Patent Description:
Reference is made to <CIT>, <CIT>, <CIT>, <CIT>, and <CIT> which refer to a chassis comprising a perforated hinge and which have been cited as relating to the state of the art.

It will be appreciated that the scope is in accordance with the claims. Accordingly, there is provided a chassis as defined in the independent claim. Further features are provided in the dependent claims.

In some implementations, an electronic stylus has a chassis.

Additional features and advantages of implementations of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims or may be learned by the practice of such implementations as set forth hereinafter.

In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific implementations thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Understanding that the drawings depict some example implementations, the implementations will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:.

This disclosure generally relates to devices, systems, and methods for supporting an electronic device. More particularly, the present disclosure relates to a hinged chassis for an electronic device that provides improved internal volume, improved strength, and improved electromagnetic interference protection. The chassis is a single integral (e.g., continuous) piece of deformable material that is hinged to provide a clamshell enclosure for electronic components. The chassis has an open state and a closed state. The chassis supports electronic components in an interior space and on exterior surfaces in the closed state.

The chassis, in at least one implementation, has a perforated hinge. In some implementations, a perforated hinge may provide the chassis with a uniform radius of curvature across the hinge in the closed state. A uniform radius of curvature can improve the usability of the interior space for housing and supporting components of the electronic device. The perforated hinge may provide the chassis with uniform surface stress in the closed state.

<FIG> and <FIG> illustrate an implementation of a chassis <NUM> in an open state and a closed state, respectively. The chassis <NUM> is made of a deformable material in a single piece, as described herein. In some implementations, the chassis <NUM> is made of a plastically deformable metal. For example, the chassis <NUM> may be made of a steel alloy. In at least one example, the chassis <NUM> may be a stainless steel alloy. In other examples, the chassis <NUM> may be an aluminum alloy. In further examples, the chassis <NUM> may be a titanium alloy.

The chassis <NUM> has a first portion <NUM>-<NUM> and a second portion <NUM>-<NUM> that are connected by a hinge <NUM> positioned between at least part of the first portion <NUM>-<NUM> and the second portion <NUM>-<NUM>. In some implementations, the hinge <NUM> connects at least <NUM>% of the axial length (i.e., the direction of the axis of the hinge <NUM>) of the first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM>. In other implementations, the hinge <NUM> connects at least <NUM>% of the axial length of the first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM>. In yet other implementations, the hinge <NUM> connects the entire axial length of the first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM>.

The hinge <NUM> of the chassis <NUM> is perforated with a plurality of perforations <NUM>. In some implementations, the perforations <NUM> are sized, shaped, and positioned to provide a uniform radius of curvature across the hinge <NUM> in the closed state. For example, a uniform radius of curvature may be a radius of curvature that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In other examples, a uniform radius of curvature may be a radius of curvature that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In yet other examples, a uniform radius of curvature may be a radius of curvature that varies by less than <NUM>% across the entire area of the hinge <NUM>. In further examples, a uniform radius of curvature may be a radius of curvature that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In yet further examples, a uniform radius of curvature may be a radius of curvature that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In still further examples, a uniform radius of curvature may be a radius of curvature that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In at least one example, it may be critical that a uniform radius of curvature may be a radius of curvature that varies by less than <NUM>% across the entire area of the hinge <NUM>.

In other implementations, the perforations <NUM> are sized, shaped, and positioned to provide a uniform surface stress across the hinge <NUM> in the closed state. For example, a uniform surface stress may be a surface stress that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In other examples, a uniform surface stress may be a surface stress that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In yet other examples, a uniform surface stress may be a surface stress that varies by less than <NUM>% across the entire area of the hinge <NUM>. In further examples, a uniform surface stress may be a surface stress that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In yet further examples, a uniform surface stress may be a surface stress that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In still further examples, a uniform surface stress may be a surface stress that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In at least one example, a unif uniform surface stress may be a surface stress that varies by less than <NUM>% across the entire area of the hinge <NUM>.

In yet other implementations, the perforations <NUM> are sized, shaped, and positioned to provide a uniform internal stress across the hinge <NUM> in the closed state. For example, a uniform internal stress may be an internal stress that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In other examples, a uniform internal stress may be an internal stress that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In yet other examples, a uniform internal stress may be an internal stress that varies by less than <NUM>% across the entire area of the hinge <NUM>. In further examples, a uniform internal stress may be an internal stress that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In yet further examples, a uniform internal stress may be an internal stress that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In still further examples, a uniform internal stress may be an internal stress that varies by less than <NUM>% across at least <NUM>% of the area of the hinge <NUM>. In at least one example, a uniform internal stress may be an internal stress that varies by less than <NUM>% across the entire area of the hinge <NUM>.

The first portion <NUM>-<NUM> has a first outer edge <NUM>-<NUM> and a first inner edge <NUM>-<NUM>. The second portion <NUM>-<NUM> has a second outer edge <NUM>-<NUM> and a second inner edge <NUM>-<NUM>. The hinge <NUM> connects to the first portion <NUM>-<NUM> along the first inner edge <NUM>-<NUM> and to the second portion <NUM>-<NUM> along the second inner edge <NUM>-<NUM>. The first outer edge <NUM>-<NUM> and second outer edge <NUM>-<NUM> are configured to contact when in the closed state. In some implementations, the first outer edge <NUM>-<NUM> and second outer edge <NUM>-<NUM> have complementary alignment features <NUM>-<NUM>, <NUM>-<NUM> and/or complementary connection features <NUM>-<NUM>, <NUM>-<NUM>.

Referring now to <FIG>, the chassis <NUM> provides strength and durability to an electronic device <NUM>. In the closed state, the first portion <NUM>-<NUM> and second portion <NUM>-<NUM> may remain rigid as the hinge <NUM> deforms to allow the first outer edge <NUM>-<NUM> and second outer edge <NUM>-<NUM> to contact one another. In some examples, a rigid first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM> may deform less than <NUM>% across at least <NUM>% of the area of the first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM>. In other examples, a rigid first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM> may deform less than <NUM>% across at least <NUM>% of the area of the first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM>. In yet other examples, a rigid first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM> may deform less than <NUM>% across the entire area of the first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM>. In further examples, a rigid first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM> may deform less than <NUM>% across at least <NUM>% of the area of the first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM>. In yet further examples, a rigid first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM> may deform less than <NUM>% across at least <NUM>% of the area of the first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM>. In at least one example, a rigid first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM> may deform less than <NUM>% across the entire area of the first portion <NUM>-<NUM> and/or second portion <NUM>-<NUM>.

The plurality of complementary connection features <NUM>-<NUM>, <NUM>-<NUM> connect and hold the first portion <NUM>-<NUM> in contact with the second portion <NUM>-<NUM>. In some implementations, the complementary connection features <NUM>-<NUM>, <NUM>-<NUM> include or are mechanical connection features that connect and hold by a friction fit, a snap fit, a press fit, a deformable tab and slot, other mechanical connections, or combinations thereof. In other implementations, the complementary connection features <NUM>-<NUM>, <NUM>-<NUM> include a mechanical fastener such as a pin, rod, bolt, clip, clamp, other mechanical fasteners, or combinations thereof. In yet other implementations, the complementary connection features <NUM>-<NUM>, <NUM>-<NUM> include additional connection support, such as welding, brazing, adhesives, or combinations thereof. For example, the complementary connection features <NUM>-<NUM>, <NUM>-<NUM> may include a slot and tab that snap together, and the slot and tab may be subsequently welded to further support the complementary connection features <NUM>-<NUM>, <NUM>-<NUM>.

In some implementations, the plurality of complementary alignment features <NUM>-<NUM>, <NUM>-<NUM> engage with one another along at least a portion of the first outer edge <NUM>-<NUM> and second outer edge <NUM>-<NUM> to align the first portion <NUM>-<NUM> and second portion <NUM>-<NUM> in the closed state. The complementary alignment features <NUM>-<NUM>, <NUM>-<NUM> can limit and/or prevent the movement of the first portion <NUM>-<NUM> and second portion <NUM>-<NUM> relative to one another during use and/or transport of the electronic device. For example, the complementary alignment features <NUM>-<NUM>, <NUM>-<NUM> may be a series of castellations that engage with one another and to both align and prevent axial movement of the first portion <NUM>-<NUM> and second portion <NUM>-<NUM> relative to one another, such as during three-point bending of the chassis <NUM>.

In the closed state, the chassis <NUM> defines an interior space <NUM> between the first portion <NUM>-<NUM> and second portion <NUM>-<NUM>. In some implementations, the chassis <NUM> has a plurality of fasteners <NUM> that are positioned through at least a portion of the interior space <NUM> to apply a compressive force and retain the chassis <NUM> in the closed state. The interior space <NUM> allows the chassis <NUM> to support and house one or more electronic components, such as a printed circuit board (PCB) <NUM> including a force sensor that may measure force applied to an end of the electronic device <NUM>.

<FIG> is a cross-sectional view of an electronic device <NUM> with a chassis <NUM>. In some implementations, the electronic device <NUM> is a stylus. The stylus includes the chassis <NUM> with a PCB <NUM> and a battery <NUM> housed in the interior space <NUM>. The volume of the interior space <NUM> is partially determined by a chassis height <NUM> and a chassis thickness <NUM>. In some implementations, the chassis height <NUM> is the same as a hinge height. In other implementations, the chassis height <NUM> may be greater than the hinge height.

In some implementations, the chassis thickness <NUM> is substantially constant through chassis <NUM>. In other implementations, the chassis thickness <NUM> is smaller in the hinge <NUM>. For example, the chassis thickness <NUM> may decrease in at least a portion of the hinge <NUM> to aid in the deformation of the hinge <NUM> while a greater chassis thickness <NUM> in other areas of the chassis <NUM> may promote rigidity. In at least one example, such as a stylus, the chassis thickness <NUM> may be approximately <NUM> millimeters (mm) throughout the chassis <NUM>. In at least another example, the chassis thickness may be approximately <NUM> throughout the hinge <NUM> and approximately <NUM> in the remainder of the chassis <NUM>.

<FIG> illustrates an example of a hinge <NUM> with a uniform radius of curvature <NUM>. As described herein, a hinge <NUM> may have some variation across the hinge <NUM> while still considered uniform. In the illustrated implementation of a stylus the radius of curvature <NUM> of the hinge <NUM> is approximately <NUM>. The hinge <NUM>, therefore, has a <NUM> diameter, providing an interior space with a <NUM> height.

In some implementations, the chassis <NUM> provides the finished outer surface of the electronic device <NUM>. In other implementations, an outer sleeve <NUM> is positioned over at least a portion of the chassis <NUM> to provide additional housing for electronic components, a different finish, various colorway options, or different surface textures to improve grip during use or transport. For example, the outer sleeve <NUM> may be a polymer that is softer and has a higher coefficient of friction than the chassis <NUM>. The outer sleeve <NUM> may be more comfortable to hold and use for a user than the chassis <NUM> itself.

<FIG> is a perspective view of the electronic device <NUM> of <FIG>. In some implementations, the electronic device <NUM> includes a plurality of electronic components positioned at least partially inside the interior space <NUM> of the chassis <NUM>, such as the PCB <NUM>, and at least one electronic component supported by an outer surface <NUM> of the chassis <NUM>, such as a communication device <NUM>. In some implementations, an electrically conductive chassis <NUM> forms a gaussian cage around the electronic components in the interior space <NUM>. The gaussian cage can reduce electromagnetic interference (EMI) between the electronic components in the interior space <NUM> and the electronic components supported on the outer surface <NUM> of the chassis <NUM>. In particular, a communication device <NUM> may experience less (EMI) with a chassis <NUM> according to at least one implementation described herein than some conventional chassis.

The hinge <NUM> has a plurality of perforations <NUM> therein that allow the hinge <NUM> to deform more easily than the rest of the chassis <NUM>. <FIG> is a detail view of an implementation of a perforated hinge <NUM>. In some implementations, the perforations <NUM> are sized, shaped, and positioned to provide a uniform radius of curvature, a uniform surface stress, a uniform internal stress, or combinations thereof. For example, the perforations <NUM> illustrated in <FIG> are sized, shaped, and positioned to provide struts <NUM> between the perforations <NUM> with a strut width <NUM> that is the same between each perforation <NUM> along longitudinal axis <NUM> of the hinge <NUM>. In some implementations, the perforations <NUM> are positioned such that a portion of the perforations <NUM> overlap in the lateral direction. For example, each axial row of perforations <NUM> overlap the longitudinal axis <NUM>, such that at least a portion of each perforation <NUM> laterally overlaps a portion of the axially neighboring perforation <NUM>.

In some implementations, the perforations <NUM> are polygonal, such as triangles, diamonds, rectangles, squares, pentagons, hexagons, etc. In other implementations, the perforations <NUM> are round, such as circles, ovals, prolate ovals, or other shapes with continuous perimeters (i.e., no corners). In yet other implementations, the perforations <NUM> are a combination, such as a rounded polygon.

In some implementations, the perforations <NUM> are rounded triangles (i.e., guitar-pick shaped). Rounded triangle perforations <NUM> yield struts <NUM> therebetween that are arranged in triangles, providing high strength and low weight. The radius of curvature of the rounded corner can be different in different regions of the hinge <NUM> to account for different forces at different points of the hinge <NUM>. For example, the rounded triangle perforations <NUM> of the implementation in <FIG> have a forward point <NUM> and rearward points <NUM> with different minimum radii of curvature. The forward point <NUM> has a first minimum radius of curvature <NUM> that is less than the second minimum radius of curvature <NUM> of the rearward points <NUM>.

In some implementations, the perforation <NUM> has a first minimum radius of curvature <NUM> of between <NUM> and <NUM>. In other implementations, the perforation <NUM> has a first minimum radius of curvature <NUM> of between <NUM> and <NUM>. In at least one implementation, the perforation <NUM> has a first minimum radius of curvature <NUM> of about <NUM>.

In some implementations, the perforation <NUM> has a second minimum radius of curvature <NUM> of between <NUM> and <NUM>. In other implementations, the perforation <NUM> has a second minimum radius of curvature <NUM> of between <NUM> and <NUM>. In at least one implementation, the perforation <NUM> has a second minimum radius of curvature <NUM> of about <NUM>.

In other implementations, the perforations of the hinge vary in size, shape, position, or combinations thereof to provide a uniform radius of curvature, a uniform surface stress, a uniform internal stress, or both. <FIG> is a flat view of an implementation of a chassis <NUM> with a hinge <NUM> having perforations <NUM> that vary in area, shape, and spacing relative to a longitudinal axis <NUM> of the hinge <NUM>.

The perforations <NUM> may vary according to a lateral distance from the longitudinal axis <NUM>. In some implementations, the perforations <NUM> include at least a center row <NUM>. In other implementations, the perforations <NUM> include at least a center row <NUM> and secondary rows <NUM> on either side of the center row <NUM>. In yet other implementations, the perforations <NUM> include at least a center row <NUM>, secondary rows <NUM>, and tertiary rows <NUM> on either side of the center row <NUM>.

In some implementations, the perforations <NUM> of the center row <NUM> are the same along the longitudinal axis <NUM>. For example, the perforations <NUM> of the center row <NUM> may be all the same shape and size, such as illustrated in <FIG>. In other implementations, the perforations <NUM> of the center row <NUM> vary along the longitudinal axis <NUM>. For example, the perforations <NUM> of the center row <NUM> may alternate between two different shapes and/or different areas along the longitudinal axis <NUM>.

In some implementations, the perforations <NUM> of the secondary rows <NUM> are the same in the direction of the longitudinal axis <NUM>. For example, the perforations <NUM> of the secondary rows <NUM> may be all the same shape and size, such as illustrated in <FIG>. In other implementations, the perforations <NUM> of the secondary rows <NUM> vary in the direction of the longitudinal axis <NUM>. For example, the perforations <NUM> of the secondary rows <NUM> may alternate between two different shapes and/or different areas in the direction of the longitudinal axis <NUM>.

In some implementations, the perforations <NUM> of the tertiary rows <NUM> are the same in the direction of the longitudinal axis <NUM>. For example, the perforations <NUM> of the tertiary rows <NUM> may be all the same shape and size, such as illustrated in <FIG>. In other implementations, the perforations <NUM> of the tertiary rows <NUM> vary in the direction of the longitudinal axis <NUM>. For example, the perforations <NUM> of the tertiary rows <NUM> may alternate between two different shapes and/or different areas in the direction of the longitudinal axis <NUM>.

The perforations <NUM> of the center row <NUM> and the secondary rows <NUM> may be the same. In other implementations, the perforations <NUM> of the center row <NUM> and the secondary rows <NUM> may be different. For example, the perforations <NUM> of the center row <NUM> in <FIG> are oval and have a smaller area than the circular perforations <NUM> of the secondary rows <NUM> that flank the center row <NUM>. The secondary rows <NUM> have perforations that vary in both shape and size from the center row <NUM>.

The perforations <NUM> of the tertiary rows <NUM> may be the same as the center row <NUM> and/or the secondary rows <NUM>, or the perforations <NUM> of the tertiary rows <NUM> may be different from those of both the center row <NUM> and the secondary rows <NUM>. For example, all of the perforations <NUM> of the center row <NUM>, secondary rows <NUM>, and tertiary rows <NUM> may be the same. The implementation illustrated in <FIG>, however, has perforations <NUM> of the tertiary rows <NUM> that are of different shape and size from the center row <NUM> and of different size but the same shape as the secondary rows <NUM>.

<FIG> is a detail view of complementary alignment features <NUM>-<NUM>, <NUM>-<NUM> that engage when the chassis in the closed state. In some implementations, the first alignment features <NUM>-<NUM> of the first portion <NUM>-<NUM> and/or the second alignment features <NUM>-<NUM> are symmetrical in the axial direction <NUM>. For example, each of the first alignment features <NUM>-<NUM> may have a first face <NUM> and a second face <NUM> that are oriented at the same angle relative to the axial direction <NUM>. A higher angle relative to the axial direction <NUM> can produce greater resistance to relative movement of the first portion <NUM>-<NUM> and second portion <NUM>-<NUM> in the axial direction <NUM> (i.e., increasing three-point bending strength of the chassis). A lower angle relative to the longitudinal direction can provide more reliable alignment and engagement between the first portion <NUM>-<NUM> and second portion <NUM>-<NUM> during closure of the chassis.

In some implementations, the first face <NUM> and/or second face <NUM> are oriented at an angle relative to the axial direction <NUM> in a range having an upper value, a lower value, or upper and lower values including any of <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, or any values therebetween. For example, the first face <NUM> and/or second face <NUM> may be oriented at an angle relative to the axial direction <NUM> greater than <NUM>°. In other examples, the first face <NUM> and/or second face <NUM> may be oriented at an angle relative to the axial direction <NUM> less than <NUM>°. In yet other examples, the first face <NUM> and/or second face <NUM> may be oriented at an angle relative to the axial direction <NUM> between <NUM>° and <NUM>°. In further examples, the first face <NUM> and/or second face <NUM> may be oriented at an angle relative to the axial direction <NUM> between <NUM>° and <NUM>°. In at least one example, the first face <NUM> and/or second face <NUM> may be oriented at an angle relative to the axial direction <NUM> about <NUM>°. In at least another example, the first face <NUM> and/or second face <NUM> may be oriented at an angle relative to the axial direction <NUM> about <NUM>°.

In other implementations, the first alignment features <NUM>-<NUM> and/or the second alignment features <NUM>-<NUM> are asymmetrical in the axial direction <NUM>. For example, the chassis may experience greater forces applied in a known or expected orientation during use or transport. In such instances, it may be desirable to have a first face <NUM> oriented at a lower (i.e., shallower) angle relative to the axial direction <NUM> and a second face <NUM> oriented at a higher (i.e., steeper) angle relative to the axial direction <NUM>. The shallower first face <NUM> and steeper second face <NUM>, in combination with complementary faces of the second alignment features <NUM>-<NUM>, may allow more flex of the chassis in a first direction of torque and provide more rigidity in a second direction of torque on the chassis.

In some implementations, the first alignment features <NUM>-<NUM> of the first portion <NUM>-<NUM> are the same as the second alignment features <NUM>-<NUM> of the second portion <NUM>-<NUM> with an offset in the axial direction <NUM>. In other implementations, the first alignment features <NUM>-<NUM> and the second alignment features <NUM>-<NUM> and/or the spacings therebetween are different. For example, the first alignment features <NUM>-<NUM> and the second alignment features <NUM>-<NUM> may be complementary while the first alignment features <NUM>-<NUM> are longer in the axial direction <NUM> with shorter first recesses <NUM>-<NUM> positioned between the first alignment features <NUM>-<NUM>, and the second alignment features <NUM>-<NUM> are shorter in the axial direction <NUM> (to mate with the first recesses <NUM>-<NUM>) with longer second recesses <NUM>-<NUM> (to mate with the first alignment features <NUM>-<NUM>).

A tight fit of the alignment features <NUM>-<NUM>, <NUM>-<NUM> with contact along a majority of the surface of the first alignment features <NUM>-<NUM> and the second alignment features <NUM>-<NUM> may allow for greater strength, as well as improved electrical conductivity between the first portion <NUM>-<NUM> and second portion <NUM>-<NUM> of the chassis. Greater electrical conductivity through the chassis and around an interior space may provide a better gaussian cage and increase the EMI shielding of the chassis.

In some implementations, the first alignment features <NUM>-<NUM> and/or the second alignment features <NUM>-<NUM> have gaps <NUM> at the corners. For example, the corners of the first alignment features <NUM>-<NUM> and/or the second alignment features <NUM>-<NUM> may be rounded, while the corners of the first recesses <NUM>-<NUM> and second recesses <NUM>-<NUM> are angular, resulting in gaps <NUM> between the first alignment features <NUM>-<NUM> and the second alignment features <NUM>-<NUM> when the chassis is in the closed state. The gaps <NUM> can provide tolerances for machining or manufacturing accuracy. The gaps <NUM> can allow the majority of the edges of the first alignment features <NUM>-<NUM> and the second alignment features <NUM>-<NUM> to contact, even if debris or flash remains on the edges. The gaps <NUM> can allow improved contact between the first alignment features <NUM>-<NUM> and/or the second alignment features <NUM>-<NUM>, such that the chassis can provide EMI shielding without a bridging conductive element, such as copper tape, connecting the first portion <NUM>-<NUM> to the second portion <NUM>-<NUM>.

<FIG> is a flowchart illustrating an implementation of a method <NUM> of manufacturing an electronic device. The method <NUM> includes forming a chassis from a single piece of deformable material at <NUM>.

In some implementations, the chassis is formed from a plastically deformable material, such as a steel alloy, an aluminum alloy, a titanium alloy, or other plastically deformable metals. The chassis may be stamped from a single sheet of material. For example, the perforations, bosses, alignment features, connection features, or combinations thereof may be stamped from a single sheet of deformable material.

In other implementations, the chassis in the open state is formed by removing material from a billet, such as by mechanical machining, water jet, laser, or other cutting technique. For example, it may be difficult to an efficiently stamp the chassis from an elastically deformable material, while the elastically deformable material may be machinable.

In yet other implementations, the single piece of material is additively manufactured by bonding a plurality of pieces together to form the chassis. For example, the chassis may be formed by bonding a metal powder through laser melting or laser sintering. In other examples, a plurality of pieces may be integrally bonded by welding to form a single continuous piece of material.

The method <NUM> further includes positioning at least one electronic component on an inner surface of the chassis at <NUM> and then folding the chassis along a perforated hinge to close the chassis around the electronic component such that the hinge has a controlled radius of curvature at <NUM>. A controlled radius of curvature is any hinge that produces a repeatable curvature or cross-sectional shape based on the material and the geometry of the perforations. For example, a controlled radius of curvature may be a uniform radius of curvature. In other examples, a controlled radius of curvature may be a uniform radius of curvature may be a decreasing radius of curvature. In yet other examples, a controlled radius of curvature may be a parabolic radius of curvature.

<FIG> through <FIG> illustrate the folding of a chassis. <FIG> is an end view of a chassis <NUM> positioned on a press having a first plate <NUM>-<NUM> and a second plate <NUM>-<NUM>. The first plate <NUM>-<NUM> and second plate <NUM>-<NUM> are movable relative to one another to fold the first portion <NUM>-<NUM> of the chassis <NUM> toward the second portion <NUM>-<NUM> around the sheet metal bend that will form the hinge <NUM>. As the first portion <NUM>-<NUM> folds toward the second portion <NUM>-<NUM>, the hinge <NUM> deforms with a controlled radius of curvature such that the first outer edge <NUM>-<NUM> moves toward the second outer edge <NUM>-<NUM>.

<FIG> is an end side view of the chassis <NUM> and plates <NUM>-<NUM>, <NUM>-<NUM> of <FIG> midway through folding the chassis <NUM>. An electronic component, such as a PCB <NUM>, is positioned on an inner surface <NUM> of the chassis <NUM> as the first portion <NUM>-<NUM> is folded over the second portion <NUM>-<NUM> by the first plate <NUM>-<NUM> and second plate <NUM>-<NUM> moving relative to one another. Folding the chassis <NUM> allows for electronic components to be positioned in the chassis even if the electronic component is too large to be inserted axially into the chassis <NUM> in the closed state. For example, a plurality of electronic components can be placed on the inner surface <NUM> and arranged such that the electronic components at least partially support one another when the chassis <NUM> is closed.

A hinge <NUM> with a controlled radius of curvature allows the chassis <NUM> to be folded without a mandrel placed inside the sheet metal bend that forms the hinge <NUM>. For example, a conventional hinge uses a press to wrap the chassis around a mandrel to form the curve of the hinge, and the mandrel is then removed. A hinge <NUM> may fold in a controlled manner without a mandrel, allowing electronic components to be positioned inside the hinge during folding, instead of the space being occupied by the mandrel.

<FIG> is an end view of the chassis <NUM> of <FIG> in a closed state. The first outer edge <NUM>-<NUM> and second outer edge <NUM>-<NUM> are contacting and the PCB <NUM> is positioned in the interior space <NUM> defined by the chassis <NUM>. The hinge <NUM> of the illustrated implementation in <FIG> has a uniform radius of curvature. In other implementations, the hinge <NUM> has a parabolic radius of curvature, decreasing radius of curvature, or other controlled radius of curvature.

<FIG> is an end view of another chassis <NUM>. While chassis are described herein including a hinge connecting a first portion to a second portion, it should be understood that a chassis <NUM> may have a plurality of hinges <NUM>-<NUM>, <NUM>-<NUM> positioned between a first portion <NUM>-<NUM> and a second portion <NUM>-<NUM> to allow a chassis <NUM> and/or interior space <NUM> that is a rounded rectangle in end view. For example, the width of the rounded rectangle may be defined by the first portion <NUM>-<NUM> and second portion <NUM>-<NUM> of the chassis <NUM>, while a height of the rounded rectangle may be defined by a third portion <NUM>-<NUM> of the chassis <NUM> that is positioned between a first hinge <NUM>-<NUM> (between the first portion <NUM>-<NUM> and the third portion <NUM>-<NUM>) and a second hinge <NUM>-<NUM> (between the second portion <NUM>-<NUM> and the third portion <NUM>-<NUM>). In such implementations, each hinge <NUM>-<NUM>, <NUM>-<NUM> may have a controlled radius of curvature, a uniform surface stress, a uniform internal stress, or combinations thereof, as described herein.

When in the closed state, residual stress in the hinge (i.e., elastic deformation) may apply an expansion force to urge the first portion <NUM>-<NUM> away from the second portion <NUM>-<NUM>. In some implementations, the expansion force is less than <NUM> Newtons (N). In other implementations, the expansion force is less than <NUM> N. In yet other implementations, the expansion force is less than <NUM> N.

A chassis with one or more perforated hinges, in at least implementation, allow chassis to have uniform stress in the hinge. In at least one implementation, the hinge has a uniform radius of curvature. In other implementations, the hinge has a controlled radius of curvature that is parabolic, linearly decreasing, or other non-uniform shape. In yet other implementations, the chassis has a plurality of hinges that provide a generally rounded rectangular, rounded triangular, or other rounded polygonal shape in profile.

One or more specific implementations of the present disclosure are described herein. These described implementations are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these implementations, not all features of an actual implementation may be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions will be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another.

The articles "a," "an," and "the" are intended to mean that there are one or more of the elements in the preceding descriptions. Additionally, it should be understood that references to "one implementation" or "an implementation" of the present disclosure are not intended to be interpreted as excluding the existence of additional implementations that also incorporate the recited features. For example, any element described in relation to an implementation herein may be combinable with any element of any other implementation described herein. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are "about" or "approximately" the stated value, as would be appreciated by one of ordinary skill in the art encompassed by implementations of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within <NUM>%, within <NUM>%, within <NUM>%, or within <NUM>% of a stated value.

A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to implementations disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional "means-plus-function" clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words 'means for' appear together with an associated function. Each addition, deletion, and modification to the implementations that falls within the meaning and scope of the claims is to be embraced by the claims.

The terms "approximately," "about," and "substantially" as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms "approximately," "about," and "substantially" may refer to an amount that is within less than <NUM>% of, within less than <NUM>% of, within less than <NUM>% of, and within less than <NUM>% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to "up" and "down" or "above" or "below" are merely descriptive of the relative position or movement of the related elements.

Claim 1:
A chassis (<NUM>) for an electronic device, said chassis having an open state and closed state, and the chassis having a chassis height, the chassis including:
a first portion (<NUM>-<NUM>) having a first outer edge (<NUM>-<NUM>) and a first inner edge (<NUM>-<NUM>);
a second portion (<NUM>-<NUM>) having a second outer edge (<NUM>-<NUM>) and a second inner edge (<NUM>-<NUM>); and
a perforated hinge (<NUM>) including a plurality of perforations (<NUM>), the perforated hinge (<NUM>) positioned between the first portion (<NUM>-<NUM>) and the second portion (<NUM>-<NUM>) at the first inner edge (<NUM>-<NUM>) and the second inner edge (<NUM>-<NUM>), where the first portion, the second portion, and the perforated hinge (<NUM>) are integrally formed from a continuous piece and the perforated hinge (<NUM>) is configured to deform , while the chassis moves from the open state to the closed state, to mate the first outer edge (<NUM>-<NUM>) to the second outer edge (<NUM>-<NUM>) in the closed state;
wherein in the closed state, the chassis (<NUM>) defines an interior space (<NUM>) between the first portion (<NUM>-<NUM>) and second portion (<NUM>-<NUM>) said interior space containing at least one electronic component;
wherein in the closed state, the perforated hinge has a rounded shape in profile about a longitudinal axis (<NUM>, <NUM>) thereof, and a controlled radius of curvature, and a hinge height in the closed state defines the chassis height.