Co-molded Keyboard Shell with Dual-Hardness Materials

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Solution Overview

Problem

Conventional keyboards lack effective integration of shock absorption and ergonomic design, particularly in the handling and storage of data cables, which can lead to damage and inconvenience during transport and use.

Innovation Solution

A co-molded keyboard design featuring a first material member with a higher hardness value and a second material member with a lower hardness value, combined with a key matrix circuit component and elastomeric members, includes grooves for data cable attachment and shock absorption, and a seal member for dust protection, enhancing durability and usability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a single hard material is used for the keyboard shell, then structural strength is improved, but shock absorption capability deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidshock absorption capability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The keyboard shell is constructed using composite materials with different hardness values - a harder first material member for structural strength and a softer second material member for shock absorption. This composite structure resolves the contradiction by combining materials with complementary properties in a single integrated shell component.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the keyboard shell have different material properties - the first material member with higher hardness provides structural support in critical areas, while the second material member with lower hardness provides shock absorption in impact-prone areas. This local differentiation of material quality resolves the strength-shock absorption contradiction.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If conventional keyboard design is used, then manufacturing simplicity is maintained, but cable management and protection capabilities deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcable management capability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The cable management features (grooves and receptacles) are merged directly into the keyboard shell structure itself, eliminating the need for separate cable management components. This integration maintains manufacturing simplicity while significantly improving cable management and protection capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The keyboard shell serves multiple functions simultaneously: structural support, shock absorption, cable routing, cable securing, and dust protection. By making the shell multi-functional, the design improves adaptability without adding separate components that would complicate manufacturing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If no protective features are added to the keyboard shell, then manufacturing complexity is reduced, but protection against harmful factors deteriorates

Engineering Contradiction:

Improvemanufacturing complexityVSAvoiddust and debris protection

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The seal member is integrated into the keyboard shell structure, combining dust protection functionality with the existing shell components. This integration provides effective sealing against dust and debris without adding separate protective components that would increase manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

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

The co-molded design provides improved shock absorption, secure data cable management, and dust protection, resulting in a more durable and user-friendly keyboard experience.

Implementation Method 1

a co-molded keyboard design featuring a first material member with a higher hardness value and a second material member with a lower hardness value... provides improved shock absorption

Methodology Applied

Scientific EffectShock absorption: Damping

Implementation Method 2

an elastomeric member having a first surface and a plurality of openings... the elastomeric sheet positioned in at least one or more portions of the gap space between the plurality of key caps

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10466807B1Keyboard

Publication Date: 2019.11.05 PIONEER SQUARE BRANDS INC

AI summary

Systems and methods are involved with but are not limited to a shell component including a first material member and a co-molded second material member, the first material member including a periphery, and one or more curvilinear edge surfaces extended along the periphery, the second material member including one or more portions adjacent one or more portions of the one or more curvilinear edge surfaces, the first material member of a first hardness value, the second material member of a second hardness value less than the first hardness value of the first material member; a key matrix circuit component adjacent one or more portions of a first surface of the first material member; and a plurality of key caps coupled to the key matrix circuit component. In addition, other aspects are described in the claims, drawings, and text forming a part of the present disclosure.