Active Keycap with Embedded Display Using Nested Cavity
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Solution Overview
Problem
Keycaps in electronic devices are typically passive mechanical components with static appearances and functions, making it difficult to embed active elements like displays or sensors without compromising their mechanical profile, surface topology, texture, and lifetime requirements.
Innovation Solution
The integration of an active element, such as a display, within the keycap using an optically clear and low-viscosity resin, which is cured to form a solid layer adhering to the keycap structure, allowing for a thin and lightweight active keycap with preserved visual appearance and texture, and electrical connections established through vias or PCBs without increasing thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If active elements like displays or sensors are embedded in keycaps, then functionality is enhanced, but mechanical profile, surface topology, and texture are compromised
Solution Approach 1:
The active element is nested within a cavity formed in the keycap body, allowing the display or sensor to be housed inside the keycap structure without protruding or altering the external surface topology. The cavity is strategically positioned and sized to accommodate the active element while maintaining the original keycap shape and ergonomics.
Solution Approach 2:
A transparent or translucent thin film layer is applied over the active element to protect it while maintaining optical clarity and surface smoothness. This thin film preserves the tactile feel and visual appearance of the keycap surface while allowing the embedded active element to function beneath it.
2Adaptability or versatility
If active elements are embedded in keycaps, then functionality is enhanced, but thickness increases
Solution Approach 1:
The active element is nested within a cavity formed in the keycap body, allowing the display or sensor to be housed inside the keycap structure without increasing overall thickness. The cavity utilizes the internal volume of the keycap, keeping the external dimensions unchanged.
Solution Approach 2:
Instead of adding thickness in the vertical dimension, the active element is positioned in the horizontal plane within the keycap body. The electrical connections are routed through lateral pathways rather than extending the thickness, utilizing the keycap's planar space to accommodate the active element.
3Adaptability or versatility
If active elements are embedded in keycaps, then functionality is enhanced, but protection from humidity and mechanical damage is reduced
Solution Approach 1:
The active element is nested within a sealed cavity that is integrated into the keycap structure. The cavity is enclosed with protective walls and sealed interfaces that prevent humidity and contaminants from reaching the active element, while mechanical forces are distributed through the keycap structure rather than concentrating stress on the embedded component.
Solution Approach 2:
A protective transparent film or coating is applied over the active element and sealed at the edges to create a barrier against humidity and mechanical damage. This protective layer maintains optical clarity while providing environmental protection to the embedded active element.
4Adaptability or versatility
If active elements are embedded in keycaps, then functionality is enhanced, but manufacturing complexity increases
Solution Approach 1:
The keycap is designed with a pre-formed cavity that can be created using standard molding techniques. The active element is then inserted into this cavity and secured with simple fastening methods such as adhesive or clips, avoiding complex assembly processes while achieving functional integration.
Solution Approach 2:
The cavity for the active element is integrated into the keycap molding process itself, combining the structural formation and active element housing into a single manufacturing step. Electrical connection pathways are also designed to be formed during the molding process, reducing the number of separate manufacturing operations required.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the development of active keycaps that retain the ergonomic feel and visual appearance of traditional keycaps while incorporating embedded displays or sensors, providing enhanced functionality and protection from humidity and mechanical interactions.
Implementation Method 1
The integration of an active element, such as a display, within the keycap using an optically clear and low-viscosity resin, which is cured to form a solid layer adhering to the keycap structure
Data Source
Figure 1A~1B
Figure 2~3A
Figure 3B~4
AI summary
Particular embodiments described herein provide for a keycap. The keycap can include a protective layer and an active element, where the height of protective layer and the active element is less than six (6) millimeters in height. The keycap can also include a front plane layer, a back plane layer, where the front plane layer and the back plane layer comprise the active element, and an electrical connection through the keycap to provide electrical communication with the active element.