Keyboard Case Structure With Segmented Reinforcement for Thermal Gaps
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Solution Overview
Problem
Existing cases for keyboard instruments face challenges in maintaining structural integrity and aesthetic design under varying temperature conditions due to differential expansion and contraction of materials used.
Innovation Solution
A case design comprising a lower case made of resin, reinforcement members made of steel, and a front case made of wood, with asymmetrically divided reinforcement members allowing for relative movement to accommodate thermal expansion and contraction, while maintaining fixed gaps at visible joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement members are used to connect the front case and lower case, then structural integrity is improved, but differential thermal expansion causes forced strain and joint gap variation
Solution Approach 1:
The reinforcement members are divided into multiple segments along the left-right direction. Each segment is independently connectable to the lower case, allowing differential thermal expansion without forcing the entire reinforcement member to expand uniformly. This segmentation enables the structure to accommodate thermal stress while maintaining joint gap consistency.
Solution Approach 2:
The reinforcement members are designed with movable connections to the lower case, allowing them to dynamically adjust their position in response to thermal expansion. The lower case can expand relative to the divided reinforcement members without creating forced strain, as the connections permit controlled movement while maintaining structural integrity.
2Adaptability or versatility
If the case is constructed from multiple materials (resin, steel, wood), then design flexibility and material properties are improved, but differential thermal expansion causes structural stress
Solution Approach 1:
The reinforcement members made of steel are divided into segments that can independently accommodate thermal expansion differences with the resin lower case and wood front case. This segmentation reduces the cumulative thermal stress that would occur in a continuous reinforcement structure connecting materials with different expansion coefficients.
Solution Approach 2:
The divided reinforcement members act as intermediaries between the lower case and front case, absorbing and distributing thermal stress through their segmented structure. This intermediary design allows the connection of dissimilar materials while mitigating the harmful effects of differential thermal expansion.
3Stability of the object's composition
If the reinforcement members are made of steel with small linear expansion coefficient, then thermal stability is improved, but the rigid structure cannot accommodate expansion of resin lower case
Solution Approach 1:
The steel reinforcement members are divided into multiple rigid segments that maintain their thermal stability while allowing the overall structure to flex. Each segment remains rigid and thermally stable, but the segmented configuration allows controlled movement at the connection points to accommodate lower case expansion.
Solution Approach 2:
The connection between the rigid steel reinforcement members and the resin lower case is designed to be dynamic rather than fixed. This allows the rigid reinforcement segments to maintain their thermal stability while the connection permits movement to accommodate the expansion of the resin lower case, preventing structural failure.
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 design ensures consistent joint gaps and aesthetic stability despite temperature changes, preventing forced strain and maintaining a high-quality appearance.
Implementation Method 1
made of a second material having a smaller linear expansion coefficient than a linear expansion coefficient of the first material... allowing for relative movement to accommodate thermal expansion and contraction
Data Source
AI summary
A case of a keyboard instrument includes a lower case formed from a resin material which is a first material and extended long in a left-right direction which is a first direction, plural reinforcement members (a first reinforcement member, a second reinforcement member) fixed to the lower case, made from a sheet of steel which is a second material whose linear expansion coefficient is smaller than a linear expansion coefficient of the first material, and disposed to be divided in the left-right direction, a front case formed in such a manner as to extend long in the first direction and fixed to each of the plural reinforcement members, and side cases (a left side case, a right side case) disposed adjacent to the front case and fixed to ends of the reinforcement members.