WO2020219051A1

WO2020219051A1 - Living hinges for electronic devices

Info

Publication number: WO2020219051A1
Application number: PCT/US2019/029128
Authority: WO
Inventors: Kuan-Ting Wu; Cheng-Han Tsai; Wen-Hung Wang
Original assignee: Hewlett-Packard Development Company, L.P.
Priority date: 2019-04-25
Filing date: 2019-04-25
Publication date: 2020-10-29
Also published as: TWI762867B; TW202041127A

Abstract

The present disclosure is drawn to living hinges for electronic devices. In one examples, a living hinge for an electronic device can include a first attachment portion at a first edge of the living hinge to attach to a first rigid panel of the electronic device, and a second attachment portion at a second edge of the living hinge, opposite from the first edge, to attach to a second rigid panel of the electronic device. A flexing portion can connect the first attachment portion and the second attachment portion. The flexing portion can include an electromagnetic interference shielding layer that includes conductive particles compounded in an elastomer.

Description

LIVING HINGES FOR ELECTRONIC DEVICES

BACKGROUND

[0001] The use of personal electronic devices of all types continues to increase. Cellular phones, including smartphones, have become nearly ubiquitous. Tablet computers have also become widely used in recent years. Portable laptop computers continue to be used by many for personal, entertainment, and business purposes. For portable electronic devices in particular, much effort has been expended to make these devices more useful and more powerful while at the same time making the devices smaller, lighter, and more durable. Devices have also been designed with differing form factors, including convertible laptop and tablet computers. A variety of electronic accessories have also been developed, such as wireless keyboards, keyboard covers, and others.

BRIEF DESCRIPTION OF THE DRAWING

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

[0003] FIG. 1 B is an end view of the example living hinge in FIG. 1 A;

[0004] FIG. 2 is an end view illustrating another example living hinge for an electronic device in accordance with examples of the present disclosure;

[0005] FIG. 3 is an end view illustrating another example living hinge for an electronic device in accordance with examples of the present disclosure;

[0006] FIG. 4A is a top plane view illustrating an example electronic device in accordance with examples of the present disclosure; [0007] FIG. 4B is a perspective view of the example electronic device in FIG. 4A; and

[0008] FIG. 5 is a flowchart illustrating an example method of making a living hinge in accordance with examples of the present disclosure.

DETAILED DESCRIPTION

[0009] The present disclosure describes living hinges for electronic devices, electronic devices that include a living hinge, and methods of making living hinges for electronic devices. In one example, a living hinge for an electronic device can include a first attachment portion at a first edge of the living hinge to attach to a first rigid panel of the electronic device, a second attachment portion at a second edge of the living hinge, opposite from the first edge, to attach to a second rigid panel of the electronic device, and a flexing portion connecting the first attachment portion and the second attachment portion. The flexing portion can include an electromagnetic interference shielding layer including conductive particles compounded in an elastomer. In a particular example, the living hinge can include a continuous elastomer sheet substrate. The first attachment portion, second attachment portion, and flexing portion can include portions of the continuous elastomer sheet substrate. The electromagnetic interference shielding layer can be a separate layer applied to the continuous elastomer sheet substrate. In various examples, the continuous elastomer sheet substrate can include thermoplastic polyurethane, polyvinyl chloride, silicone rubber, polyisoprene, polybutadiene, chloroprene rubber, butyl rubber, styrene-butadiene rubber, nitrile rubber, hydrogenated nitrile rubbers, fluorosilicone rubber, fluoroelastomer, perfluoroelastomer, polyether block amide (PEBA), chlorosulfonated polyethylene, ethylene-vinyl acetate (EVA) copolymer, polysulfide rubber, and polyamide-polyether copolymer, or a combination thereof. In another example, the entire living hinge can be made up of the electromagnetic interference shielding layer, such that the living hinge is a homogeneous sheet of the elastomer having the conductive particles compounded therein. In some examples, the conductive particles can be present in the electromagnetic interference shielding layer at a concentration from about 3 wt% to about 15 wt% with respect to the total weight of the electromagnetic interference shielding layer. In further examples, the conductive particles can include graphene, graphite, carbon nanotube, borophene, aluminum, copper, silver, gold, or a combination thereof. In still further examples, the elastomer of the electromagnetic

interference shielding layer can include thermoplastic polyurethane, polyvinyl chloride, polyester, polyester-polyether copolymer, ethylene-vinyl acetate (EVA), nylon, polyamide-polyether copolymer, or a combination thereof. In some examples, the first attachment portion and the second attachment portion of the living hinge can include a screw hole, a double-sided tape, an adhesive layer, or a combination thereof. In further examples, the flexing portion can be sufficiently flexible to fold to a maximum angle from about 90° to about 180°.

[0010] In another example, an electronic device can include a first rigid panel having a first edge, a second rigid panel having a second edge oriented parallel to the first edge of the first rigid panel; and a living hinge attached to the first rigid panel at the first edge and the second rigid panel at the second edge. The living hinge can include an electromagnetic interference shielding layer including conductive particles compounded in an elastomer. In certain examples, the living hinge can be sufficiently flexible and the first and second rigid panels can be spaced sufficiently so that the living hinge folds to a maximum angle from 90° to 180°. In other examples, the living hinge can also include a continuous elastomer sheet substrate, and the electromagnetic interference shielding layer can be applied to the continuous elastomer sheet substrate. In further examples, the conductive particles can be present in the electromagnetic interference shielding layer at a concentration from about 3 wt% to about 15 wt% with respect to the total weight of the electromagnetic interference shielding layer, and the conductive particles can include graphene, graphite, carbon nanotube, borophene, aluminum, copper, silver, gold, or a combination thereof.

[001 1] In yet another example, a method of making a living hinge for an electronic device can include applying an electromagnetic interference shielding layer to a continuous elastomer sheet substrate. The electromagnetic

interference shielding layer can include conductive particles compounded in an elastomer. The continuous elastomer sheet substrate can include a first attachment portion at a first edge of the living hinge to attach to a first rigid panel of the electronic device, a second attachment portion at a second edge of the living hinge, opposite from the first edge, to attach to a second rigid panel of the electronic device, and a flexing portion connecting the first attachment portion and the second attachment portion. In another example, the method can include plasma treating the continuous elastomer sheet substrate before applying the electromagnetic interference shielding layer, and baking the living hinge at a temperature from about 60 °C to about 80 °C after applying the electromagnetic interference shielding layer.

[0012] In addition to the examples described above, the living hinges, the electronic devices, and the methods of manufacturing living hinges are described in greater detail below. It is also noted that when discussing the living hinges, electronic devices, methods of manufacturing living hinges, 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 an electromagnetic interference shielding layer related to the living hinge, such disclosure is also relevant to and directly supported in the context of the electronic device and methods of manufacturing living hinges described herein, and vice versa.

Living Hinges for Electronic Devices

[0013] The present disclosure describes living hinges for electronic devices. The living hinges can be sufficiently flexible to operate as a hinge while also provided electromagnetic interference shielding. Electromagnetic interference (EMI) is typically any electromagnetic disturbance generated by an external source that affects the circuitry of the electronic device by

electromagnetic induction, electrostatic coupling, conduction, and so on. EMI can be caused by many sources, such as radio transmitting devices, electric appliances, transformers, electric motors, and others. In some cases, EMI can cause an electronic device to malfunction, lose data, or cease to function altogether. Accordingly, electronic devices can be equipped with EMI shielding measures to protect circuitry of the electric devices from EMI.

[0014] The living hinges described herein can provide EMI shielding while also acting as a flexible hinge for the electronic device. As used herein,“living hinge” refers to a hinge made of a flexible material that allows for a bending or folding motion without having multiple hinge parts that rotate or slide against one another. In other words, a living hinge can provide the bending or folding motion through flexing of the living hinge material itself. Thus living hinges are different from hinges such as door hinges, which often include two rigid leaves held together by a rigid pin. In the door hinge, the leaves and pin are made of a rigid material such as metal and the leaves and pin rotate and slide against one another to provide the bending motion of the hinge. In contrast, a living hinge is flexible and can be a single piece of flexible material which provides the bending motion by flexing the material of the living hinge itself.

[0015] In certain examples, the living hinges described herein can be a sheet of flexible material, such as an elastomeric material, that is sized and shaped to be a hinge connecting two rigid components of an electronic device. For example, the living hinge can connect a front and back portion of a protective cover for a smartphone or tablet computer. In another example, the living hinge can be the central hinge in a notebook computer. In other examples, the living hinge can be used in an electronic accessory such as a wireless keyboard. In a particular example, the living hinge can be included in a convertible notebook computer that can be folded into multiple configurations, such as clamshell mode, tablet mode, and media mode.

[0016] In order to provide EMI shielding on a living hinge, one potential solution involves adding a layer of metal foil to the flexible material of the living hinge. For example, a living hinge may include an elastomeric material layer and an aluminum foil layer adhered to the elastomeric material layer. However, in many cases the aluminum foil layer can become worn and eventually break after the living hinge is flexed many (such as more than a thousand) times. Instead of including metal foil, the living hinges described herein can include an

electromagnetic interference shielding layer that includes conductive particles compounded in an elastomer. The conductive particles can provide EMI shielding and the elastomer can be flexible and able to bend many times without breaking.

[0017] FIG. 1A shows a top plane view of an example living hinge 100 for an electronic device in accordance with examples of the present disclosure. The living hinge includes a first attachment portion 1 10 at a first edge 1 15 of the living hinge and a second attachment portion 120 at a second edge 125 of the living hinge opposite from the first edge. A flexing portion 130 connects the first attachment portion and the second attachment portion. The first attachment portion can attach to a first rigid panel of the electronic device and the second attachment portion can attach to a second rigid panel of the electronic device using screw holes 140. In this example, the entire living hinge is made up of an electromagnetic interference shielding layer 150 that includes conductive particles compounded in an elastomer. Thus, the living hinge is formed as a single sheet of an elastomer having conductive particles compounded therein. FIG. 1 B shows an end view of the living hinge, showing that the living hinge is a single layer of material. The first attachment portion, second attachment portion, and flexing portion are not separate components, but rather are specific areas of the living hinge as shown in FIG. 1 B.

[0018] In other examples, living hinges for electronic devices may include multiple layers of material. For example, the living hinge can include a continuous elastomer sheet substrate that does not include conductive particles, and then an electromagnetic interference shielding layer can be a separate layer applied to the continuous elastomer sheet substrate. The electromagnetic interference shielding can be applied to the entire elastomer sheet substrate or to a portion of the substrate, such as to the flexing portion.

[0019] FIG. 2 shows an edge view of an example living hinge 200 for an electronic device in accordance with examples of the present disclosure. In this example, the living hinge includes a continuous elastomer sheet substrate 205. The first attachment portion 210, second attachment portion 220, and flexing portion 230 are portions of the continuous elastomer sheet substrate. The first attachment portion is at a first edge 215 of the living hinge and the second attachment portion is at a second edge 225 of the living hinge. An electromagnetic interference shielding layer 250 is a separate layer applied to the continuous elastomer sheet substrate. In this example, the electromagnetic interference shielding layer has the same dimensions as the continuous elastomer sheet substrate. Therefore, the electromagnetic interference shielding layer covers an entire surface of the continuous elastomer sheet substrate.

[0020] FIG. 3 shows a different example living hinge 300 for an electronic device in accordance with examples of the present disclosure. This example includes a continuous elastomer sheet substrate 305 with a first attachment portion 310 at a first edge 315, a second attachment portion 320 at a second edge 325, and a flexing portion 330 between the first attachment portion and the second attachment portion. An electromagnetic interference shielding layer 350 is applied to the flexing portion but not the first or second attachment portions. In this example, the first and second attachment portions can be electromagnetically shielded by the rigid panels of the electronic device to which the living hinge is attached.

[0021] The living hinges described herein can have any size and shape to fit particular electronic devices for which the living hinges may be designed. In various examples, the living hinges can be used in electronic devices such as smartphones, tablet computers, laptop computers, wireless keyboards, keyboard covers, and others. In some examples, the living hinge can have a width from about 5 mm to about 20 cm, or from about 1 cm to about 10 cm. The living hinge can have a length from about 1 cm to about 50 cm, or from about 2 cm to about 40 cm, depending on the type of electronic device in which the living hinge is included. In further examples, the living hinge can have a thickness from about 0.5 mm to about 5 mm.

Elastomer Sheet Substrate

[0022] As mentioned above, in some examples the living hinge can include a continuous elastomer sheet substrate. As used herein,“continuous elastomer sheet” refers to a single sheet of an elastomeric material. The sheet can be relatively thin compared to the length and/or width of the sheet, which can allow the sheet to bend and fold easily. In some examples, the elastomer sheet can be sufficiently flexible to fold to an angle of about 90° to about 180°. More specifically, the fold angle can refer to the change in the angle between the first attachment portion and second attachment portion when the flexing portion bends to fold the living hinge. By extension, the angle can refer to the change in angle between a first and second rigid panel of the electronic device, where the first and second rigid panels are attached to the first and second attachment portions. For example, the living hinge can be flat and unbent, in which case the fold angle is 0°. If the flexing portion bends to the point that the second attachment portion is at a right angle to the first attachment portion, then the flexing portion has folded to an angle of 90°. If the hinge folds completely over so that the second attachment portion is in contact with or parallel to the first attachment portion, then the flexing portion has folded to an angle of 180°.

Generally, 180° is the highest folding angle that can be achieved because at 180° the rigid panels of the electronic device will contact on another and the living hinge will fold no further.

[0023] In various examples, the continuous elastomer sheet substrate can have any of the dimensions disclosed above for the living hinge. For example, the continuous elastomer sheet substrate can have a width from about 5 mm to about 20 cm, or from about 1 cm to about 10 cm. The length can be from about 1 cm to about 50 cm, or from about 2 cm to about 40 cm, depending on the type of electronic device in which the living hinge is included. The continuous elastomer sheet substrate can make up a portion of the thickness of the living hinge, because the electromagnetic interference shielding layer can be applied to a surface of the substrate. In some examples, the continuous elastomer sheet substrate can have a thickness from about 0.1 mm to about 4 mm.

[0024] The first attachment portion and second attachment portion can have dimensions appropriate to allow attachment to rigid panels of the electronic device. In some examples, the first attachment portion can include a portion of the width of the living hinge, beginning at a first edge of the living hinge. In some examples, the first attachment portion can include from about 5% to about 49% of the width of the living hinge, measured starting at the first edge of the living hinge. The second attachment portion can also include from about 5% to about 49% of the width of the living hinge, measured starting at the second edge of the living hinge. The flexing portion can be the portion of the living hinge that is between the first attachment portion and the second attachment portion.

[0025] In further examples, the first attachment portion and/or second attachment portion can include features for attachment to a rigid panel of an electronic device. Non-limiting examples of attachment features can include screw holes, double-sided tape, adhesive layers, and combinations thereof. In other examples, the living hinge may not include an attachment feature, but the panels of the electronic device can be designed to attach to the living hinge in some way such as by clamping.

[0026] The continuous elastomer sheet substrate can be made from any elastomer that has sufficient flexible to bend or fold as a hinge and sufficient strength to withstand many bending/folding cycles and other normal use of an electronic device. Non-limiting examples of elastomeric materials that can be used include thermoplastic polyurethane, polyvinyl chloride, silicone rubber, polyisoprene, polybutadiene, chloroprene rubber, butyl rubber, styrene-butadiene rubber, nitrile rubber, hydrogenated nitrile rubbers, fluorosilicone rubber, fluoroelastomer, perfluoroelastomer, polyether block amide (PEBA),

chlorosulfonated polyethylene, ethylene-vinyl acetate (EVA) copolymer, polysulfide rubber, and polyamide-polyether copolymer, and combinations thereof. In some examples, the substrate can be made of a homogeneous mixture or copolymer of two or more of the above materials. In other examples, the substrate can include multiple layers of material. Multiple layers of a single material or multiple layers of different materials can be used in various examples.

Electromagnetic Interference Shielding Layer

[0027] The living hinges described herein can include an electromagnetic interference shielding layer at the flexing portion of the living hinge. The electromagnetic interference shielding layer can include conductive particles compounded in an elastomer. In some examples, the electromagnetic interference shielding layer can be applied to a surface of a continuous elastomer sheet substrate as described above. In other examples, the electromagnetic interference shielding layer can be used without a separate substrate layer. For example, the living hinge can substantially consist of the electromagnetic interference shielding layer.

[0028] In some examples, the electromagnetic interference shielding layer can have the same dimensions as disclosed above for the continuous elastomer sheet substrate. For example, the shielding layer can have a width from about 5 mm to about 20 cm, or from about 1 cm to about 10 cm. The length can be from about 1 cm to about 50 cm, or from about 2 cm to about 40 cm, depending on the type of electronic device in which the living hinge is included. The shielding layer can be used alone, without a separate substrate layer. In such examples, the shielding layer can have a thickness from about 0.5 mm to about 5 mm. In other examples, the shielding layer can make up a portion of the thickness of the living hinge along with the separate elastomer sheet substrate layer. In such examples, the shielding layer can have a thickness from about 0.1 mm to about 4 mm.

[0029] In further examples, the electromagnetic interference shielding layer can be applied over a portion of the surface of the continuous elastomer sheet substrate. In some examples, the electromagnetic interference shielding layer can be applied over the flexing portion. In more specific examples, the electromagnetic interference shielding layer can have a width that is from about 50% of the width of the flexing portion up to the entire width of the living hinge.

[0030] The electromagnetic interference shielding layer can include conductive particles compounded in an elastomer. As used herein,

“compounded” can refer to mixing the conductive particles into the elastomer when the elastomer is in a molten or softened state. The conductive particles can be mixed thoroughly into the elastomer so that the distribution of conductive particles is substantially uniform throughout the elastomer. The concentration of conductive particles in the elastomer can be sufficient to provide electromagnetic interference shielding to the electronic device into which the living hinge is incorporated. In some examples, the concentration of conductive particles in the electromagnetic interference shielding layer can be from about 3 wt% to about 15 wt% with respect to the total weight of the electromagnetic shielding layer. [0031] The conductive particles can be made of any conductive material that can provide electromagnetic interference shielding. In certain examples, the conductive particles can include graphene, graphite, carbon nanotube, borophene, aluminum, copper, silver, gold, or a combination thereof. The conductive particles can generally have any shape. In some examples, the average particle size of the conductive particles can be from about 10 nm to about 100 pm, or from about 50 nm to about 10 pm.

[0032] In further examples, the elastomeric material used in the electromagnetic interference shielding layer can be any material that is sufficiently flexible to bend and fold as a hinge, and sufficiently strong to withstand many bend/fold cycles. In some examples, the elastomeric material can be one of the elastomers disclosed above for use in the continuous elastomer sheet substrate. In other examples, the elastomer used in the electromagnetic interference shielding layer can include thermoplastic polyurethane, polyvinyl chloride, polyester, polyester-polyether copolymer, ethylene-vinyl acetate (EVA), nylon, polyamide-polyether copolymer, or a combination thereof.

Electronic Devices

[0033] The living hinges described herein can be used in any type of electronic device that has segments designed to fold or bend with respect to one another. In one example, the electronic device can be a laptop computer. The living hinge can connect the display portion of the laptop computer to the keyboard portion of the laptop computer. The living hinge can be able to fold 180° to allow the display portion to close against the keyboard portion. In this example, the living hinge may also be able to fold 180° in the opposite direction, such that the display is visible and the keyboard is folded flat behind the display portion. This type of design can be used as a convertible laptop that can convert to a tablet mode, for example.

[0034] In another example, the living hinge can be used in a protective cover for a tablet computer. The living hinge can allow one panel of the cover to fold out of the way and the electromagnetic interference shielding layer can provide shielding for the tablet computer. As used herein,“electronic device” can include accessories for electronic devices, such as covers. In another example, the protective cover can include a wireless keyboard to allow typing on the tablet computer. In a further example, the protective cover can include multiple living hinges that can fold in various directions to allow the cover to be converted into multiple shapes.

[0035] Other electronic devices that can include the living hinge can include smartphones, tablet computers, laptop computers, wireless keyboards, keyboard covers, and others.

[0036] FIG. 4A shows a top plane view of an example electronic device 400. The device includes a living hinge 402 that is attached to a first rigid panel 412 and a second rigid panel 422 using screws 440. FIG. 4B shows a perspective view of the electronic device with the flexing portion of the living hinge bent so that the rigid panels are at an angle one with another. In some examples, the living hinge can bend sufficiently so that the rigid panels fold to a maximum angle from about 90° to about 180°.

[0037] The rigid panels attached to the living hinge can be any parts of the electronic device in which the living hinge is incorporated. In some examples, the panels can be interior parts of the device such as a chassis part or a circuit board or other internal component, while in other examples the panels can be exterior cover panels or the like. The rigid panels can have any shape and size, and are not limited to flat rectangular panels as shown in the figures. Generally, the living hinges can be used in any electronic device that is desired to bend or fold, and therefore a rigid panel can be any rigid part of the electronic device that is designed to bend or fold with respect to another panel or part of the electronic device. In some examples, the rigid panels themselves can be made of a material that can provide electromagnetic interference shielding. In certain examples, the rigid panels can include a metal such as steel, aluminum, magnesium, titanium, lithium, niobium, zinc, or alloys thereof. In further examples, the rigid panels can be an aluminum alloy or a magnesium alloy. Non-limiting examples of additional elements that can be included in aluminum or magnesium alloys can include aluminum, magnesium, titanium, lithium, niobium, zinc, bismuth, copper, cadmium, iron, thorium, strontium, zirconium, manganese, nickel, lead, silver, chromium, silicon, tin, gadolinium, yttrium, calcium, antimony, cerium, lanthanum, or others.

Methods of Making Living Hinges

[0038] Methods of making the living hinges described herein can include forming the electromagnetic interference shielding layer having the appropriate shape and concentration of compounded conductive particles to provide electromagnetic interference shielding. In some examples, the conductive particles can be compounded with an elastomer as described above, by melting or softening the elastomer and mixing conductive particles with the elastomer. In some examples, the living hinge can be a single layer made up of the

electromagnetic interference shielding layer. This layer can be formed by any suitable method of forming elastomer sheets, such as extrusion, casting, coating, pressing, and so on. In certain examples, a large sheet of the elastomer having conductive particles therein can be formed and then the sheet can be cut to size to form individual electromagnetic interference shielding layers for living hinges.

[0039] In certain examples, methods of making living hinges can include applying the electromagnetic interference shielding layer to a continuous elastomer sheet substrate. The shielding layer can be applied to the substrate by a variety of methods, such as coating, co-extrusion, adhering with adhesive, pressing, laminating, and so on.

[0040] In a particular example, the continuous elastomer sheet substrate can be prepared to receive the electromagnetic interference shielding layer by plasma treating the continuous elastomer sheet substrate. Plasma treatment can be performed using various plasma treating processes, such as argon/oxygen plasma treatment, CF4 plasma treatment, SF6 plasma treatment, NF3 plasma treatment, or a combination thereof. The electromagnetic interference shielding layer can then be applied to the continuous elastomer sheet substrate by a roll-to-roll coating process. In certain examples, the shielding layer and the substrate layer can be baked at a temperature from about 60°C to about 80°C after applying the shielding layer. The baking can be performed for a baking time of about 20 minutes to about 40 minutes in some examples. [0041] FIG. 5 is a flowchart showing one example method 500 of making a living hinge for an electronic device. The method includes: applying 510 an electromagnetic interference shielding layer to a continuous elastomer sheet substrate, wherein the electromagnetic interference shielding layer includes conductive particles compounded in an elastomer, and wherein the continuous elastomer sheet substrate includes: a first attachment portion at a first edge of the living hinge to attach to a first rigid panel of the electronic device; a second attachment portion at a second edge of the living hinge, opposite from the first edge, to attach to a second rigid panel of the electronic device; and a flexing portion connecting the first attachment portion and the second attachment portion.

Definitions

[0042] 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.

[0043] The term "about" as used herein, when referring to a numerical value or range, allows for a degree of variability in the value or range, for example, within 5% or other reasonable added range breadth of a stated value or of a stated limit of a range. The term“about” when modifying a numerical range is also understood to include the exact numerical value indicated, e.g., the range of about 1 wt% to about 5 wt% includes 1 wt% to 5 wt% as an explicitly supported sub-range.

[0044] As used herein,“average particle size” refers to a number average of the diameter of the particles for spherical particles, or a number average of the volume equivalent sphere diameter for non-spherical particles. The volume equivalent sphere diameter is the diameter of a sphere having the same volume as the particle. Average particle size can be measured using a particle analyzer such as the Nanotrac® Wave II particle size analyzer available from Microtrac Inc., Pennsylvania. The particle analyzer can measure particle size using laser diffraction. A laser beam can pass through a sample of particles and the angular variation in intensity of light scattered by the particles can be measured. Larger particles scatter light at smaller angles, while small particles scatter light at larger angles. The particle analyzer can then analyze the angular scattering data to calculate the size of the particles using the Mie theory of light scattering. The particle size can be reported as a volume equivalent sphere diameter.

[0045] 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 the 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.

[0046] 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 the numerical values explicitly recited as the limits of the range, and also to include 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 layer thickness from about 0.1 pm to about 0.5 pm should be interpreted to include the explicitly recited limits of 0.1 pm to 0.5 pm, and to include thicknesses such as about 0.1 pm and about 0.5 pm, as well as subranges such as about 0.2 pm to about 0.4 pm, about 0.2 pm to about 0.5 pm, about 0.1 pm to about 0.4 pm etc.

[0047] The following illustrates an example of the present disclosure. However, it is to be understood that the following is illustrative of the application of the principles of the present disclosure. Numerous modifications and alternative compositions, methods, and systems may be devised without departing from the spirit and scope of the present disclosure. The appended claims are intended to cover such modifications and arrangements.

Example

[0048] An example living hinge for an electronic device is made as follows: 1 ) A continuous elastomer sheet substrate is prepared from thermoplastic polyurethane, having a thickness of about 2 mm.

2) The substrate is plasma treated by an argon/oxygen plasma treatment process.

3) Conductive aluminum powder is compounded with thermoplastic

polyurethane to make an elastomeric material for the

electromagnetic interference shielding layer.

4) This elastomeric material is coated onto the substrate by a roll-to-roll coating process to form the electromagnetic interference shielding layer.

5) The sheet is then baked at a temperature between about 60°C and about 80°C for a baking time of about 20 minutes to about 40 minutes.

6) The sheet is cut to a size of about 5 cm by about 20 cm to form a living hinge and screw holes are cut near edges of the living hinge.

7) The living hinge is attached to two rigid panels of an electronic device by using screws attached through the screw holes.

8) The living hinge is tested by bending back and forth 1 ,000 times without any breakage of the living hinge.

Claims

What is claimed is: 1. A living hinge for an electronic device comprising:

a first attachment portion at a first edge of the living hinge to attach to a first rigid panel of the electronic device;

a second attachment portion at a second edge of the living hinge, opposite from the first edge, to attach to a second rigid panel of the electronic device; and a flexing portion connecting the first attachment portion and the second attachment portion, wherein the flexing portion comprises an electromagnetic interference shielding layer comprising conductive particles compounded in an elastomer.

2. The living hinge of claim 1 , wherein the living hinge comprises a continuous elastomer sheet substrate, wherein the first attachment portion, second attachment portion, and flexing portion comprise portions of the continuous elastomer sheet substrate, and wherein the electromagnetic interference shielding layer is a separate layer applied to the continuous elastomer sheet substrate.

3. The living hinge of claim 2, wherein the continuous elastomer sheet substrate comprises thermoplastic polyurethane, polyvinyl chloride, silicone rubber, polyisoprene, polybutadiene, chloroprene rubber, butyl rubber, styrene-butadiene rubber, nitrile rubber, hydrogenated nitrile rubbers, fluorosilicone rubber, fluoroelastomer, perfluoroelastomer, polyether block amide (PEBA), chlorosulfonated polyethylene, ethylene-vinyl acetate (EVA) copolymer, polysulfide rubber, and polyamide-polyether copolymer, or a combination thereof.

4. The living hinge of claim 1 , wherein the entire living hinge is made up of the electromagnetic interference shielding layer, such that the living hinge is a homogeneous sheet of the elastomer having the conductive particles

compounded therein.

5. The living hinge of claim 1 , wherein the conductive particles are present in the electromagnetic interference shielding layer at a concentration from about 3 wt% to about 15 wt% with respect to the total weight of the electromagnetic interference shielding layer.

6. The living hinge of claim 1 , wherein the conductive particles comprise graphene, graphite, carbon nanotube, borophene, aluminum, copper, silver, gold, or a combination thereof.

7. The living hinge of claim 1 , wherein the elastomer of the electromagnetic interference shielding layer comprises thermoplastic polyurethane, polyvinyl chloride, polyester, polyester-polyether copolymer, ethylene-vinyl acetate (EVA), nylon, polyamide-polyether copolymer, or a combination thereof.

8. The living hinge of claim 1 , wherein the first attachment portion and the second attachment portion include a screw hole, a double-sided tape, an adhesive layer, or a combination thereof.

9. The living hinge of claim 1 , wherein the flexing portion is sufficiently flexible to fold to a maximum angle from about 90° to about 180°.

10. An electronic device comprising:

a first rigid panel having a first edge;

a second rigid panel having a second edge oriented parallel to the first edge of the first rigid panel; and

a living hinge attached to the first rigid panel at the first edge and the second rigid panel at the second edge, wherein the living hinge comprises an electromagnetic interference shielding layer comprising conductive particles compounded in an elastomer.

1 1. The electronic device of claim 10, wherein the living hinge is sufficiently flexible and the first and second rigid panels are spaced sufficiently so that the living hinge folds to a maximum angle from 90° to 180°.

12. The electronic device of claim 10, wherein the living hinge further comprises a continuous elastomer sheet substrate, and wherein the

electromagnetic interference shielding layer is applied to the continuous elastomer sheet substrate.

13. The electronic device of claim 10, wherein the conductive particles are present in the electromagnetic interference shielding layer at a concentration from about 3 wt% to about 15 wt% with respect to the total weight of the electromagnetic interference shielding layer, and wherein the conductive particles comprise graphene, graphite, carbon nanotube, borophene, aluminum, copper, silver, gold, or a combination thereof.

14. A method of making a living hinge for an electronic device comprising applying an electromagnetic interference shielding layer to a continuous elastomer sheet substrate, wherein the electromagnetic interference shielding layer comprises conductive particles compounded in an elastomer, and wherein the continuous elastomer sheet substrate comprises:

a second attachment portion at a second edge of the living hinge, opposite from the first edge, to attach to a second rigid panel of the electronic device; and a flexing portion connecting the first attachment portion and the second attachment portion.

15. The method of claim 14, further comprising plasma treating the continuous elastomer sheet substrate before applying the electromagnetic interference shielding layer, and baking the living hinge at a temperature from about 60 °C to about 80 °C after applying the electromagnetic interference shielding layer.