Keyboard Key Base Rib Structure for Removable Counterweights

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Solution Overview

Problem

Existing keyboard instruments face challenges in efficiently attaching and removing weights from key bases, particularly when resin and metal components are involved, leading to difficulties in disposal and maintenance.

Innovation Solution

A keyboard instrument design that incorporates a key base with ribs and auxiliary ribs to securely fix weights, allowing for easy attachment and removal of weights using insert molding, and a molding method that aligns weights within a mold for precise positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If weights are attached to key bases using conventional methods, then the counterweight effect is achieved, but the attachment and removal process becomes difficult and time-consuming

Engineering Contradiction:

Improveease of weight attachment and removalVSAvoidtime for weight attachment and removal

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The key base is segmented into multiple ribs that can independently engage with the weight. This segmentation allows the weight to be attached and removed by simply detaching from the rib structures, significantly reducing the time and effort required compared to conventional methods that require complete disassembly or complex fastening mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The resin material acts as an intermediary between the metal weight and the key base structure. Through insert molding, the resin is injected to surround and bond the weight to the ribs, creating a secure yet reversible attachment. This intermediary material facilitates easy attachment and removal while maintaining the counterweight effect during normal operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If weights are securely fixed in key bases, then the counterweight effect is maintained, but disposal and maintenance become difficult

Engineering Contradiction:

Improvesecurity of weight attachmentVSAvoidease of weight removal for maintenance

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The attachment system transitions from a static permanent bond to a dynamic reversible connection. The ribs are designed to hold the weight securely during key operation through precise geometric engagement, but allow for easy release when maintenance or disposal is needed. This dynamic characteristic enables the system to adapt between secure operation and easy maintenance states.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

By dividing the key base into multiple rib structures rather than a monolithic base, the invention enables selective access and removal of weights. Each rib can be independently engaged or disengaged, allowing maintenance personnel to remove weights for disposal or replacement without damaging the overall key base structure or requiring complete disassembly of the keyboard instrument.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If conventional key base molding methods are used, then manufacturing is simple, but weight positioning precision is insufficient

Engineering Contradiction:

Improveweight positioning precisionVSAvoidmolding process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The weight is positioned and secured within the key base during the molding process itself through insert molding. The weight is placed in the mold cavity before resin injection, and the resin is then injected to surround and bond the weight to the ribs. This preliminary positioning action ensures high manufacturing precision for weight placement without requiring complex post-processing or separate assembly steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention merges the weight attachment function with the key base molding process. Instead of separately molding the key base and then attaching weights, the ribs are molded as integral parts of the key base structure that simultaneously engage with the weight. This merging of functions achieves high positioning precision while avoiding the need for complex separate assembly operations.

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

Enables secure attachment and easy removal of weights from key bases, facilitating disposal and maintenance, while maintaining the desired counterweight effect for improved key depression feel.

Implementation Method 1

at least one rib configured to fix the weight by holding the weight from below

Methodology Applied

Scientific EffectMechanical support: Mechanical Force

Implementation Method 2

injecting a molten resin into the mold so clamped to mold a key base including a rib configured to fix the weight

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS20250349271A1Keyboard instrument, key base molding method, and key base molding mold

Publication Date: 2025.11.13 CASIO COMPUTER CO LTD

AI summary

A keyboard instrument includes a key comprising a weight and a key base. The key base includes a top plate and at least one rib which extends in a vertical direction and which is configured to fix the weight by holding the weight from below in such a state that the weight is kept in abutment with a lower surface of the top plate.