to a hole of any shape that partially or completely penetrates the thickness of the lightened hinge material 106.

[0011] In the example of device 102(1), the desired hinge characteristics of the lightened flexible hinge 108(1) between the keyboard 112 and the tablet 114 can be a relatively large hinge radius and a low-friction (e.g., easy to rotate) hinge. The three rows of parallel through-holes 104 of the lightened hinge material 106(1) can facilitate these characteristics.

[0012] Still relative to device 102(1), the desired hinge characteristics of the lightened flexible hinge 108(2) between the tablet 114 and the stand 116 can be a relatively high-resistance hinge with a smaller hinge radius. The selected lightened hinge material 106(2) can provide these characteristics.

[0013] In an example of device 102(2), the lightweighted flexible hinge 108(3) can rotatably fix parts 110(4) and 110(5) in a series of orientations. In this case, the desired hinge characteristics can be a relatively small hinge radius and additional hinge strength at the hinge ends, where the hinge ends are subject to increased stress. A single-row through-hole 104 spaced backward from each end of the lightweighted hinge material 106(3) can provide these desired hinge characteristics in the lightweighted flexible hinge 108(3).

[0014] Of course, these three example configurations are provided for purposes of explanation, and other lightweighted hinge material 106 configurations are contemplated, and further examples are described below. Thus, the discussion regarding Figure 1 explains that the general hinge material 100 can be used for a given hinge application and can be lightweighted by different designs of the through-holes 104 to achieve various specific hinge characteristics. Note that the lightweighted hinge material 106 can be fixed to the device part using conventional techniques and thus is not described in further detail.

[0015] Figures 2A - 2D Other lightweighted hinge material configurations are shown together. Figure 2A The hinge material 100 is shown, such as a fabric material. In some cases, the hinge material can be a woven Kevlar fabric material. Figure 2B An area of the hinge material is shown, such as a Kevlar fabric material impregnated with a resin (type material) 202 to create a composite material 204. The composite material 204 has at least some composite areas 206 where the hinge material 100 is impregnated with the resin 202.

[0016] Figure 2C The through-holes 104 formed through the hinge material 100 are shown to produce the lightweighted hinge material 106(4). The through-holes 104 can be oriented relative to the hinge axis (HA) to promote desired hinge characteristics, such as resistance to bending. In this case, the through-holes 104 have two different sizes; the smaller size alternates with the larger size. In other implementations, such as the implementation illustrated for the lightweighted hinge material 106(1) with respect to Figure 1 the through-holes have the same size.

[0017] Figure 2D An alternative configuration related to the lightweighted hinge material 106(5) is shown. Figure 2C In Figure 2DIn the case where the through holes 104 are formed in two rows, which can define a hinge axis. This pattern can facilitate uniform bending around the hinge axis. In this case, the through holes are not equally spaced because no through holes 104 are formed in the central region 208. In this example, conductors (not shown) can pass from the upper or first part of the device through the central region 208 to the lower or second part of the device (see Figure 1 each device part in). Omitting the through holes 104 near the conductors can reduce damage to the conductors during the opening and closing life of the reduced-flexibility hinge 108(5), while the through holes 104 in the remaining regions facilitate other desired hinge characteristics.

[0018] From one perspective, the through holes 104 can be regarded as formed in the hinge region 210, which is between two wing regions 212. The reduced hinge material 106(5) can be fixed to the device via the wing regions 212 to form the reduced-flexibility hinge 108(5).

[0019] Figures 3A - 3C Together illustrate an example composite reduced-flexibility hinge 108 configuration. Figure 3A Shows a cross-sectional view of the reduced-flexibility hinge 108(4) as shown in Figure 2C . The configuration illustrated in Figure 3A can represent a first configuration of the reduced hinge material 106(4). The first configuration may involve using a hinge material 100 in the form of a dry Kevlar fabric, which is partially impregnated with a (rigid) resin 202 (such as epoxy resin), limited to the regions of the two wings or wing regions 212. The hinge region 210 may involve dry Kevlar, and some resin diffuses from the wing regions 212 during impregnation.

[0020] Figure 3B Illustrates another configuration of the reduced-flexibility hinge 108(6), where the hinge region 210 and the wing region 212 have a similar structure, but the through holes 104 in the hinge region cause the hinge region to tend to bend when a force is applied to the reduced-flexibility hinge 108(6), while the wing regions remain relatively rigid. Another composite reduced hinge material 106 configuration may involve a dry Kevlar fabric completely impregnated with a flexible resin (such as polyurethane). The hinge region 210 can be a wet Kevlar fabric in a polyurethane matrix.

[0021] Figure 3CAnother example of a lightweighted flexure hinge 108(7) configuration is shown, where the multi-layer structural material 302 is constructed on the wing region 212 rather than on the hinge region 210. The multi-layer structural material 302 can form a relatively rigid composite wing region 212, while the through-holes 104 in the hinge region 210 contribute to its flexibility. For example, the wing region 212 may involve various structural materials 302, such as dry Kevlar partially impregnated with a rigid resin (e.g., polycarbonate) in the wing region 212 and dry Kevlar partially impregnated with a flexible resin (TPU) in the hinge region 210. In some of these cases, the wing region 212 can be laminated with a rigid layer (e.g., carbon fiber plus epoxy resin) to achieve mechanical functions or ease of operation and assembly.

[0022] Figures 4A - 4D Another lightweighted hinge material configuration is shown together. In this case, Figure 4A the hinge material 100 is shown. Figure 4B All of the hinge material impregnated with the resin 202 to form the composite material 204 is shown. In this case, the hinge material has resin or rigid composite layers on both sides (e.g., the material is sandwiched between resin layers). In other configurations, the resin can be applied only to one side of the hinge material 100. Figure 4C and 4D The through-holes 104 formed in the composite material to customize the properties of the composite material are shown. In this case, some of the through-holes 104 completely penetrate the composite material 204 (e.g., the through-through hole 402), while some of the through-holes only partially penetrate (e.g., the partial through-hole 404).

[0023] Figure 5A and 5B Two different lightweighted flexure hinge structures are shown. In the Figure 5A lightweighted flexure hinge 108(9) configuration, the hinge material 100 is a single flexible layer of Kevlar fabric inserted between two rigid layers of structural material 302 (such as carbon fiber in epoxy resin). In the Figure 5B configuration, the hinge material 100 is a flexible laminate among multiple Kevlar layers sandwiched between two rigid layers of structural material 302 (such as carbon fiber in epoxy resin). Thus, in some cases, a rigid material in the form of a composite layer (e.g., carbon fiber in epoxy resin or polycarbonate) is laminated on one or both sides of the flexible hinge material 100. In these illustrated configurations, offset blind through-holes or partial through-holes 404 are formed from both sides of the lightweighted flexure hinge 108(10). In various configurations, the partial through-holes 404 can be formed in a single layer of Kevlar, multiple layers, or a resin / CF-Kevlar-resin / CF laminate.

[0024] The lightweight flexible hinge 108 may include a single layer of flexible hinge material 100( Figure 5A ) or multiple layers of flexible hinge materials 100(1) and 100(2)( Figure 5B ). In these cases, Kevlar is an example of a flexible hinge material. In addition to having resin on both sides of the flexible Kevlar, a rigid composite layer (such as CF impregnated in epoxy or polycarbonate) can be laminated or clamped around the flexible hinge material.

[0025] Figures 6 - 10 Additional configurations of the lightweight flexible hinges 108(11)-108(15) are shown respectively.

[0026] Figure 6 A configuration is shown where the lightweight flexible hinge 108(11) includes a through hole 104 formed in the composite region 206 but not in the central region 208 of the hinge material 100. This configuration can facilitate bending in the composite region 206 to accompany bending in the central region 208. In this example, the through hole 104 has a square shape. Other illustrated through holes are circular. Other through hole shapes (including regular and irregular) are contemplated.

[0027] Figure 7 Another lightweight flexible hinge 108(12) is shown. In this case, the hinge region 210 is the composite region 206, and the wing region 212 is the uncoated hinge material 100. The lightweight flexible hinge 108(12) has through holes 104 arranged in three rows in the hinge region 210 to define three hinge axes (HA). This configuration can facilitate various hinge characteristics. For example, the through holes 104 can cause the relatively more rigid composite material region 206 to bend in a manner similar to the uncoated wing region 212.

[0028] In the first region 702, a relatively lower density of through holes 104 per unit area is employed compared to the second region 704. Such a configuration can facilitate various characteristics of the lightweight flexible hinge 108(12). For example, the lightweight flexible hinge 108(12) can be easily bent while restricting degradation of the region 702.

[0029] Figure 8Another relieved flexure hinge 108(13) is shown. In this case, dashed lines are used to indicate the hinge axis (HA) associated with the through holes 104. In this example, a row of relatively small through holes 104 is inserted between several rows of relatively large through holes 104. This configuration can facilitate various desired hinge characteristics. For example, in this case, the small through holes are located at the center (e.g., along the central hinge axis). The relieved flexure hinge may be more prone to bending along this central axis compared to bending along the other two hinge axes. The larger through holes 104 along the other two hinge axes may cause bending along all three hinge axes to occur more evenly than before.

[0030] Figure 9 Another relieved flexure hinge 108(14) is shown. In this case, the size of the through holes 104 alternates or otherwise changes along the hinge axis (HA). In this example, relatively small and large through holes 104 alternate along a single hinge axis. Additionally, the pattern is offset on adjacent hinge axes to avoid over-weakening the relieved flexure hinge 108(14).

[0031] In other words, the through holes 104 can alter the characteristics associated with the relieved flexure hinge 108 and produce bending relative to the indicated axes. From one perspective, the through holes 104 can locally weaken the relieved flexure hinge. This weakening can facilitate bending / kinking along the hinge axis. The hinge axis can be defined by the pattern and / or size of the through holes 104. From another perspective, the through holes change the characteristics of the hinge material, and a combination of through holes 104 of various shapes and / or sizes can result in customized folding curvatures and mechanical responses. In the above configuration, the hinge axes defined by the through holes 104 are generally parallel to each other. Examples involving multiple hinge axes where at least some of the hinge axes are not parallel to each other are provided below.

[0032] Figure 10 Another relieved flexure hinge 108(15) is shown. In this case, the relieved hinge material 106 includes an array of multiple through holes 104. The through holes 104 can facilitate bending along multiple hinge axes, which are indicated by dashed lines. In this case, the bending can be along at least a first hinge axis (HA1), a second hinge axis (HA2), and an additional hinge axis (HA3). In this example, the first hinge axis is substantially vertical on the drawing page (e.g., parallel to the longer side of the relieved hinge material 106). There are seven second hinge axes perpendicular to the first hinge axis, and six additional hinge axes that form an oblique angle with respect to the first and second hinge axes and extend between the first and second hinge axes in this case. This can create a folding configuration that results in dimensional shrinkage or flexion, as indicated at 1002 on the drawing page.

[0033] Figure 11A and Figure 11B andFigure 12A and Figure 12B together illustrate another example of a lightweight flexible hinge 108(16). In this case, the lightweight flexible hinge 108(16) can be used in cooperation with a flexible display 1102 that extends from a first portion 110(6), through the lightweight hinge material 106, and to a second portion 110(7). A flexible cover 1104 can cover the device opposite the flexible display 1102. The lightweight hinge material 106 can include through-holes 104 that are selectively placed to promote flexibility of the lightweight flexible hinge 108(16) at desired locations and less flexibility at other locations to avoid curling the flexible display 1102 when the device rotates from Figure 11A an open 180-degree orientation to other smaller angles (such as Figure 11B a 100-degree orientation) and ultimately to Figure 12A and 12B a zero-degree closed orientation of Figure 11A As can be seen, in this implementation, the through-holes 104 are not oriented perpendicular to the main surface of the lightweight hinge material 106 (which is parallel to the xy-reference plane), but at an oblique angle. Of course, other numbers, sizes, patterns, and / or positions of the through-holes 104 on the lightweight hinge material 106 are also contemplated to promote the desired hinge characteristics.

[0034] One novel aspect described herein can be the ability to fabricate general and customized flexible hinges to meet various design criteria by reducing portions of the hinge material. For example, in some cases, a flexible hinge can be lightweighted with a pattern of one or more rows or micron- or nano-sized through-holes 104 (e.g., holes) that can be drilled along the length (or a portion thereof) by laser or other methods to form a lightweight flexible hinge 108. The through-holes 104 can be any size from micron-sized to millimeter-sized and can be visible or invisible to the user. The performance of the lightweight flexible hinge 108 can be optimized by various diameters, numbers, and / or patterns of the through-holes 104. This is a very effective method for fabricating composite belt hinges with specified mechanical properties. Additionally, it is also a method for tuning hinge performance and reducing production variations.

[0035] The inventive concept provides a more efficient method for developing flexible hinges (such as lightweight flexible hinges) with optimized performance. The inventive concept also provides a viable method to tune hinge performance back to design specifications even after the flexible hinge is fully cured. For example, if a flexible hinge tests harder than the design parameter tolerances, through-holes can be strategically formed in the flexible hinge and the hinge testing can be repeated.

[0036] This concept can be used for various types of fibers, including at least Kevlar, carbon fiber, LCP, etc. The fibers can have different fiber moduli and strengths. The fibers can be woven, such as plain weave, twill weave, or others. Various types of resins (such as epoxy resin, PUR / TPU, etc.) can be employed.

[0037] Traditional methods for developing flexible hinges require a significant amount of time, money, and effort to determine the correct belt hinge formulation. Production deviations in flexible hinges can lead to changes in hinge performance. However, traditional flexible hinges cannot be adjusted after composite lamination and curing.

[0038] In contrast, this implementation can enhance / optimize flexible hinge performance through micro / nano drilling to form a lightweight flexible hinge. Some implementations may involve the lamination of a general belt hinge, which can be based on a fabric with a reasonably high modulus, a resin with a reasonable modulus / hardness, a single type of weave, and one or more layers. The general belt hinge can be adjusted by performing micro-scale or nano-scale laser drilling along the length of the composite hinge. The laser drilling cuts the fibers in the composite hinge. By reducing the number of continuous fibers, the mechanical strength and modulus of the hinge in the hinge area can be adjusted as needed. This method can not only simplify and accelerate the development of flexible hinges with a defined torque but also be used to reduce deviations in mass production. In other words, for example, a hinge that has a greater resistance to bending than the specification during testing can have through-holes and / or additional through-holes formed therein to bring the flexural resistance within the specification range.

[0039] The lightweight flexible hinge concept of the present invention can be used with any type of device, such as but not limited to laptop computers, smartphones, wearable smart devices, tablets, and / or other types of existing, under-development, and / or yet-to-be-developed devices.

[0040] Although technologies, methods, devices, systems, etc. related to lightweight flexible hinges have been described in language specific to structural features and / or method acts, it is understood that the subject matter defined in the appended claims is not limited to the specific features or acts. Instead, these specific features and acts are disclosed as example forms for implementing the claimed methods, devices, systems, etc.

[0041] Various examples have been described above. Additional examples are described below. One example includes a device that includes: a first portion and a second portion; and a lightweight flexible hinge rotatably securing the first portion and the second portion, the lightweight flexible hinge including a flexible hinge material that includes a hinge region between wing regions, at least the flexible hinge material of the wing regions being coated with a resin and the flexible hinge material of the hinge region defining a plurality of linearly arranged through-holes that weaken the flexible hinge material to define a hinge axis, the lightweight flexible hinge bending along the hinge axis as the first portion and the second portion rotate through a series of orientations.

[0042] Another example may include any of the above and / or below examples, wherein the through-holes define a plurality of hinge axes.

[0043] Another example may include any of the above and / or below examples, wherein the plurality of hinge axes are parallel to each other.

[0044] Another example may include any of the above and / or below examples, wherein the plurality of hinge axes define a folding shape.

[0045] Another example may include any of the above and / or below examples, wherein both the hinge region and the wing regions are coated with a resin.

[0046] Another example may include any of the above and / or below examples, wherein the flexible hinge material includes multiple layers of flexible material.

[0047] Another example may include any of the above and / or below examples, wherein the wing regions secure the flexible hinge material to the first portion and the second portion.

[0048] Another example includes a device that includes: a first portion and a second portion; and a lightweight flexible hinge rotatably securing the first portion and the second portion, the lightweight flexible hinge including a flexible hinge material having a plurality of through-holes formed therein that weaken the flexible hinge material to define at least one hinge axis, the lightweight flexible hinge bending along the hinge axis as the first portion and the second portion rotate relative to each other through a series of orientations.

[0049] Another example may include any of the above and / or below examples, wherein the through-holes are linearly arranged, or wherein the through-holes are not linearly arranged.

[0050] Another example may include any of the above and / or below examples, wherein the through-holes define a plurality of hinge axes.

[0051] Another example may include any of the above and / or below examples, wherein the plurality of hinge axes are parallel to each other.

[0052] Another example may include any of the above and / or below examples, wherein some of the plurality of hinge axes are not parallel to each other.

[0053] Another example may include any of the above and / or below examples, wherein the through holes are all of the same size.

[0054] Another example may include any of the above and / or below examples, wherein the through holes defining a single hinge axis are all of the same size, but are different from the through holes defining another single hinge axis.

[0055] Another example may include any of the above and / or below examples, wherein the through holes defining a single hinge axis are different in size.

[0056] Another example may include any of the above and / or below examples, wherein the through holes defining a single hinge axis are equally spaced along the hinge axis in the flexible hinge material.

[0057] Another example includes an apparatus that includes: a first part and a second part; and a lightweight flexible hinge that rotatably secures the first part and the second part.

[0058] Another example may include any of the above and / or below examples, wherein the lightweight flexible hinge includes a rubber material, a fabric material, or a fabric-resin composite.

[0059] Another example may include any of the above and / or below examples, wherein the lightweight flexible hinge includes a plurality of through holes arranged relative to the hinge axis in the rubber material, the fabric material, or the fabric-resin composite.

[0060] Another example may include any of the above and / or below examples, wherein the lightweight flexible hinge defines a thickness, and wherein at least some of the through holes penetrate the entire thickness.

[0061] Another example may include any of the above and / or below examples, wherein the lightweight flexible hinge defines a thickness, and wherein at least some of the through holes do not extend through the entire thickness.

[0062] Another example may include any of the above and / or below examples, wherein the lightweight flexible hinge defines a plurality of through holes arranged relative to a plurality of hinge axes.

Claims

1. A device, comprising: a first part and a second part; and, a lightweight flexible hinge rotatably fixing the first part and the second part, the lightweight flexible hinge comprising a flexible hinge material, the flexible hinge comprising two wing regions and a hinge region between the two wing regions, at least the flexible hinge material of the wing regions being coated with a rigid resin and the flexible hinge material of the hinge region defining an array of a plurality of through-holes, the array of through-holes facilitating bending along a plurality of hinge axes, the plurality of hinge axes including a first hinge axis, a plurality of second hinge axes perpendicular to the first hinge axis, and a plurality of additional hinge axes forming an oblique angle with respect to the first hinge axis and the second hinge axis and extending between the first hinge axis and the second hinge axis.

2. The device according to claim 1, characterized in that, The hinge region is coated with a flexible resin.

3. The device according to claim 1, characterized in that, The flexible hinge material comprises a multi-layer flexible material.

4. The device according to claim 1, characterized in that, The wing regions fix the flexible hinge material to the first part and the second part.

5. A device, comprising: a first part and a second part; and, a lightweight flexible hinge rotatably fixing the first part and the second part, the lightweight flexible hinge comprising a flexible hinge material, the flexible hinge material having an array of a plurality of through-holes formed therein, the array of through-holes facilitating bending along a plurality of hinge axes, the plurality of hinge axes including a first hinge axis, a plurality of second hinge axes perpendicular to the first hinge axis, and a plurality of additional hinge axes forming an oblique angle with respect to the first hinge axis and the second hinge axis and extending between the first hinge axis and the second hinge axis.

6. The device according to claim 5, characterized in that, The through-holes are all of the same size.

7. The device according to claim 5, characterized in that, The through-holes defining a single hinge axis are all of the same size, but are different from the through-holes defining another single hinge axis.

8. The device according to claim 5, characterized in that The through-holes defining a single hinge axis are of different sizes.

9. The device according to claim 5, characterized in that, The through-holes defining a single hinge axis are equally spaced along the hinge axis in the flexible hinge material.

10. The device according to claim 5, characterized in that, The lightweight flexible hinge defines a thickness, and at least some of the through-holes penetrate the entire thickness.

11. The device according to claim 5, characterized in that, The lightweight flexible hinge defines a thickness, and at least some of the through-holes do not extend through the entire thickness.

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