BACKGROUND

[0001 ] A hinge is a type of bearing that connects two solid objects together and allows the two objects to rotate relative to one another about a fixed axis of rotation. Hinges can be used in a variety of situations to allow two objects to rotate relative to one another about a fixed axis of rotation. For example, hinges are often used with doors, lids, various types of machinery, musical instruments, electronic devices, etc. Non-limiting examples of hinges can include barrel hinges, butterfly hinges, case hinges, concealed hinges, flag hinges, mortise hinges, piano hinges, pivot hinges, spring hinges, and strap hinges.

BRIEF DESCRIPTION OF THE DRAWINGS

[0002] FIG. 1 A is a perspective view of an example hinge for an electronic device in accordance with the present disclosure;

[0003] FIG. 1 B is a cross-sectional view of the hinge of FIG. 1 A along line A-A’;

[0004] FIG. 2 is a cross-sectional view of an example hydrophobic coating in accordance with the present disclosure;

[0005] FIG. 3 is a flowchart illustrating an example method of manufacturing a hinge for an electronic device in accordance with the present disclosure;

[0006] FIG. 4 is a schematic representation of an example hinge assembly in accordance with the present disclosure; and

[0007] FIG. 5 is another schematic representation of an example hinge assembly in accordance with the present disclosure. DETAILED DESCRIPTION

[0008] The present disclosure is related to hinges for electronic devices. In one example, a hinge for an electronic device can include a monolithic metal hinge body including a first attachment end to attach to a first gear shaft and a second attachment end opposite the first attachment end to attach to a second gear shaft, and a

hydrophobic coating on the monolithic metal hinge body, wherein the hinge has a surface roughness from about 0.1 pm to about 2 pm. In some examples, the monolithic metal hinge body can have a tensile strength from about 400 MPa to about 2100 MPa.

In some additional examples, the monolithic metal hinge body can include carbon steel having from about 0.2 wt% to about 0.7 wt% carbon. In still additional examples, the hydrophobic coating can include a ceramic material. In some further examples, the hydrophobic coating can include tetraethyl orthosilicate (TEOS), a substituted or unsubstituted C8-C24 alkyl silane, polytetrafluoroethylene, dodecyltrimethoxysilane, mecaptoundecyltrimethoxysilane, triethoxysilylundecanal, 11 - aminoundecyltriethoxysilane, N-(2-aminoethyl)-11 -undecyltrimethoxysilane,

polyvinylidene fluoride, or a combination thereof. In still further examples, the

hydrophobic coating can have a water contact angle from about 90° to about 150°.

[0009] In another example, a method of manufacturing a hinge for an electronic device can include forming a monolithic metal hinge body including a first attachment end to attach to a first gear shaft and a second attachment end opposite the first attachment end to attach to a second gear shaft, and coating the monolithic metal hinge body with a hydrophobic coating, the hydrophobic coating providing a surface roughness to the hinge at from about 0.1 pm to about 2 pm. In some examples, forming a monolithic metal hinge body can be by metal injection molding. In additional examples, the metal hinge body can have a thickness of from about 0.8 mm to about 10 mm. In still additional examples, the metal hinge body can have a length of from 5 mm to about 18 mm. In some further examples, coating the monolithic metal hinge body includes dip coating, centrifuge coating, spray coating, or a combination thereof. In still further examples, the hydrophobic coating can have a thickness of from about 3 pm to about 25 pm. [0010] In another example, a hinge assembly can include a first gear shaft, a second gear shaft, an idler gear operably connected between the first gear shaft and the second gear shaft, and a hinge coupled to the first gear shaft at a first attachment end and to the second gear shaft at the second attachment end. The hinge can include a monolithic metal hinge body including the first attachment end and the second attachment end opposite the first attachment end, and a hydrophobic coating on the monolithic metal hinge body, the hydrophobic coating providing a surface roughness to the hinge at from about 0.1 pm to about 2 pm. In some examples, the hinge assembly can be operably coupled to an electronic device. In some additional examples, the electronic device can be a desktop computer, a laptop computer, a tablet, a phone, a portable media player, a speaker, or a monitor.

[0011 ] In addition to the examples described above, the hinges for electronic devices, methods of manufacturing hinges for electronic devices, and hinge assemblies will be described in greater detail below. It is also noted that when discussing the hinges, methods of manufacturing hinges, and hinge assemblies described herein, these relative discussions can be considered applicable to the other examples, whether or not they are explicitly discussed in the context of that example. Thus, for example, in discussing a hydrophobic coating related to a hinge, such disclosure is also relevant to and directly supported in the context of the methods of manufacturing a hinge and the hinge assemblies described herein, and vice versa.

[0012] Turning now to FIG. 1A, an example of a hinge 100 for an electronic device is depicted. The hinge can include a first attachment end 102 that defines a first engagement clip 103 for attaching to a first gear shaft (not shown, but shown in FIGS. 4 and 5) and a second attachment end 104 that defines a second engagement clip 105 opposite the first attachment end for attaching to a second gear shaft (not shown, but shown in FIGS. 4 and 5). These engagement clips in this example are C-shaped engagement clips, but could be any other shape suitable for attaching to the respective gear shafts.

[0013] FIG. 1 B illustrates a cross-sectional view of the hinge 100 of FIG. 1A cut along line A-A’. As can be seen from FIG. 1 B, the hinge can include a monolithic metal hinge body 110 forming the general shape of the hinge. More specifically, the monolithic metal hinge body can be shaped to include the first attachment end 102 with the first engagement clip 103 and a second attachment end 104 with the second engagement clip 105 opposite the first attachment end. By“monolithic,” it is meant that the metal hinge body is formed as a single piece or single unit, rather than a plurality of individual units coupled or connected together. Additionally, the monolithic metal hinge body can generally be a homogenous material in one example, as it is formed to be a single monolithic unit.

[0014] The monolithic metal hinge body 110 can be formed of a variety of metal materials. However, generally the metal material used to form the monolithic metal hinge body can provide the monolithic metal hinge body with a tensile strength from about 400 megapascals (MPa) to about 2100 MPa. In other examples, the metal material can provide the monolithic metal hinge body with a tensile strength from about 400 MPa to about 800 MPa, from about 800 MPA to about 1200 MPa, from about 1200 MPa to about 1700 MPa, or from about 1700 MPa to about 2100 MPa. It is noted that the strength of the monolithic metal hinge body can also be affected by the method of manufacturing (e.g. metal sintering vs metal injection molding, for example). Different methods of manufacturing the monolithic metal hinge body are discussed below.

[0015] Thus, a variety of metal materials can be employed to manufacture the monolithic metal hinge body. Non-limiting examples, can include steel, titanium, tungsten, inconel, the like, alloys thereof, or a combination thereof. In some examples, the monolithic metal hinge body can be formed using steel, such as carbon steel, stainless steel, tool steel, a steel alloy (e.g. including nickel, copper, aluminum, etc., or a combination thereof), or the like. In some specific examples, the monolithic metal hinge body can be formed using carbon steel. Where this is the case, the carbon steel can typically include from about 0.2 wt% to about 0.7 wt% carbon, based on a total weight of the carbon steel. In other examples, the carbon steel can include from about 0.2 wt% to about 0.6 wt%, from about 0.2 wt% to about 0.5 wt%, from about 0.2 wt% to about 0.4 wt%, from about 0.3 wt% to about 0.7 wt%, from about 0.3 wt% to about 0.6 wt%, from about 0.3 wt% to about 0.5 wt% carbon, based on a total weight of the carbon steel.

[0016] The first attachment end 102 and the second attachment end 104 can be open or closed. In this example, the first and second attachments ends are C-shaped engagement clips, but could be some other open shape, or even O-shaped (closed), for example. In other words, as shown in FIGS. 1 A and 1 B, the first attachment end and the second attachment end are open (e.g., there is a gap in a portion of both of the annular attachment ends). In other examples, the first attachment end and the second attachment end can both be closed (e.g., without the gap illustrated in FIG. 1A, forming an enclosed ring at both ends of the hinge). In other examples, the first attachment end can be open and the second attachment end can be closed, or vice versa.

[0017] Turning again more specifically to FIG. 1 B, a hydrophobic coating 120 can be applied on the monolithic metal hinge body 110. The coating in this example may not be structural, but rather provides benefits of a hydrophobic coating. Thus, the hinge body is still considered monolithic. The hydrophobic coating can provide a number of benefits to the hinge 100. For example, the hydrophobic coating can protect the monolithic metal hinge against moisture. Further, the hydrophobic coating can reduce the friction between the hinge and adjacent parts in contact with the hinge. Further still, the hydrophobic coating can decrease the surface roughness of the hinge to reduce the hinge decay rate. Thus, the hydrophobic coating can help improve the functionality of the hinge and prolong the life of the hinge.

[0018] The hydrophobic coating 120 can be formed of a variety of materials. Generally, the hydrophobic coating can be formed using a material that provides the hinge with a suitable surface roughness and a suitable water contact angle (shown in FIG. 2). As used herein,“surface roughness” refers to the distance between peaks and valleys of the hydrophobic coating surface. Surface roughness can be measured using an atomic force microscopy (AFM), a surface profilometer (stylus-type or optical-type), confocal microscopy, or other suitable analytical technique. In some examples, the hydrophobic coating can be formed using a material that provides the hinge with a surface roughness of from about 0.1 pm to about 2 pm. In some additional examples, the hydrophobic coating can be formed using a material that provides the hinge with a surface roughness of from about 0.1 pm to about 0.5 pm, from about 0.5 pm to about 1 pm, or from about 1 pm to about 1.5 pm. In some specific examples, the hydrophobic coating can be formed using a material that provides the hinge with a surface

roughness of from about 0.5 pm to about 1 pm. [0019] Additionally, the hydrophobic coating can have a suitable water contact angle. Contact angle is a conventional technique that is used to measure the wettability of a solid surface using a liquid. More specifically, the contact angle is the angle where the liquid-vapor interface meets a solid surface (e.g. the hydrophobic coating). One non limiting example is illustrated in FIG. 2. In further detail, a drop of water 222 can be placed on a surface 220 of the hydrophobic coating 221. The angle (A) between interface of the drop of water and the hydrophobic coating can be measured and can be referred to as the“contact angle.” With this in mind, the hydrophobic coating 120 can generally have a water contact angle of from about 90° to about 150°. In some additional examples, the hydrophobic coating can have a water contact angle of from about 90° to about 105°, from about 105° to about 120°, from about 120° to about 135°, or from about 135° to about 150°. In some specific examples, the hydrophobic coating can have a water contact angle from about 90° to about 1 15°.

[0020] Thus, a variety of coating materials can be used to achieve a hydrophobic coating with a suitable surface roughness and water contact angle. Non-limiting examples can include tetraethyl orthosilicate (TEOS), a substituted or unsubstituted Cs- C24 alkyl silane, polytetrafluoroethylene, dodecyltrimethoxysilane,

mecaptoundecyltrimethoxysilane, triethoxysilylundecanal, 1 1 - aminoundecyltriethoxysilane, N-(2-aminoethyl)-1 1 -undecyltrimethoxysilane,

polyvinylidene fluoride, the like, or a combination thereof. In some specific examples, the hydrophobic coating can include a ceramic material, such as TEOS. In some further examples, the hydrophobic coating can include TEOS with about 0.05 wt% to about 0.5 wt%, or about 0.1 wt% to about 0.3 wt%, polyvinylidene fluoride,

polytetrafluoroethylene, other fluoropolymer, or the like based on a total weight of the hydrophobic coating.

[0021 ] Turning again to FIG. 1 B, the hinge 100 can have a variety of dimensions. Generally, the hinge can have a thickness and length suitable for use in an electronic device. For example, the hinge can have a total thickness (T1 ). The thickness of the hinge can typically be from about 1 mm to about 10 mm. In some examples, the thickness of the hinge can be from about 1 mm to about 8 mm, or from about 1 .2 mm to about 7 mm. In other examples, the thickness of the hinge can be from about 1 mm to about 5 mm, from about 1.5 to about 5 mm, from about 1 to about 3, from about 2 mm to about 4 mm, from about 3 mm to about 5 mm, from about 4 mm to about 6 mm, or from about 5 mm to about 8 mm. The hinge can also have a length L. The length of the hinge can typically be from about 5 mm to about 18 mm. In some examples, the length of the hinge can be from about 5 mm to about 8 mm, about 7 mm to about 10 mm, about 9 mm to about 12 mm, from about 10 mm to about 14 mm, from about 12 mm to about 15 mm, from about 13 mm to about 17 mm, or from about 15 mm to about 18 mm.

[0022] As the hinge is predominantly formed of the monolithic metal hinge body 110, the thickness (T2) of the monolithic metal hinge body can generally approximate the total thickness (T1 ) of the hinge. Thus, (T1 ) can be about equal to (T2), with only the coating thickness (T3) in this example, which may be deminimis, accounting for the difference. Thus, the monolithic metal hinge body (T2) can have a thickness of the same order of magnitude of total thickness (T1 ) of the hinge, minus the coating thickness (T3).

[0023] The coating thickness (T3) of the hydrophobic coating 120 can typically be from about 3 pm to about 25 pm. In some examples, the hydrophobic coating can have a thickness of from about 3 pm to about 9 pm, from about 6 pm to about 12 pm, from about 9 pm to about 15 pm, from about 12 pm to about 18 pm, from about 15 pm to about 21 pm, or from about 18 pm to about 24 pm. In some specific examples, the hydrophobic coating can have a thickness of from about 9 pm to about 18 pm.

[0024] The present disclosure also describes methods of manufacturing hinges for electronic devices. FIG. 3 presents a flowchart of an example of a method 300 of manufacturing a hinge for an electronic device. The method can include forming 310 a monolithic metal hinge body including a first attachment end to attach to a first gear shaft and a second attachment end opposite the first attachment end to attach to a second gear shaft. The method can further include coating 320 the monolithic metal hinge body with a hydrophobic coating, the hydrophobic coating providing a surface roughness to the hinge at from about 0.1 pm to about 2 pm.

[0025] The monolithic metal hinge body can be formed in a variety of ways. Non limiting examples can include metal injection molding, additive manufacturing, computer numerical control (CNC) machining, investment casting, conventional powder metallurgy, or the like. In some specific examples, the monolithic metal hinge body can be formed by metal injection molding. In some examples, metal injection molding is capable of producing geometries that effectively eliminate the need for secondary operations to detail or finish the monolithic metal hinge body. Further, metal injection molding can form a monolithic metal hinge body with good density, corrosion resistance, and strength. For example, the metal injection molding can provide a monolithic metal hinge body with a density of from about 96% to about 99% of the anticipated theoretical density after sintering.

[0026] The monolithic metal hinge body alone can generally have a surface roughness that can lead to accelerated hinge decay rates, e.g., surface roughness may initially be greater than 2 pm in some examples. Accordingly, the monolithic metal hinge bodies described herein can be coated with a hydrophobic coating to provide a lower surface roughness as compared to the monolithic metal hinge body alone. This can enhance hinge durability, prolong hinge lifetime, and improve hinge performance.

[0027] The hydrophobic coating can be applied to the monolithic metal hinge body in a number of ways. In some examples, the hydrophobic coating can be applied to the entire surface of the monolithic metal hinge body. In other examples, the hydrophobic coating can be applied to select portions of the monolithic metal hinge body (e.g. portions intended to contact other components of a hinge assembly). In some specific examples, the hydrophobic coating can be applied to the monolithic metal hinge body by dip coating, centrifuge coating, spray coating, additive manufacturing, the like, or a combination thereof. In some specific examples, the hydrophobic coating can be applied by dip coating. Dip coating is generally performed by immersing the monolithic metal hinge body in the hydrophobic coating material at a constant rate, maintaining the monolithic metal hinge body in the hydrophobic coating material for a period of time, and withdrawing the monolithic metal hinge body from the hydrophobic coating material at a constant rate. In some specific examples, the immersing and withdrawing portions of the dip coating process can independently be performed at a constant rate of from about 2 mm/second to about 10 mm/second, or from about 4 mm/second to about 8 mm/second. In some additional examples, the immersing and withdrawing portions of the dip coating process can independently be performed at a constant rate of from about 2 mm/second to about 4 mm/second, from about 4 mm/second to about 6 mm/second, about 5 mm/second to about 7 mm/second, or from about 6 mm/second to about 8 mm/second. After withdrawing the monolithic metal hinge body from the hydrophobic coating material, the coated monolithic metal hinge body can be

centrifuged to remove excess coating material.

[0028] The present disclosure also describes hinge assemblies. One non-limiting example of a hinge assembly 400 is illustrated in FIG. 4. The hinge assembly can include a first gear shaft 430, a second gear shaft 432, an idler gear 440 operably connected between the first gear shaft and the second gear shaft, and a hinge 100 coupled to the first gear shaft at a first attachment end 102 and to the second gear shaft at a second attachment end 104.

[0029] In further detail, the idler gear 440 can be operably connected to both the first gear shaft 430 and the second gear shaft 432. The idler gear can function to transfer rotational motion from the first gear shaft to the second gear shaft, and vice versa. The idler gear, first gear shaft, and second gear shaft can be formed of a variety of materials. In some examples, the idler gear, the first gear shaft and the second gear shaft can include or be formed of the same type of material or materials. In other examples, the idler gear can include or be formed of a material that is different from the first gear shaft or the second gear shaft. In still other examples, the idler gear, the first gear shaft and the second gear shaft can both include or be made of different materials. In some further examples, the idler gear, the first gear shaft, and the second gear shaft can independently include steel, titanium, tungsten, inconel, the like, alloys thereof, or a combination thereof. In some examples, the idler gear, the first gear shaft, the second gear shaft, or a combination thereof can be formed using steel, such as carbon steel, stainless steel, tool steel, a steel alloy (e.g. including nickel, copper, aluminum, etc., or a combination thereof), or the like. In some specific examples, the idler gear, the first gear shaft, and the second gear shaft can include or be formed of carbon steel. The idler gear, first gear shaft and second fear shaft can also be formed in a variety of ways. Non-limiting examples can include metal injection molding, additive manufacturing, CNC machining, investment casting, conventional powder metallurgy, or the like. In some specific examples, the idler gear, the first gear shaft, and the second gear shaft can be formed using CNC machining.

[0030] The hinge 100 can help maintain an intended spacing between the first gear shaft 430 and the second gear shaft 432 while allowing the two gear shafts to rotate relative to one another. Further the hinge can help maintain operable contact between the idler gear 440 and the first and second gear shafts. Thus, the first gear shaft can rotate 360° relative to the second gear shaft, and vice versa. As such, the gear assembly can be useful in and included in a variety of electronic devices and electronic device cases. Non-limiting examples can include a desktop computer, a laptop computer, a tablet, a phone, a portable media player, a speaker, a monitor, the like, or a case thereof.

[0031 ] Another illustrative example of a hinge assembly 500 is illustrated in FIG. 5. In this example, the hinge assembly is depicted with a variety of additional components that can optionally be included in the hinge assembly. For example, in some cases, the hinge assembly can further include a gear chassis 542 housing the idler gear 540 and portions of the first gear shaft 530 and the second gear shaft 532. The hinge 100 can additionally be coupled to the first gear shaft and the second gear shaft. The hinge can be positioned between the gear chassis and attachment components 560 (e.g. clips, washers, nuts, etc.) on both the first gear shaft and the second gear shaft. In this particular example, the first gear shaft is coupled to an upper bracket 550 and the second gear shaft is coupled to a lower bracket 552. As one non limiting example, the upper bracket can be further coupled to a screen portion of a laptop computer and the lower bracket can be further coupled to a keyboard portion of the laptop computer. This can allow the screen portion to rotate 360° relative to the keyboard portion and to be held at any desirable angle from 0° (e.g. closed laptop with screen on top of keyboard portion and parallel to keyboard portion) to 360° (e.g. screen portion on bottom of keyboard portion and parallel to keyboard portion) relative to the keyboard portion.

[0032] It is noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the content clearly dictates otherwise. [0033] As used herein, the term“about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be“a little above” or“a little below” the endpoint. The degree of flexibility of this term can be dictated by the particular variable and would be within the knowledge of those in the field technology determine based on experience and the associated description herein.

[0034] As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience.

However, these lists should be construed as though individual members of the list are individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary.

[0035] Concentrations, dimensions, amounts, and other numerical data may be presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity and should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also all the individual numerical values or sub-ranges encompassed within that range as if individual numerical values and sub-ranges are explicitly recited. For example, a weight ratio range of about 1 wt% to about 20 wt% should be interpreted to include not only the explicitly recited limits of about 1 wt% and about 20 wt%, but also to include individual weights such as 2 wt%, 11 wt%, 14 wt%, and sub-ranges such as 10 wt% to 20 wt%, 5 wt% to 15 wt%, etc.

EXAMPLE

[0036] The following example illustrates the technology of the present disclosure. However, it is to be understood that the following are only exemplary or illustrative of the application of the principles of the presented hinges, associated methods, and hinge assemblies. Numerous modifications and alternatives may be devised without departing from the present disclosure. The appended claims are intended to cover such modifications and arrangements. Thus, while the disclosure has been provided with particularity, the following describes further detail in connection with what are presently deemed to be an acceptable example.

[0037] Carbon steel was metal injection molded to form a monolithic metal hinge body having a first attachment end and a second attachment end opposite the first attachment end. The monolithic metal hinge body had a 2.5 mm thickness and 8 mm length. The monolithic metal hinge body was then dip coated at a constant rate of 6 mm/second in TEOS to from a hydrophobic coating thereon. After dip coating, the coated monolithic metal hinge body was centrifuged to remove the extra coating material. The surface roughness of the hinge was then measured to be 0.3 pm using confocal microscope. Further, the water contact angle of the TEOS coating was determined to be 113°.

[0038] While the present technology has been described with reference to certain examples, various modifications, changes, omissions, and substitutions can be made without departing from the spirit of the disclosure. It is intended, therefore, that the disclosure be limited only by the scope of the following claims.