Patent Publication Number: US-2015067983-A1

Title: Multi-segmented living hinge

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application Ser. Nos. 61/877,078 and 61/909,112 both entitled “LIVING HINGE” filed on and Sep. 12, 2013 and Nov. 26, 2013 respectively. The entireties of the above-noted applications are incorporated by reference herein. 
    
    
     ORIGIN 
     The innovation disclosed herein relates to a hinge and more specifically to a living hinge. 
     BACKGROUND 
     Conventional plastic formed “living hinges” are simple, “in forming action” direction portions of the mold/tooling and are intend only to provide the desired kinematic action in an axis parallel to this forming action (“parting line/mold split”) of the part being made. 
     In addition, forming a flexible structure that incorporates a living hinge provides a challenge in that during the process, if the desired structure were to include additional parts, these parts would be added (in-mold-inserted) by hand just prior closing the mold. This has been a major “safety” concern in the industry for a long time. Until (and with the expense and its own safety issue) the advent of the robot, the common practice was to have with “safety switches” the labor/operator directly install the pieces by hand into either side of the mold cavities. 
     SUMMARY 
     The following presents a simplified summary in order to provide a basic understanding of some aspects of the innovation. This summary is not an extensive overview of the innovation. It is not intended to identify key/critical elements or to delineate the scope of the innovation. Its sole purpose is to present some concepts of the innovation in a simplified form as a prelude to the more detailed description that is presented later. 
     In one aspect, the innovation is the orientation/configuration of multiple segments of “living hinges” aligned such that they provide the required kinematic, controlled motion of associated members. An in plane forming action of the closure and normal operation of the tooling/mold/die to the part geometry is limited to only to shaping. Thus, the innovation facilitates multiple designed degrees of freedom that can be formed in the parts without the use of complicated forming techniques. 
     In another aspect of the innovation a flexible structure is disclosed and includes a plurality of members and a plurality of hinge sets, wherein a hinge set provides a connection between adjacent members. The hinge set includes a plurality of segment portions and a plurality of living hinges, wherein a first living hinge is disposed between one of the plurality of members and one of the plurality of segment portions, a second living hinge is disposed between the one of the plurality of segment portions and another one of the plurality of segment portions, and a third living hinge is disposed between the another one of the plurality of segment portions and another of the plurality of members. 
     In yet another aspect of the innovation when the plurality of hinges sets are in an extended position, a plane defined by a face of each of the plurality of segment portions is essentially parallel to a longitudinal axis of the plurality of members. 
     In still yet another aspect of the innovation when the plurality of hinge sets are in a closed position, a plane defined by a face of each of the plurality of segment portions is essentially perpendicular to a longitudinal axis of the plurality of members 
     To accomplish the foregoing and related ends, certain illustrative aspects of the innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles of the innovation can be employed and the subject innovation is intended to include all such aspects and their equivalents. Other advantages and novel features of the innovation will become apparent from the following detailed description of the innovation when considered in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an example frame type structure incorporating the innovative living hinge in accordance with an aspect of the innovation. 
         FIG. 2A  is a close-up perspective view of an example hinge set that includes at least one living hinge in accordance with an aspect of the innovation. 
         FIGS. 2B-2D  are close-up top views of the example hinge set that includes at least one living hinge in accordance with an aspect of the innovation. 
         FIGS. 3A and 3B  are perspective views of the example structure of  FIG. 1  in a collapsed position in accordance with an aspect of the innovation. 
         FIGS. 4 and 5  are close up views of the hinge set of the structure of  FIG. 1  in accordance with an aspect of the innovation. 
         FIGS. 6-10B  are illustrations of another example embodiment of a structure incorporating the innovative living hinge in accordance with an aspect of the innovation. 
         FIG. 11  is a process flow chart illustrating a method of making the innovative living hinge in accordance with the innovation. 
     
    
    
     DETAILED DESCRIPTION 
     The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the subject innovation. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the innovation. 
     While specific characteristics are described herein (e.g., thickness), it is to be understood that the features, functions and benefits of the innovation can employ characteristics that vary from those described herein. These alternatives are to be included within the scope of the innovation and claims appended hereto. 
     While, for purposes of simplicity of explanation, the one or more methodologies shown herein, e.g., in the form of a flow chart, are shown and described as a series of acts, it is to be understood and appreciated that the subject innovation is not limited by the order of acts, as some acts may, in accordance with the innovation, occur in a different order and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all illustrated acts may be required to implement a methodology in accordance with the innovation. 
     The innovation overcomes conventional living hinges by facilitating a kinematic action of plastic molded members for controlled movement in any direction or axis of freedom while minimizing an increase in production costs (e.g., requirement of additional parts, re-tooling costs, etc.). 
     In one aspect of the innovation, disclosed herein is a “living” or “mechanical” hinge so aligned and spaced that it provides a kinematic desired of an intended design. When multiple living hinges are utilized, the axis of the living hinges and the angles between them work together to provide both an intended “degrees of freedom” and will constrain the motion to a “controlled” geometry. The result can be as simple as using three hinges at 45 degrees of axis alignment to each other to produce a perpendicular to axis final resultant swing motion or as complicated as using multiple (more than three) hinges at various angles to produce initial swing motion perpendicular to the axis morphing into parallel to axis motions. So it is in designing both the hinge placements and their respective angles to each other that the ultimate resultant paths of the attached members follow. 
     Other factors affecting this action include (but are not limited to); friction in the hinge (material hysteresis or drag), distance and forcing members or outside influences to the members involved in the motion, gravity and changing directions of the members in the applicable force field, other interactive forces designed as part of the intended action of the members. 
     One example application of the development of the innovation is a grouping of blow molded members joined together to form a multiple position product supporting device (e.g., a plastic skid). Using three living hinges for each hinge set at each connection joint, the four hinge sets join four members to provide a linearly parallel, tightly packaged part that is moldable and shippable in this tightly packed space to minimize production and shipping costs. When deployed for use at the intended manufactures attaching location, the configuration allows a user to simply spread open the contiguous assembly without the required labor to complete the assembly process but while still providing the required large picture frame opened condition and shape to perform the function of supporting and protecting the product it is attached to. 
     It is to be understood that the innovation is not dependent on the number of members, the number of hinge sets, the number of living hinges or the number of segment portions. The innovation can be utilized on applications that require any number of members and, hence, hinge sets. Further, the number of living hinges in a given hinge set can vary from application to application. Still further, the number of living hinges may vary from hinge set to hinges on the same application (structure). 
     Other potential applications include (but are not limited to); transport tight and expand open structures or framing, caging or structure interior volume variability, multiple folded sequence designs for variable finished position obtainment. These applications may include (but are not limited to); temporary structures such as tents, collapsible/insert-able/extendable protection caging systems for vehicles, tunnels, mines, etc . . . , constraining frame for expandable fluid containers, folding table structures, folding scaffolding, and many other flexible position member location based designs. 
     With reference now to the figures,  FIG. 1  is a perspective view of an example frame type structure  100  incorporating the innovative living hinge in accordance with an aspect of the innovation. The example structure  100  includes multiple members  102 A- 102 D (collectively  102  where appropriate) where the ends of each member  102 A- 102 D are connected by a hinge set (joint connection)  104 A- 104 D (collectively  104  where appropriate). Each hinge set  104 A- 104 D includes at least one living hinge, as will be described further below. The living hinge(s) facilitate a flexible-kinematic action of moving the members  102 A- 102 D in a controlled motion along a hinge axis with the required path of motion of the members. 
       FIG. 2A  is a close-up perspective view and  FIGS. 2B-2D  are close-up top views of an example hinge set  104  that includes at least one living hinge in accordance with an aspect of the innovation.  FIGS. 2A and 2B  illustrate the hinge set  104  in an extended (open) position,  FIG. 2C  illustrates the hinge set  104  in a partially extended (partially open) position, and  FIG. 2D  illustrates the hinge set  104  in a collapsed (closed) position. 
     The hinge set  104  includes at least one living hinge  110 A,  110 B,  110 C (collectively  110  where appropriate) where adjacent living hinges  110  are separated by a segment portion  112 A,  112 B (collectively  112  where appropriate). It is to be understood that the innovation disclosed herein is not dependent on the number of living hinges  110  included in a hinge set  104 . For example, the number of living hinges can range from one living hinge to any number of living hinges (e.g.,  110 A . . .  110 N). Consequently, the number of segment portions separating the living hinges will range from zero (e.g., in applications where one living hinge is provided between two members) to one less than the number of living hinges (e.g.,  110 A . . .  110 N- 1 ). For simplicity, the example embodiment illustrated in  FIGS. 2A-2D  includes three living hinges. Thus, the example embodiment disclosed herein and illustrated in the figures is for illustrative purposes only and is not intended to limit the scope of the innovation. 
     The hinge set  104  and hence the living hinges  110 , provide a connection between members  102 A,  102 B, as illustrated in the figures. Specifically, a first living hinge  110 A provides a connection between a first member  102 A and a first segment portion  112 A, a second living hinge  112 B provides a connection between the first segment portion  112 A and a second segment portion  112 B, and a third living hinge  110 C provides a connection between the second segment portion  112 B and a second member  102 B. 
     As mentioned above,  FIGS. 2A and 2B  illustrate the hinge set (connection joint)  104  in an extended (open) position. In this position, the first and second members  102 A,  102 B are essentially on the same axis A of approximately 180 degrees (as shown in  FIGS. 3A and 3   b,  connected members may also be substantially parallel to each other but not on the same axis). In this open position, a plane defined by a face  114 A of the first segment portion  112 A and a plane defined by a face  114 B of the second segment portion  112 B are nearly parallel with the axis A formed by the first and second members  102 A,  102 B. 
       FIG. 2C  illustrates the hinge set  104  in a partially extended (partially open or closed) position. In this position, the angle between the first and second members  102 A,  102 B is between 90 and 180 degrees. In addition, as illustrated in  FIG. 2C , the faces  114 A,  114 B of the first and second segments  112 A,  112 B begin to collapse or fold in on each other as the first and second members  102 A,  102 B are rotated from the extended position to the closed position. 
       FIG. 2D  illustrates the hinge set  104  in a collapsed (closed) position. In this position, the angle between the first and second members  102 A,  102 B is approximately 90 degrees. In addition, as illustrated in  FIG. 2D , the faces  114 A,  114 B of the first and second segments  112 A,  112 B are facing each other such that the plane defined by the faces  116 A,  116 B of the first and second members  102 A,  102 B are essentially perpendicular to a longitudinal member axis B where adjacent longitudinal axes B form the axis A defined by two adjacent members  102  when the hinge set  104  is in the extended position. 
     The living hinge  110  configuration above allows the first and second members  102 A,  102 B to rotate through an angle of approximately  90  degrees while simultaneously bending to take up the compression of the plane of the initial position of the first and second segment portions  112 A,  112 B. In addition, when the hinge set  104  is in the partially extended position, as shown in  FIG. 2C , the living hinge(s)  110  provide a degree of control of the motion of the first and second members  102 A,  102 B to each other. 
     When the first and second members  102 A,  102 B are in the closed position, as shown in  FIG. 2D , the living hinge(s)  110  are such that they provide a good out of axis resistance to motion of various force inputs on the first and second members  102 A,  102 B. In addition, in the closed position, the first and second segment portions  112 A,  112 B are at an angle of approximately 90 degrees to the first and second members  102 A,  102 B respectively. This configuration allows the entire assembly to resist forces into and out of a plane defined by the structure. 
     Referring back to  FIG. 1  and to  FIGS. 3A ,  3 B,  4 , and  5 ,  FIGS. 3A and 3B  are perspective views of the example structure  100  shown in  FIG. 1  in accordance with an aspect of the innovation. Specifically,  FIGS. 3A and 3B  are illustrations of the structure  100  shown in  FIG. 1  showing the structure in a collapsed (or folded) position. In this position, the hinge sets  104  are in the extended or open position. The innovative living hinge(s)  110  facilitates the collapse of the structure  100  for storage and/or shipping purposes.  FIGS. 4 and 5  are close up views of the hinge set  104 D,  104 A, and  104 C respectively when the structure is in the collapsed position, as shown in  FIGS. 3A and 3B . 
     Additional features such as snap locks, indents, protrusions can be integrated into the design of the innovation to provide additional structural stability and force resistance. 
       FIGS. 6-10B  are illustrations of another example embodiment of a structure  600  incorporating the innovative living hinge in accordance with an aspect of the innovation. The structure  600  includes a plurality of members including a pair of oppositely disposed end beams (members)  602 , multiple cross beams (members)  604  having a first end  606  and a second end  608  connected to the end beams  602 , and a flexible material  610  that covers a top of the structure  600 . The structure  600  illustrated in the figures is an example skid utilized for transporting a product or products. It is to be understood that the structure is not limited to a skid. Thus, the example embodiment illustrated in the figures is for illustrative purposes only and is not intended to limit the scope of the innovation. 
     Multiple notches  612  are defined along an inside face  614  of each end beam  102 , best shown in  FIG. 8 . The notches  612  are adapted to receive the first and second end  606 ,  608  of each cross beam  604 . The notches  612  illustrated in the figures are semi-circular in shape. It is to be understood, however, that the shape of the notches can be any shape, such as but not limited to, square, rectangular, triangular, etc. 
     The cross beams  604  are spaced apart and extend between each end beam  602 , as shown in  FIG. 7 . Specifically, both the first and second end  606 ,  608  of each cross beam  604  extends into the notches  612  defined on the inside face  614  of the end beam  602  when in an unfolded (useable or open) position shown in  FIG. 7 . Both the first and second end  606 ,  606  of each cross beam  604  are pivotally connected to the end beam  602 . 
     As shown in  FIG. 8 , a living hinge  616  provides a connection at a connection point  617  between the first end  606  of the cross beam  604  and one end beam  602  and between the second end  608  of the cross beam  604  and the opposite end beam  604 . Thus, two living hinges  616  are provided for each connection of a cross beam  104  to the opposite end beams  102 . The two living hinges  616  are disposed on diagonally opposite ends of the cross beams  604  from each other. The living hinge  616  facilitates a pivot action between the end beams  602  and the cross beams  604  such that the structure  600  can be configured in a folded (stored or shipping) position, as shown in  FIG. 10A . 
     An angle ‘A’ is defined between a hinged side edge  620  at each end of each cross beam  604  and each end beam  602 . When the structure  600  is in an open position, as shown in  FIG. 7 , the angle ‘A’ between the hinged side edge  620  of each of the plurality of cross beams  604  and each of the pair of end beams  602  is essentially  90  degrees. When the structure  600  is in the folded position the angle ‘A’ between the hinged side edge  620  of each of the plurality of cross beams  604  and each of the pair of end beams  602  is less than 90 degrees. 
     The flexible material  610  may be made of any suitable material, such as but not limited to, a polymer, plastic, etc. The flexible material  610  covers a top of the structure  600  to prevent any product from falling through the structure  600  due to the spacing of the cross beams  604 . The flexible material  610  can attach to the end beams  602  and cross beams  604  with fasteners  618 , such as but not limited to, screws, rivets, hook and loop, etc. 
     As mentioned above, the living hinge  616  allows the structure  600  to be manipulated from an unfolded position, shown in  FIG. 7  to a folded (or collapsed) position, shown in  FIG. 10A . This configuration has several advantages. First, storing and transporting the structure  600  in the folded position requires less space. Second, molds to form the structure can be configured to produce the structure  600  in the folded position, see  FIG. 10B . Producing the structure  600  in the folded position reduces the amount of material the structure requires. Thus, there is less waste that requires reprocessing, thereby increasing efficiency and reducing production costs. 
     In addition, a bulge or shaping can be applied as needed to allow for a correctly shaped cross member to allow for a secondary process (in mold or out of mold) that indents this bulge into the blown member itself. The resulting shaping allows both part walls of the material to bend together with a radius having a size that facilitates the reduction of point stress, thus, increasing the longevity of the hinge. 
     Still further, the shaping and double wall stock forms a spherical shape, which aids in the overall strength and stiffness of the living hinge. This feature provides flexibility and strength to thereby allow the skid to flex between the unfolded and folded positions, as well as allowing the skid to be self-supporting. 
     It is to be understood that the innovation is not dependent on the number of members, the number of hinge sets, the number of living hinges or the number of segment portions. The innovation can be utilized on applications that require any number of members and, hence, hinge sets. Further, the number of living hinges in a given hinge set can vary from application to application. Still further, the number of living hinges may vary from hinge set to hinges on the same application (structure). 
     Referring to  FIG. 11 , a method of manufacturing the structure incorporating the innovative living hinge will now be described via a blow molding process. At  1102  and  1104 , the material is melted and extruded into a hollow tube (parison). At  1106 , the parison is inserted into a mold and the mold is closed. The mold has a shape that includes the entire structure including the members and the multiple living hinges described herein. In addition, the cavity of the mold has a shape such that the structure is formed in a folded or collapsed state, as shown in  FIG. 10B . At  1108 , a pre-blow is performed where air is blown into the parison to partially inflate it into the desired shape, such as the structure including the living hinge disclosed herein. At  1110 , the excess material is trimmed away. At  1112 , a final blow is performed to fully inflate the parison into the desired shape. At  1114 , the mold is cooled to a predetermined temperature. At  1116 , the mold is opened and the final structure is removed. 
     An advantage to the innovative living hinge is that the living hinge can be molded in as part of the same parison that is already in place to form the structure. Thus, the living hinge is included as part of the structure during the molding process. This allows for a dynamic structure (structure that has moving parts with respect to each other) to be molded as a single unit without any additional tooling and/or costs, thus, overcoming a processing disadvantage discussed above. 
     Another advantage is that the required shaping does not eliminate the use of most if not all “in-mold” de-flashing or gate trim mechanisms, which is important in processing steps  1106 ,  1114  and  1116 . In addition, due to the general form and dynamics of the innovation, the mold cavity has an optimal size that facilitates allows for a higher parts per process cost reduction. In other words, since the structure is a dynamic structure, the structure can be molded in the folded or collapsed state (see  FIGS. 3A and 10 ). Thus, for example the cavity of the mold would have the shape as the outlined shape  622  in  FIG. 10B  for the second embodiment. This reduces the amount of material that needs to be trimmed during the manufacturing process. In turn, since the amount of waste is reduced so is the amount of material that needs to be recycled thereby reducing recovery/production costs. 
     What has been described above includes examples of the innovation. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the subject innovation, but one of ordinary skill in the art may recognize that many further combinations and permutations of the innovation are possible. Accordingly, the innovation is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.