Dual-axis over-molded hinge

Abstract

One aspect is an overmolded hinge device having a first and a second shaft, each having first and second ends. A first friction element is mounted on the first shaft. A first molded housing is at least partially enclosing the first shaft and a second molded housing is at least partially enclosing the second shaft. A first molded outer link is at least partially enclosing each of the first and second shafts and a second molded outer link is at least partially enclosing each of the first and second shafts. One of the first molded housing and the first molded outer link enclose the first friction element

What is claimed is: 
     
         1 . An overmolded friction hinge device comprising:
 a first and a second shaft, each having first and second ends;   a first friction element mounted on the first shaft and having a lubricating substance trapped between the first friction element and the first shaft;   a first molded housing at least partially enclosing the first shaft;   a second molded housing at least partially enclosing the second shaft;   a first molded outer link at least partially enclosing each of the first and second shafts; and   a second molded outer link at least partially enclosing each of the first and second shafts   wherein one of the first molded housing and the first molded outer link enclose the first friction element.   
     
     
         2 . The overmolded hinge device of  claim 1 , wherein the first molded outer link at least partially encloses the first end of each of the first and second shafts, and wherein the second molded outer link at least partially encloses the second ends of each of the first and second shafts. 
     
     
         3 . The overmolded hinge device of  claim 1  further comprising a second friction element mounted on the second shaft, wherein one of the second molded housing, first molded outer link, and second molded outer link at least partially encloses the second friction element and the second shaft. 
     
     
         4 . The overmolded hinge device of  claim 1 , wherein the first molded housing does not enclose any portion of the second shaft and wherein the second molded housing does not enclose any portion of the first shaft. 
     
     
         5 . The overmolded hinge device of  claim 1 , wherein the first and second ends of each of the first and a second shafts comprise knurls. 
     
     
         6 . The overmolded hinge device of  claim 3 , wherein the first and second molded housings each comprise a shaft overmold portion and a bracket portion, the shaft overmold portion of the first and second molded housings respectively enclosing the first and second friction elements. 
     
     
         7 . The overmolded hinge device of  claim 6 , wherein the shaft overmold portion of the first and second molded housings respectively enclose the first and second friction elements such that the first friction element must rotate with the first molded housing and the second friction element must rotate with the second molded housing. 
     
     
         8 . The overmolded hinge device of  claim 6 , wherein the bracket portion of the first and second molded housings are respectively configured to be mounted to a first and a second hinged element. 
     
     
         9 . The overmolded hinge device of  claim 6 , wherein each of the shaft overmold portions of the first and second molded housings are between the first and second molded outer links, and are immediately adjacent thereto. 
     
     
         10 . The overmolded hinge device of  claim 3 , wherein each of the first and second friction elements comprise a plurality of clips. 
     
     
         11 . The overmolded hinge device of  claim 10 , wherein the number of clip in the plurality of clips on the first shaft is not the same as the number of clip in the plurality of clips on the second shaft. 
     
     
         12 . The overmolded hinge device of  claim 1  further comprising a one-way clutch on at least one of the first and second shafts. 
     
     
         13 . The overmolded hinge device of  claim 1 , wherein the overmolded hinge device comprises an outer periphery and wherein at least a portion of each of the first and second molded housings and the first and second molded outer links lie on the outer periphery the overmolded hinge device. 
     
     
         14 . A method of forming an overmolded hinge device comprising:
 providing a first and a second shaft, each having first and second ends;   mounting a first friction element on the first shaft to form a friction assembly;   placing the friction assembly into a mold cavity;   forming a first molded housing at least partially enclosing the first shaft;   forming a second molded housing at least partially enclosing and the second shaft;   forming a first molded outer link at least partially enclosing each of the first and second shafts; and   forming a second molded outer link at least partially enclosing each of the first and second shafts;   wherein one of the first molded housing and the first molded outer link at least partially enclose the first friction element.   
     
     
         15 . The method of  claim 14 , wherein the forming of first molded housing, the second molded housing, the first molded outer link, and the second molded outer link is done with injection molding with a single cycle of injection. 
     
     
         16 . The method of  claim 14  further comprising forming the first molded outer link such that it at least partially encloses the first end of each of the first and second shafts, and forming the second molded outer link such that it at least partially encloses the second ends of each of the first and second shafts. 
     
     
         17 . The method of  claim 14  further comprising mounting a second friction element on the second shaft and forming one of second molded housing, the first molded outer link, or the second molded outer link over the second friction element. 
     
     
         18 . The method of  claim 14  further comprising forming the first and second molded housings such that each comprise a shaft overmold portion and a bracket portion, the shaft overmold portion of the first and second molded housings respectively enclosing the first and second friction elements. 
     
     
         19 . The method of  claim 18  further comprising forming the shaft overmold portion of the first and second molded housings respectively enclosing the first and second friction elements such that the first friction element must rotate with the first molded housing and the second friction element must rotate with the second molded housing. 
     
     
         20 . The method of  claim 18  further comprising forming the first and second molded outer links such that they are located on either side of the friction overmolded portion of the first and second molded housings, and are immediately adjacent thereto. 
     
     
         21 . An overmolded friction hinge device comprising:
 at least one torque insert comprising a first shaft, at least one friction element mounted on the first shaft and having a lubricating substance trapped between the first friction element and the first shaft, and a tubing over the at least one friction element and the first shaft;   a second shaft;   a first molded housing enclosing the at least one torque insert;   a second molded housing at least partially enclosing the second shaft;   a first molded outer link at least partially enclosing each of the first and second shafts; and   a second molded outer link at least partially enclosing each of the first and second shafts.