Key Module Plunger Rib Guidance and Labyrinth Seal
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Solution Overview
Problem
Conventional key modules are high and difficult to integrate into flat keyboards, lack synchronous clicking noise and LED illumination, are prone to water damage, require numerous expensive variants for different force curves, and face challenges with mounting electronic components due to height constraints and electrostatic discharge risks.
Innovation Solution
A key module design featuring a plunger with a driver lug and guide section, a contactor assembly, and a housing element with a receiving cup for rib guidance, allowing smooth plunger movement and integrated LED illumination, while using a labyrinth seal for water resistance and a shock absorber for noise reduction, enabling cost-effective production and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional key modules use additional mechanisms for clicking noise, then clicking noise is generated, but the electrical switching process becomes decoupled from clicking sound generation and is no longer synchronous
Solution Approach 1:
The patent combines the electrical switching function and clicking sound generation into a single integrated mechanism. The contactor assembly with contact piece and contactor unit performs both electrical contact closure and generates clicking noise through mechanical interaction, eliminating the need for separate clicking mechanisms and ensuring synchronous operation.
Solution Approach 2:
The contactor assembly serves multiple functions simultaneously: it provides electrical contact closure, generates clicking noise, and provides mechanical guidance. This multi-functional design reduces overall device complexity while maintaining reliable synchronous operation between electrical switching and acoustic feedback.
2Length of stationary object
If key modules are designed with reduced height for flat keyboards, then integration into flat keyboards becomes possible, but mounting electronic components on the top side of printed circuit board becomes difficult or impossible
Solution Approach 1:
The patent relocates electronic component mounting from the top side to the underside of the printed circuit board. This dimensional change allows reduced key module height while maintaining ease of manufacturing, as components are mounted on the opposite side where space is available and does not interfere with the compact key module structure.
3Ease of manufacture
If key modules are designed to be relatively leaky for cost reasons, then production costs are reduced, but damage to keyboards occurs quickly if water or aqueous liquids are poured over them
Solution Approach 1:
The patent employs a labyrinth seal formed by overlapping sealing surfaces between the cover element and housing element. These flexible sealing surfaces create liquid-tight barriers at critical interfaces, protecting internal components from water damage while maintaining cost-effective manufacturing through simple geometric sealing structures rather than complex gasket systems.
4Length of stationary object
If plunger guidance is shortened in low key modules, then overall height is reduced, but the risk of key jamming increases
Solution Approach 1:
The patent divides plunger guidance into two distinct segments: upper guidance through the cover element and lower guidance through the housing element. This segmentation allows each guidance section to be optimized for its specific function, maintaining adequate guidance length for reliable plunger movement while keeping the overall module height reduced through efficient vertical stacking.
Solution Approach 2:
The patent enhances plunger guidance by adding lateral ribs on the plunger that engage with recesses in the housing element's receiving cup. This lateral guidance dimension complements the vertical guidance, providing stable plunger movement and preventing jamming within the constrained height of a low-profile key module.
Data Source
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AI summary
The invention relates to a key module (100) having a cover element (110) and a plunger (105), which has a carrier nose (135), wherein the plunger (105) is movably mounted by the cover element along a movement axis (200), wherein the plunger (105) has a cylindrical pushbutton carrier portion (160) in an opening region (210), in which the plunger protrudes through the cover element (160), and has at least one rib (170) on a guide portion (165) adjoining the pushbutton carrier portion (160) on an outer side (167). The key module (100) furthermore comprises a contact encoder unit (115) which is designed and arranged in order to be carried by the carrier nose (135) and a contact piece (120), which is designed and arranged for electrical contact closure together with the contact nose (140). Finally, the key module (100) comprises a housing element (130) for receiving the contact piece (120), the contact encoder unit (115), and the plunger (105), wherein the housing element (130) has, for receiving the guide portion (165) of the plunger (105), at least one receiving cup (175) having at least one recess (1100) for receiving the at least one rib (170) of the plunger (105).