PATENT DOCUMENT

Publication Number: US-10683591-B1
Application Number: US-201916276203-A
Country: US
Kind Code: B1

Title: Items with fabric hinges

Abstract:
An item such as a removable device cover or a portable electronic device may have a fabric hinge. The item may have first and second structures that are configured to rotate relative to each other. The fabric hinge may have first and second fabric layers that are coupled to the first structure and third and fourth fabric layers that are coupled to the second structure. A center portion of the fabric hinge may have one side that is coupled to the first and second fabric layers and an opposing second side that is coupled to the third and fourth fabric layers. In the center portion, first strands of material may extend outwardly into the first and fourth fabric layers and second parallel strands that are interspersed with the first strands may extend outwardly into the second and third fabric layers.

Claims:
What is claimed is: 
     
       1. An item, comprising:
 a first structure; 
 a second structure; 
 a fabric hinge coupled between the first and second structures and configured to allow the first and second structures to rotate relative to each other about a hinge axis, wherein the fabric hinge comprises:
 first and second fabric layers coupled to the first structure; 
 third and fourth fabric layers coupled to the second structure; and 
 a center portion, wherein first strands of material in the center portion that run perpendicular to the hinge axis extend into the first fabric layer and into the fourth fabric layer and wherein second strands of material in the center portion that are interspersed with the first strands of material and that run perpendicular to the hinge axis extend into the second fabric layer and the third fabric layer. 
 
 
     
     
       2. The item defined in  claim 1  wherein the first, second, third, and fourth fabric layers comprise orthogonal strands of material that run orthogonal to the first and second strands. 
     
     
       3. The item defined in  claim 2  wherein the first fabric layer comprises a first woven fabric layer in which the first strands are interwoven with a first portion of the orthogonal strands, the second fabric layer comprises a second woven fabric layer in which the second strands are interwoven with a second portion of the orthogonal strands, the third fabric layer comprises a third woven fabric layer in which the second strands of material are interwoven with a third portion of the orthogonal strands, and the fourth fabric layer comprises a fourth woven fabric layer in which the first strands of material are interwoven with the a fourth portion of the orthogonal strands, and wherein the center portion does not include any strands orthogonal to the first and second strands. 
     
     
       4. The item defined in  claim 3  wherein the first structure is configured to form a first housing portion of a portable electronic device housing, wherein the second structure is configured to form a second housing portion of the portable electronic device housing, and wherein the item further comprises a keyboard in the first housing portion and a display in the second housing portion. 
     
     
       5. The item defined in  claim 2  wherein the center portion does not include strands orthogonal to the first and second strands, wherein the first structure is configured to form a first housing portion of a portable electronic device housing, and wherein the second structure is configured to form a second housing portion of the portable electronic device housing. 
     
     
       6. The item defined in  claim 5  further comprising a first display in the first housing portion and a second display in the second housing portion. 
     
     
       7. The item defined in  claim 5  wherein the first and second housing portions have respective first and second bearing surfaces configured to bear against each other as the first and second housing portions rotate relative to each other. 
     
     
       8. The item defined in  claim 7  wherein the first and second bearing surfaces comprise respective curved surfaces. 
     
     
       9. The item defined in  claim 8  wherein the first and second bearing surfaces each have a semicircular cross-sectional profile. 
     
     
       10. The item defined in  claim 7  wherein the first and second bearing surfaces each have a planar area configured to form an angular rotation detent. 
     
     
       11. The item defined in  claim 1  wherein the first and second structures are configured to form an electronic device housing. 
     
     
       12. The item defined in  claim 1  further comprising:
 first electrical components in the first structure; and 
 second electrical components in the second structure, wherein the first strands include conductive strands forming signal paths between the first and second electrical components. 
 
     
     
       13. The item defined in  claim 1  wherein the first and second structures are configured to form a removable cover for an electronic device. 
     
     
       14. The item defined in  claim 1  wherein the first and second structures are configured to form a computer housing. 
     
     
       15. The item defined in  claim 1  further comprising polymer material in the first fabric layer that binds the first strands to orthogonal strands running perpendicular to the first strands. 
     
     
       16. The item defined in  claim 15  wherein polymer material comprises fusible strands. 
     
     
       17. The item defined in  claim 1  further comprising openings in the first fabric layer configured to receive portions of the first structure. 
     
     
       18. A fabric hinge comprising:
 first and second fabric layers; 
 third and fourth fabric layers; and 
 a center portion having a first side coupled to the first and second fabric layers and an opposing second side coupled to the third and fourth fabric layers, wherein first strands of material in the center portion extend across the center portion from the first fabric layer to the fourth fabric layer and wherein second strands of material in the center portion that are interspersed with the first strands of material extend across the center portion from the second fabric layer to the first fabric layer, and wherein the first, second, third, and fourth fabric layers comprise orthogonal strands of material that run perpendicular to the first and second strands. 
 
     
     
       19. The fabric hinge defined in  claim 18  wherein the first fabric layer comprises a first woven fabric layer in which the first strands are interwoven with the orthogonal strands, the second fabric layer comprises a second woven fabric layer in which the second strands are interwoven with the orthogonal strands, the third fabric layer comprises a third woven fabric layer in which the second strands of material are interwoven with the orthogonal strands, and the fourth fabric layer comprises a fourth woven fabric layer in which the first strands of material are interwoven with the orthogonal strands, and wherein the center portion does not include any strands orthogonal to the first and second strands. 
     
     
       20. An electronic device, comprising:
 a first housing portion; 
 first electrical components in the first housing portion; 
 a second housing portion configured to rotate relative to the first housing portion about a hinge axis; 
 second electrical components in the second housing portion; 
 a fabric hinge that extends along the hinge axis, wherein the fabric hinge comprises:
 first and second fabric layers coupled to the first housing portion; 
 third and fourth fabric layers coupled to the second housing portion; and 
 a center portion, wherein first strands of material in the center portion extend into the first fabric layer and into the fourth fabric layer, wherein second strands of material in the center portion that are interspersed with the first strands of material extend into the second fabric layer and the third fabric layer, and wherein the first, second, third, and fourth fabric layers comprise orthogonal strands of material that run orthogonal to the first and second strands. 
 
 
     
     
       21. The electronic device defined in  claim 20  further comprising:
 conductive strands of material forming signal paths through the fabric hinge.

Description:
This application claims priority to U.S. provisional patent application No. 62/661,581 filed on Apr. 23, 2018, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD 
     This relates generally to items with fabric structures and, more particularly, to items having fabric hinges. 
     BACKGROUND 
     Hinges such as hinges for laptop computers have interlocking metal parts. These parts can be bulky and unattractive. Covers for devices such as tablet computers may have structures formed from flexible layers of material. A flexible layer of material such as a plastic sheet may be sufficiently flexible to allow a cover or other item to bend over a desired range of angles, but provides limited control and stability. 
     SUMMARY 
     An item such as a portable electronic device or a cover for an electronic device may have a fabric hinge. The item may have first and second structures that are configured to rotate relative to each other. The first and second structures may form portions of a cover, may form housing portions for a portable electronic device, may include electrical components such as one or more displays, keyboards, touch sensors, and/or other electrical components, and/or may form other structures in the item. 
     The fabric hinge may have first and second fabric layers that are coupled to the first structure and third and fourth fabric layers that are coupled to the second structure. A center portion of the fabric may have one side that is coupled to the first and second fabric layers and an opposing second side that is coupled to the third and fourth fabric layers. 
     In the center portion, first strands of material may extend outwardly into the first and fourth fabric layers and seconds strands that are interspersed amongst the first strands may extend outwardly into the second and third fabric layers. 
     The first and second structures may have bearing surfaces that bear against each other as the first and second structures are rotated relative to each other. Rotational orientation detents and other structures may be formed from the first and second structures. In some configurations, electrical paths may be formed through the hinge structures to pass signals between electrical components in the first structure and electrical components in the second structure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of an illustrative item with a fabric hinge accordance with an embodiment. 
         FIG. 2  is perspective view of an illustrative fabric hinge in accordance with an embodiment. 
         FIGS. 3 and 4  are side views of structures such as housing structures in an item joined using a fabric hinge in accordance with an embodiment. 
         FIG. 5  is a cross-sectional side view of a fabric hinge during fabrication using sacrificial fabric layers in accordance with an embodiment. 
         FIG. 6  is a cross-sectional side view of a fabric hinge formed using a fabrication process of the type illustrated in  FIG. 5  in accordance with an embodiment. 
         FIG. 7  is a top view of a portion of a fabric structure containing a leno weave fabric layer that may be used in a fabric hinge in accordance with an embodiment. 
         FIG. 8  is a cross-sectional side view of an illustrative electronic device such as a laptop computer with a fabric hinge in accordance with an embodiment. 
         FIG. 9  is a top view of an illustrative fabric hinge with fabric openings in accordance with an embodiment. 
         FIG. 10  is a cross-sectional side view of an illustrative fabric hinge coupled to a pair of housing structures having flat detents on otherwise curved bearing surfaces in accordance with an embodiment. 
         FIG. 11  is a cross-sectional side view of an illustrative housing structure having bearing surfaces with multiple planar detent regions in accordance with an embodiment. 
         FIG. 12  is a top view of illustrative hinge structures with different properties along a hinge axis in accordance with an embodiment. 
         FIG. 13  is a cross-sectional side view of an illustrative fabric hinge in accordance with an embodiment. 
         FIG. 14  is a cross-sectional side view of closed housing structures with a fabric hinge of the type shown in  FIG. 13  in accordance with an embodiment. 
         FIG. 15  is a cross-sectional side view of open housing structures with a fabric hinge of the type show in  FIG. 13  in accordance with an embodiment. 
         FIG. 16  is a cross-sectional side view of an illustrative electronic device with two movable portions coupled by a fabric hinge in accordance with an embodiment. 
         FIG. 17  is a perspective view of an illustrative multi-link hinge formed using fabric hinge structures and housing links in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Items such as electronic devices, covers for electronic devices, and other items may include hinges. The hinges may be formed using fabric. Fabric hinges may be formed from woven fabric, knit fabric, fabric with braided strands of material, and/or other intertwined strands of material. Illustrative configurations in which items are provided with woven fabric hinges are sometimes described herein as an example. 
     A woven fabric hinge includes interwoven strands of material. The strands of material may include polymer strands, conductive strands including metal and/or polymer cores and/or polymer coatings, may include strands of natural materials such as cotton or wool, and/or may include strands of other materials. The strands of material may be monofilaments and/or multifilament yarn. 
       FIG. 1  is a schematic diagram of an illustrative item with a fabric hinge. Item  10  of  FIG. 1  has a housing such as housing  12  with portions  12 L and  12 R that rotate relative to each other about hinge axis  16 . Each housing portion (e.g., portion  12 L and/or portion  12 R) may include one or more housing structures (e.g., frame structures, housing walls forming exterior surfaces for a device enclosure, hinge members that are coupled to other housing structures while forming bearing surfaces and/or other portions of a hinge, and/or other housing structures). 
     Components  18  may be formed in housing  12 . In some arrangements, front faces F of housing portions  12 L and  12 R may include input-output devices such as displays, keyboard, trackpads, and other electrical components  18  that receive input from a user and that supply output to a user. The opposing sides of housing portions  12 L and  12 R, which may sometimes be referred to as rear faces R, may contain planar and/or curved housing structures (e.g., a housing wall formed from glass, polymer, metal, other materials, and/or combinations of these materials) and/or electrical components  18  may be mounted on rear faces R. For example, displays, keyboard, touch pads, and/or other components  18  may be mounted on rear faces R. In some configurations, duplicate components may be formed in portions  12 R and  12 L. For example, a first display may be formed in housing portion  12 R and a second display may be formed in housing portion  12 L. 
     A fabric hinge may be formed along axis  16  to hold housing portions  12 L and  12 R together while allowing portions  12 L and  12 R to be rotated to different angular orientations with respect to each other. As shown in the example of  FIG. 1 , housing portions  12 L and  12 R may, if desired, be placed in a flat configuration in which both housing portion  12 L and housing portion  12 R lie in a common plane. When it is desired to enhance the visibility of a display in housing portion  12 R or when it is otherwise desired to change the orientation of housing portion  12 R relative to housing portion  12 L, housing portion  12 R may be rotated about axis  16  until housing portion  12 R reaches a position such as position  20  in which housing portion  12 R lies in a plane that is oriented at a non-zero angle A with respect to the plane of portion  12 R. In an illustrative arrangement, further rotation of housing portion  12 R about axis  16  is possible. For example, housing portion  12 R may be rotated until angle A is equal to 180° (e.g., housing portion  12 R may be placed in a front-to-front configuration with housing portion  12 L as illustrated by position  22  for housing portion  12 R). In another illustrative arrangement, housing portion  12 R may be rotated clockwise to position  24 , so that housing portions  12 L and  12 R are oriented in a rear-to-rear configuration. 
     Housing portions  12 L and  12 R may have surfaces  14  that bear against each other during rotation. These mating surfaces  14 , which may sometimes be referred to as bearing surfaces or hinge surfaces, may have curved profiles or other suitable profiles that allow the housing of device  10  to fold on itself in a front-to-front and/or rear-to-rear configuration (if desired). A single hinge axis  16  is shown in  FIG. 1 , but item  10  may, if desired, have two, three, or more than three hinge axes and associated fabric hinges. 
     Item  10  may be a foldable computer such as a laptop computer, a foldable tablet computer or foldable cellular telephone, a cover for a tablet computer, a cover for a cellular telephone, a cover for a laptop computer, a foldable cover with a keyboard or other input-output circuitry, a wristwatch device, a media player, an accessory such as a keyboard or mouse, audio equipment, electrical equipment embedded in furniture or a vehicle, a wireless charging mat, or other electronic equipment with structures that rotate relative to each other about a hinge axis. 
     In some configurations, such as when item  10  is a cover, item  10  may or may not include electrical components (e.g., an optional keyboard, circuitry for coupling the keyboard to an external electronic device, a supplemental battery, etc.). In other configurations such as when item  10  is a tablet computer, cellular telephone, laptop computer, or other portable electronic device, electrical components  18  are mounted in housing  12 . 
     Electrical components  18  may include control circuitry. Control circuitry in components  18  may be formed from one or more integrated circuits such as microprocessors, microcontrollers, application-specific integrated circuits, digital signal processors, etc. Control circuitry in components  18  may be used to control the operation of item  10  by controlling electrically controllable (electrically adjustable) components in item  10  and may be used to support communications with external electrical equipment. Components  18  may, for example, include wired and/or wireless communications circuitry (e.g., radio-frequency transceiver circuitry, antennas, etc.). In some configuration, inductive wireless power coils may be included in components  18  (e.g., to support the transmission and/or reception of wireless power signals). 
     Components  18  may be formed from integrated circuits, semiconductor dies, discrete components such as resistors, inductors, and capacitors, and/or other electrical components. Input-output devices in components  18  may include components for providing a user of item  10  with output (e.g., light-emitting diodes, lasers, and other light-producing components for emitting light as part of a pixel array of other output device, audio transducers, haptic output devices such as piezoelectric devices for producing vibrations and other haptic output, antennas for transmitting wireless signals, communications circuits for transmitting data over wired communications links, etc.). Input-output devices in components  18  may also include components for gathering input from a user and from a user&#39;s surroundings. Components  18  may, for example, include temperature sensors, pressure sensors, force sensors, gas sensors (e.g., carbon monoxide sensors), particulate sensors, moisture sensors, light sensors, magnetic sensors, capacitive sensors (e.g., sensors for touch or proximity measurements), gesture sensors, image sensors, proximity sensors, touch sensors, button sensors (e.g., switches coupled to movable button members or button regions), sensors that gather other types of input and/or hybrid sensors that include sensor functionality from any two or more of these sensors. Input and output can also be provided using accessories (e.g., other items  10  such as pointing devices, etc.). Components  18  may be formed in one or both of housing portions  12 L and  12 R and, if desired, signal paths such as conductive paths formed through a fabric hinge may be used in conveying power and/or data signals between these components. 
     The fabric hinge formed along hinge axis  16  and, if desired, other portions of item  10  such as portions of housing  12 , can include strands of material. The strands of material may be embedded in polymer or other binder, may be free of binder, may be intertwined to form fabric, or may be otherwise incorporated into item  10 . Strands can be formed from polymer, metal, glass, and/or other materials. In some configurations, strands of material in item  10  include multiple types of material (e.g., embedded conductive paths formed from metal wires, polymer, etc.). Wires can be insulating (e.g., when formed of plastic, glass, or other dielectric) and/or may be conductive (e.g., when a polymer strand is coated with a metal layer and/or one or more metal lines is coated with polymer to form a strand). 
     The fabric of a fabric hinge or other fabric in item  10  may have properties that vary across the fabric. These properties may include optical properties such as color, light reflectance, light absorption, and/or light transmission, mechanical properties such as stiffness, moisture repellency, abrasion resistance, etc., electrical properties such as electrical conductivity, input-output capabilities (e.g., display capabilities, acoustic input and output capabilities, sensing capabilities), etc. Properties such as these may be varied by adjusting the amount of binder or other material that is incorporated into the fabric, by adjusting the fabric construction (strands per inch, number of fabric layers, weave pattern, etc.) used in forming the fabric, and/or adjusting the composition of individual strands of material in the fabric. In some configuration, fabric may have strands of material with properties that vary along their lengths (e.g., stiffness, diameter, optical properties, etc.). 
       FIG. 2  is a perspective view of an illustrative fabric hinge. As shown in  FIG. 2 , fabric hinge  30  includes outer portions (outer hinge portions)  38  and includes center portion (center hinge portion)  36  coupled between outer portions  38 . Center portion  36  is formed from a layer of strands  32  that run perpendicular to hinge axis  16 . With an illustrative configuration, hinge  30  is formed by weaving weft and warp strands together. Strands  32  may be warp or weft strands and perpendicular (orthogonal) strands  34  may respectively be weft or warp strands. In the illustrative example described herein, strands  32  are weft strands and strands  34  are warp strands. Any desired patterns may be used in interweaving strands  32  and strands  34  (e.g., a plain weave, basket weave, etc.). 
     Center portion  36  contains weft strands  32 , but does not contain warp strands  34  and is free of polymer binding material (e.g., fusible strands, cured liquid polymer, thermoplastic polymer, etc.). As a result, strands  32  are able to move relative to each other and allow hinge  30  to bend about axis  16 . 
     In outer regions  38 , weft strands  32  are divided into first and second fabric layers. In the illustrative configuration of  FIG. 2 , weft strands  32 A are interwoven with warp strands  34  to form fabric layer  38 LT on the upper left of  FIG. 2 . On the lower right of  FIG. 2 , weft strands  32 A are interwoven with warp strands  34  to form fabric layer  38 RB. Weft strands  32 B are interwoven with warp strands  34  to form fabric layer  38 LB on the lower left of  FIG. 2  and are interwoven with warp strands  34  to form fabric layer  38 RT on the upper right of  FIG. 2 . Hinge  30  therefore includes at least two fabric layers in each of outer portions  38  (e.g., layers  38 LT and  38 LB in outer portion  38  on the left of center portion  36  and layers  38 RT and  38 RB on the in outer portion  38  on the right of center portion  36 ). Weft strands  32 A are interspersed with weft strands  32 B (e.g., weft strands  32 A and weft strands  32 B alternate along axis  16  in an odd/even pattern, groups of weft strands  32 A alternate with groups of weft strands  32 B, and/or other interleaving pattern may be used to distribute weft strands  32 A among weft strands  32 B). 
     The operation of an illustrative hinge in item  10  is shown in  FIGS. 3 and 4 . In the configuration of  FIG. 3 , housing portion  12 R has been rotated counterclockwise relative to housing portion  12 L so that portion  12 R lies in a plane (plane  52 ) that is oriented at a 135° angle with respect to the plane in which portion  12 L lines (plane  50 ). In the configuration of  FIG. 4 , housing portion  12 R has been rotated clockwise so that plane  52  is now oriented at a −45° angle with respect to plane  50 . Hinge  30  and item  10  may be configured to allow any suitable degree of rotation (e.g., +/−180° of rotation or less). 
     In the example of  FIGS. 3 and 4 , bearing surfaces  14  are semicircular (e.g., each surface forms a half-circle). The half circle formed by bearing surface  14  (e.g., the surface of the semicircular portion of housing portion  12 R) has a radius originating at center point  40 . The half circle of mating bearing surface  14  in housing portion  12 L has a radius originating at center point  42 . These half-circle bearing surfaces may have the same length (e.g., half of the circumference of the circle formed by the radiuses extending from center points  40  and  42 , respectively) and/or bearing surfaces  14  on portions  12 R and  12 L may have different lengths around center points  40  and  42 . As an example, portion  12 L may be thicker and may have a longer curved bearing surface  14  around center point  42  than portion  12 R (which may be thinner and may have a shorter curved bearing surface extending around center point  40 ). By adjusting the shapes and sizes of bearing surfaces  14  of housing portions  12 L and  12 R, the amount of angular rotation and other attributes of the hinge in item  10  may be adjusted. 
     To hold hinge  30  in place, fabric layer  38 RT may be coupled to a surface of housing portion  12 R such as surface  12 RT and fabric layer  38 RB may be attached to a surface of housing portion  12 R such as surface  12 RB (e.g., using clamps, adhesive, interlocking structures that pass through fabric openings, and/or other attachment mechanisms). Similarly, fabric layer  38 LT may be attached to surface  12 LT of portion  12 L and fabric layer  38 LB may be attached to surface  12 LB of portion  12 L. 
     Strands  32  in center portion  36  of fabric hinge  30  are not solidly attached to bearing surfaces  12  of housing portions  12 R and  12 L and are therefore free to move as hinge  30  flexes. As a result, the strands in center portion  36  of fabric hinge  30  wrap around different lengths of bearing surfaces  12  as housing portions  12 R and  12 L rotate relative to each other. Consider, as an example, the scenario of  FIG. 3 . In this position, most of strands  32 A in center region  36  are wrapped around bearing surface  14  of housing portion  12 R and most of strands  32 B in region  36  are wrapped around bearing surface  14  of housing portion  12 L. When housing portions  12 L and  12 R are placed into the orientation of  FIG. 4 , however, most of strands  32 A in center region  36  are wrapped around bearing surface  14  of housing portion  12 L and most of strands  32 B in center region  36  are wrapped around bearing surface  14  of housing portion  12 R. Because interspersed strands  32 A and  32 B are not constrained by warp strands  34  in center region  36 , hinge  30  can flex freely as strands  32 A and  32 B move relative to each other in center region  36  while still exhibiting tight and well controlled hinge behavior. 
       FIG. 5  is a cross-sectional side view of fabric hinge  30  during an illustrative manufacturing process using sacrificial fabric layers. As shown in  FIG. 5 , hinge  30  may be woven so that there are two fabric layers  38 LT and  38 RT on the left of center portion  36  and two fabric layers  38 RT and  38 RB on the right of center portion  36 . In center portion  36 , weft strands  32 A from layer  38 LT cross weft strands  32 B and thereby extend from upper left layer  38 LT into lower right layer  38 RB. Weft strands  32 B cross strands  32 A and extend from lower left layer  38 LB into upper right layer  38 RT. Removable warp strands  34 R are initially intertwined with weft strands  32  in center region  36 , but are removed before fabrication of hinge  30  is complete. 
     To help secure the warp and weft strands in the fabric layers of outer regions  38 , fusible strands of material such as fusible weft strands  56  may be woven into the fabric. Fusible weft strands  56  may be formed from meltable polymer weft strands that serve as a polymer binding material when heated. In center portion  36 , fusible weft strands  56  are woven into sacrificial fabric layers  54 . In outer portions  38 , fusible weft strands  56  are woven into layers  38 LT,  38 LB,  38 RT, and  38 RB. Fusible material is not desired in center region  36 , because strands  32 A and  32 B should be free to move relative to each other in center region  36 . Accordingly, portion  56 P of fusible strands  56  is removed from fabric hinge  30 . This can be accomplished, for example, by applying heat to portion  36 P with heating elements  58  to soften and weaken strands  56  while pulling sacrificial layers  54  away from center portion  36 . 
     After removing portions  56 P, a left non-stick member can be temporarily placed between layers  38 LT and  38 LB and a right non-stick member can be temporarily placed between layers  38 RT and  38 RB. Heat and, if desired, pressure, can then be applied to soften and/or melt the fusible material of strands  56  and thereby set the fabric in outer portions  38 . The non-stick members can then be removed and temporary warp strands  34 R can be removed from center portion  36 . Following stretching along the length of weft strands  32  to remove residual waviness in weft strands  32  in region  36 , hinge  30  is complete and may appear as shown in  FIG. 6 . If desired, openings may be cut in one or more of the fabric layers in outer portions  38  (e.g., to facilitate mounting to protruding portions of housing  12 , fasteners, etc. as hinge  30  is assembled into item  10 ). 
     The strands that form hinge  30  may include any suitable materials. For example strong materials such as para-aramid or other strong polymers may be used in forming strands  32  (e.g., to help allow hinge  30  to be tensioned). Temporary warp strands  34 R may be formed from a slippery material such as nylon (e.g., nylon monofilaments). Other warp strands  34  and/or weft strands  32  may be formed from polyester, para-aramid, and/or other materials. Metal and other conductive materials can be formed in the strands (e.g., weft strands  32 ) to carry signals (e.g., to carry power and/or data signals between components  18  in housing portions  12 L and  12 R across hinge axis  16 ). Multifilament strands (yarn) and/or monofilaments may be used in forming hinge  30 . 
     If desired, warp strands  34  may be secured in outer portions  38  using a leno weave. This type of arrangement is shown in  FIG. 7 . As shown in  FIG. 7 , instead of removing fusible strands  56  from center portion  36 , the fabric layers of hinge  30  may be constructed so that warp strands  34  are secured using intertwined strands  34 ′. If desired, strands  34 ′ may include fusible material and can be set under heat and pressure to form fused fabric layers in outer portion  38 , as described in connection with fusible strands  56  of  FIGS. 5 and 6 . Additional polymer binder (e.g., liquid polymer) may also be incorporated into the fabric of outer portions  38 , if desired. 
       FIG. 8  is a cross-sectional side view of a portion of item  10  in the vicinity of hinge  30 . As shown in  FIG. 8 , housing  12  of item  10  may include portions such as clamp members  12 L′ and  12 R′ to help clamp the fabric layers of hinge  30  to other portions of housing  12  (e.g., to portions  12 L and  12 R). Housing members with rounded surfaces such as illustrative cylindrical rod housing members  12 L″ and  12 R″ may be used in forming bearing surfaces  14 . In general housing  12  may be formed from one or more joined members (e.g., portion  12 R and portion  12 L may each include one or more housing portions that are coupled together). In the example of  FIG. 8 , item  10  may be a foldable portable electronic device such as a laptop computer or foldable tablet computer (or foldable phone). Component  18  on portion  12 L may be, for example, a keyboard or touch screen display and component  18  on portion  12 R may be, for example, a display. 
       FIG. 9  is a top view of hinge  30  showing how fabric layers in outer portions  38  may be provided with openings  60 . Openings  60  may be configured to receive protruding portions of housing  12  (see, e.g., illustrative housing protrusion  12 P), fasteners such as screws, and/or other locking features on housing  12 . This may help tension strands  32  in hinge  30  when hinge  30  is incorporated into item  10 . 
     If desired, bearing surfaces  12  may include one or more planar surfaces such as illustrative planar surfaces  14 F of  FIG. 10 . Surfaces  14 F in the illustrative configuration of  FIG. 10  are oriented so that housing portions  12 L and  12 R preferentially rest at a detent associated with a 90° orientation. Detents in one or more additional angular orientations between housing portions  12 L and  12 R may also be formed by creating appropriate flattened surface regions on bearing surfaces  14 , if desired. As shown in  FIG. 11 , as an example, there may be numerous flattened bearing surface areas  14 F on each bearing surface  14 , thereby providing for numerous corresponding angular detents in the relative angular orientation of portions  12 L and  12 R. In general, hinge  30  (e.g., housing structures forming bearing surfaces  14  and associated fabric hinge structures) may be configured to form a hinge with any suitable number of angular detents (none, one, at least two, at least three, at least 5, at least 10, fewer than 8, fewer than 3, etc.). 
     Fabric in hinge  30  and/or the detent surfaces and/or other bearing surface features of housing  12  or other hinge structures in item  10  may, if desired, having varying properties (e.g., along the length of hinge axis  16  and/or in other directions). As shown in  FIG. 12 , for example, portions of housing  12  may have curved bearing surfaces  14  or other properties in regions  62  and may have flattened bearing surfaces  14  (e.g., bearing surfaces  14  with one or more detents) in other locations along the length of axis  16 . The properties of the fabric in hinge  30  may also vary along the length of axis  16 . For example, at some locations (e.g., locations  30 L of  FIG. 12 ) one or more conductive strands may be use to form data and/or power paths between components  18  in housing  12  on opposing sides of hinge  30 , whereas other locations may include no conductive strands. As another example, optical properties such as color and reflectance may be varied (e.g., to achieve a desired appearance for hinge  30 ). Fabric from hinge  30  may, if desired, extend over the outer surface of housing  12  (e.g., to form an item with a fabric that forms an outer housing wall and/or cosmetic wall covering and that also forms fabric layers in hinge  30 ). 
     The illustrative arrangement of item  10  of  FIGS. 13, 14, 15, and 16  shows how hinge  30  may be formed without using curved bearing surfaces  14 .  FIG. 13  is a cross-sectional side view of fabric hinge  30  showing layers of fabric that may be used in forming hinge  30 .  FIGS. 14 and 15  show how these layers of fabric may be coupled to housing structures  12 . In the configuration of  FIG. 14 , the housing of item  10  is in a closed position (e.g., a front-to-front closed position). In the configuration of  FIG. 15 , the housing of item  10  is in an open position (e.g., an arrangement in which housing portions  12 L and  12 R lie in a common plane and in which item  10  has a flat appearance).  FIG. 16  is a cross-sectional side view of another illustrative arrangement for hinge  30  in item  10 . A shown in  FIG. 16 , housing  12  may have openings such as openings  12 H through which layers of fabric in hinge  30  may be pulled during manufacturing to help tension strands  32  of hinge  30 . In the arrangements of  FIGS. 14, 15, 16 , and  17 , portions of housing  12  adjacent to hinge  30  have rectangular edges, showing how bearing surfaces  14  need not have curved semicircular shapes of the type illustrated in  FIGS. 3 and 4 . In general, any suitable shapes may be used for housing  12  along hinge axis  16 . 
       FIG. 17  is an illustrative hinge for item  10  showing how a hinge may include links  12 K (e.g., housing links formed from metal, polymer, and/or other housing materials). Links  12 K may, for example, be formed in columns that are staggered with respect to each other as shown in  FIG. 17  and may be interlocked using pins  70  that extend between adjacent links  12 K along hinge axis  16  to rotatably couple these adjacent links. Individual fabric hinges  30  (e.g., link-level hinges each with a corresponding link-level hinge axis) may be formed on the bearing surfaces  14  between adjoining links  12 K. The inclusion of fabric hinge structures in the hinge links between housing portions  12 L and  12 R may lock the movement of these housing portions together. For example, if housing portion  12 L of  FIG. 17  is moved in direction  100  relative to links  12 K, housing portion  12 R will be caused to rotated by a comparable (e.g., equal) amount  102  in the opposite direction about hinge axis  16  due to the fabric of hinges  30 . Links  12 K may be inserted into hinge fabric layers during weaving (as an example). 
     The foregoing is merely illustrative and various modifications can be made to the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20190214
Publication Date: 20200616
Grant Date: 20200616
Priority Date: 20180423
Inventors: PODHAJNY, DANIEL A.
SUNSHINE, Daniel D.
Gomes, Didio V.
ROBINSON, KEVIN M.
LANAS, MARIEL L.
MILLER, ARI P.
FARAHANI, HOUTAN
Assignee: APPLE INC
CPC Classifications: [{"code": "A45C11/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C11/002", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D11/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C13/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1616", "inventive": true, "first": true, "tree": "[]"}, {"code": "E05D1/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1662", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1637", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D1/0088", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D7/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "E05D1/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D2700/0166", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "A45C11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D2700/0137", "inventive": false, "first": false, "tree": "[]"}, {"code": "E05Y2900/606", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2011/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "A45C2011/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "E05D1/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1637", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D7/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1662", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D1/0088", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D2700/0144", "inventive": false, "first": false, "tree": "[]"}, {"code": "E05Y2999/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "E05Y2999/00", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 71075216