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FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to a living hinge and, more particularly, to the manufacturing of the hinges. 
       BACKGROUND OF THE INVENTION 
       [0002]    A small portable device, such as a mobile phone with a cover, requires one or more hinges to allow the portable device to open and close. To be used on a small portable device such as a mobile phone, the hinges must be sufficiently small. However, a small plastic living hinge is usually not strong enough mechanically to last a large number of flexing cycles. It is desirable that the hinges are of a small size and it is required that the hinges can be used for a large number of cycles. 
       SUMMARY OF THE INVENTION 
       [0003]    In a plastic living hinge having very thin but strong side sections to miniaturize the hinge element and thus the device, the present invention integrates one or more rigid metal plates in a side section to enhance the strength of living hinge structure. In particular, the metal plates are firmly bonded to the plastic side sections of a plastic living hinge. In a manufacturing process where a plastic living hinge is produced by over-molding, one ore more metal plates are used as inserts and the living hinge is over-molded so that the plastic adheres to the metal inserts in the mold to produce an enhanced living hinge structure. Furthermore, it is possible to fix the living hinge directly into the device without the need for post-assembling by using screws, adhesive, welding or heat stacking. 
         [0004]    Thus, the first aspect of the present invention provides a living hinge structure which comprises: a first plastic section, a second plastic section, and a plastic connecting section connecting the first plastic section to the second plastic section, wherein the plastic connecting section is dimensioned to bend for changing an angle between the first and second plastic sections, wherein one or both of the plastic sections have a metal support integrated thereto. Each of the metal supports can be located on the upper or lower side of the plastic section. One of the metal supports located on the upper side can be extended to the plastic connecting section without being attached to the connecting section. The metal supports can be dimensioned such that the hinge structure can be only stretched out from a bending position up to a certain angle. 
         [0005]    The second aspect of the present invention provides a method for producing a living hinge structure. The method comprises providing a plastic hinge part comprising a first plastic side section, a second plastic side section and a plastic connecting section connecting the first plastic side section to the second plastic side section, and integrating a metal support to one or both of the first and second plastic side sections. The integrating can be carried out by a molding process. 
         [0006]    The third aspect of the present invention provides an electronic device having a first device part and a section device part mechanically engaged with a living hinge structure wherein the living hinge structure has a first plastic section connected to the first device part, a second plastic section connected to the second device part and a plastic connecting section connecting the first plastic section to the second plastic section, and wherein each of the first and second plastic sections has a metal support adhered thereto. The metal support can be a metal plate attached to the corresponding plastic section in a molding process. The metal support can also be a segment of the device part integrated with the corresponding plastic section. The electronic device can be a mobile phone, for example. 
         [0007]    The present invention will become apparent upon reading the description taken in conjunction with  FIGS. 1   a  to  8   e.    
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1   a  is a side view showing a living hinge structure, according to one embodiment of the present invention, in a bent position. 
           [0009]      FIG. 1   b  is a side view showing the living hinge structure, according to one embodiment of present invention, in a stretched out position. 
           [0010]      FIG. 1   c  is a plan view of a living hinge structure as shown in  FIG. 1   b.    
           [0011]      FIG. 2   a  is a side view showing a living structure, according to another embodiment of the present invention, in a bent position. 
           [0012]      FIG. 2   b  is a side view showing the living structure of  FIG. 2   a,  in a stretched out position. 
           [0013]      FIG. 2   c  shows a variation of the living hinge as shown in  FIG. 2   a.    
           [0014]      FIG. 2   d  shows another variation of the living hinge as shown in  FIG. 2   a.    
           [0015]      FIG. 3   a  is a side view showing a living hinge structure, according to another embodiment of the present invention, in a bent position. 
           [0016]      FIG. 3   b  is a side view showing the living hinge structure of  FIG. 3   b  in a stretched out position. 
           [0017]      FIG. 4   a  is side view showing a living hinge structure, according to yet another embodiment of the present invention, in a bent position. 
           [0018]      FIG. 4   b  is a side view showing the living hinge structure of  FIG. 4   b  in a stretched out position. 
           [0019]      FIG. 5   a  is a side view showing a living hinge structure, according to a different embodiment of the present invention, in a bent position. 
           [0020]      FIG. 5   b  is a side view showing the living hinge structure of  FIG. 5   b  in a stretched out position. 
           [0021]      FIG. 5   c  is a side view showing a variation of the living hinge as shown in  FIG. 5   a.    
           [0022]      FIG. 5   d  is a side view showing the living hinge of  FIG. 5   c  in a stretched out position. 
           [0023]      FIG. 6   a  is a side view showing a living hinge structure, according to a 5 th  embodiment of the present invention, in a bent position. 
           [0024]      FIG. 6   b  is a side view showing the living hinge structure of  FIG. 6   b  in a stretched out position. 
           [0025]      FIG. 7   a  is a side view showing a living hinge structure, according to a 6 th  embodiment of the present invention, in a bent position. 
           [0026]      FIG. 7   b  is a side view showing the living hinge structure of  FIG. 7   b  in a stretched out position. 
           [0027]      FIG. 8   a  shows a product having a living hinge structure, according to one embodiment of the present invention. 
           [0028]      FIG. 8   b  shows the product in an open position. 
           [0029]      FIG. 8   c  shows a device having metal parts in two device parts for supporting a living hinge, according to one embodiment of the present invention. 
           [0030]      FIG. 8   d  shows a device having metal parts in two device parts for supporting a living hinge, according to another embodiment of the present invention. 
           [0031]      FIG. 8   e  shows a device having metal parts in two device parts for supporting a living hinge, according to a different embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]      FIGS. 1   a  to  1   c  show a living hinge structure, according to one embodiment of the present invention. As shown, the living hinge structure  10  is made of a plastic hinge part  1  and two metal plates. The plastic hinge part  1  has a first side section  2  and a second side section  4  connected by a connecting section  6 . The metal plate  22  is firmly attached to the first side section  2  and the metal plate  24  is firmly attached to the second side section  4 . However, the connecting section  6  of the plastic hinge part is not attached to any metal plate. In manufacturing, it is preferred that the metal plates  22  and  24  are used as inserts and the plastic living hinge is over-molded so that the plastic parts (sections  2  and  4 ) adhere firmly to the metal parts (segments  22  and  24 ) to form a living hinge structure  10 . The plastic material can be virtually any thermoplastic elastomer with sufficient fatigue resistance. For example, the plastic material can be a thermoplastic polyurethane, styrene block-copolymers, thermoplastic silicone elastomer, thermoplastic vulcanisate. Alternatively, a more rigid plastic material such as polyethylene, polypropylene or polyamide is used to provide potential characteristics of the plastic hinge part  1 . The metal plates are made of basically any metal. It is preferred, however, that the metal plates  22 ,  24  are made of aluminum or stainless steel. 
         [0033]    Before molding, the metal part is activated by physical or chemical etching or polymer coating so that the metal plate can be bonded to the plastic parts more firmly. Depending on the surface treatment, the plastic material needs to be carefully selected to achieve perfect bonding with the metal. 
         [0034]    It is preferred that the metal plates  22 ,  24  are located at the outer surface of the plastic hinge part  1  so that the metal can also be used to protect the surface of the polymer hinge from scratches or other types of physical damages, which may cause a notch on the polymer hinge. 
         [0035]    It should be noted that, as shown in  FIG. 1   c,  the height of the metal plates  22 ,  24  are the same as the height of the plastic side sections  2  and  4 . However, the height of the metal plates  22 ,  24  can be different from the height of the plastic side sections  2 ,  4 . Furthermore, as shown in  FIGS. 2   a  and  2   b,  the metal plates are narrower than the side sections. However, the width of the metal plates can be equal to or greater than the width of the plastic side sections. As shown in  FIGS. 3   a  and  3   b,  the metal plates  22 ,  24  are wider than the plastic side sections  2  and  4 . 
         [0036]    Because each of the plastic side sections  2  and  4  has a metal support, the thickness of the side sections  2  and  4  can be reduced. For example, the thickness of the side sections  2  and  4  can be smaller or the same as the thickness of the connecting section  6 , as shown in  FIGS. 2   a  and  2   b.    FIG. 2   a  shows the living hinge structure  10  in a bending position whereas  FIG. 2   b  shows the living hinge in a stretched out position. Furthermore, the metal supports or metal plates  22 ,  24  are located on the outer side of the plastic hinge part  1 . The metal supports  22 ,  24  can be located on the inner side of the plastic hinge part  1 , as show in  FIG. 2   c.  Alternatively, one metal support  22  is located on the inner side and the other metal support  24  is located on the outer side of the plastic hinge part  1 . 
         [0037]    As shown in  FIG. 4   a  and  4   b,  while the metal plate  22  is wider than the plastic side section  2 , the metal plate  24  is narrower than the plastic side section  4 . In the above embodiments, the living hinge structure  10  can be stretched out to a very wide angle. As shown in  FIGS. 1   b,    2   b,    3   b  and  4   b,  the stretched out angle is substantially equal to 180 degrees. 
         [0038]    It is possible to extend one of the metal plates so that part of the metal plate covers at least part of the connecting section  6  of the plastic hinge part  1 . As shown in  FIG. 5   a,  part of the metal plate  25  is firmly attached to the plastic side section  4 . However, the extended part of the metal plate  25  is not attached to the connecting section  6 . With the extended part of the metal plate  25 , it may not be possible to stretch out the living hinge structure more than a certain angle. For example, as shown in  FIG. 5   b,  the stretched out angle is substantially equal to 120 degrees. 
         [0039]    According to one embodiment of the present invention, the length and the arrangement of the metal plates  22  and  25  can be made to restrict the opening angle of the hinge and thus the opening angle of the device that uses the hinge. As shown in  FIG. 5   c  and  5   d,  the metal plate  22  is extended toward the connecting part  6  such that when the hinge is opened to a predetermined angle, the metal plate  25  encounters the metal plate  22 , preventing the opening angle from increasing further. 
         [0040]    In  FIGS. 5   a  to  5   d,  the metal plates  22  and  25  only cover part of the plastic side sections  2  and  4 . However, it is possible to use a wider metal plates  22 ,  25  in a living hinge structure, as shown in  FIGS. 6   a  and  6   b.  It is also possible that one of metal plates is wider than the bonded plastic side section while the other metal plate is narrower than the corresponding plastic side section, as shown in  FIGS. 7   a  and  7   b.  Similar to  FIGS. 5   c  and  5   d,  either one or both metal plates  22  and  25  in  FIGS. 6   a  to  7   b  can be extended toward each other to reduce the opening angle, or shortened to increase the opening angle. 
         [0041]    The living hinge structure  10  can be an integral part of a product. As shown in  FIGS. 8   a  and  8   b,  the product or device  100  has a first plastic part  62  and a second plastic part  64 . The first side section  2  and the second side section  4  of the plastic hinge part  1  can be molded together with the first plastic part  62  and the second plastic part  64 , respectively, so that the connecting section  6  keeps the product parts  62 ,  64  together. At the same time, the metal plates  22  and  24  are caused to adhere to the first and second side sections  2  and  4  in the over-molding process. The product or device  100  can be a housing of the portable device. The product can be a container having a container body and a lid or cover, for example. The lid has a first plastic part  62  and the container body has a second plastic part  64 . The material for the plastic parts  62  and  64  can be the same or different. Furthermore, the living hinge  10  can be made of a different plastic from the parts  62  and  64 . 
         [0042]    Alternatively, a part of the lid or the entire lid  124  is made of metal and the plastic side section  4  is adhered to the metal part of the lid  124 . As such, the metal plate  24  may not be necessary. Likewise, a part of the device body or the entire device body  122  is made of metal and the plastic side section  2  is adhered to the metal part  122 . As such, the metal plate  22  may not be necessary. The adhesion between the plastic side sections  2  and  4  to the metal parts  122  and  124  can be realized in the manufacturing process to make the plastic side sections an integral part of the device or product  100 . As shown in  FIG. 8   c,  the metal parts  124  and  122  are located on the inner side of the plastic hinge part  1 . As shown in  FIG. 8   d,  while the metal part  124  is located on the outer side of the hinge, the metal part  122  is located on the inner side of the plastic hinge part  1 . As shown in  FIG. 8   e,  both the metal parts  122  and  124  are location on the outer side of plastic hinge part  1 . 
         [0043]    The product or device  100 , can be a portable electronic device, such as a mobile phone, a communicator device and the like. Thus, the plastic side sections  2  and  4  can be an integral part of a mobile phone, for example. As such, the mobile phone can be made thinner. 
         [0044]    In sum, the present invention provides a method for producing a living hinge structure and integrating such a living hinge with an electronic device. The method comprises providing a plastic hinge part comprising a first plastic side section, a second plastic side section and a plastic connecting section connecting the first plastic side section to the second plastic side section; and integrating a metal support to at least one of the first and second plastic side sections. The integrating is carried out by a molding process. The present invention also provides a living hinge structure which comprises: a first plastic section; a second plastic section; and a plastic connecting means connecting the first plastic section to the second plastic section, wherein the plastic connecting means is dimensioned to bend for changing an angle between the first and second plastic sections; a first metal supporting means integrated with the first plastic section for providing mechanical support and a second metal supporting means integrated with the second plastic section for providing mechanical support. The first metal supporting means and the second metal supporting means are depicted as metal plates or metal parts of a device that uses the living hinge to mechanically couple a first device part to a second device part. 
         [0045]    Thus, although the present has been described with respect to one or more embodiments thereof, it will be understood by those skilled in the art that the foregoing and various other changes, omissions and deviations in the form and detail thereof may be made without departing from the scope of this invention.

Summary:
A living hinge structure has two plastic side sections and a plastic connecting section, wherein the plastic side sections are integrated with metal supports so as to enhance the strength of the living hinge structure. The metal supports can be metal inserts bonded to the plastic side sections in an over-molding process. Each of the metal supports can be located on the outside surface or the inside surface of the plastic section. When the metal sections are located on the outside surfaces, they can be used to restrict the opening angle of the hinge. The metal supports can also be a part of a device that uses the hinge for mechanically coupling two device parts. As such, the living hinge is directly integrated into the device without the need for post-assembling by using screws, adhesive, welding or heat stacking.