Keyboard Protective Film via Insert Molding
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Solution Overview
Problem
Conventional keyboard devices face issues with dust and liquid entering through their open-type structure, and existing protective solutions like dustproof covers or films are either detachable, hinder keypress, or affect tactile feel and visibility of keycap designs.
Innovation Solution
A keyboard device with a protective film securely fixed to a frame body using an insert molding process, eliminating the need for adhesive units on keycaps, ensuring waterproof and dustproof protection without compromising keypress feel or visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a dustproof cover or protective film is used to cover the keyboard device, then waterproof and dustproof efficacy is improved, but the protective film may detach from the keyboard device
Solution Approach 1:
The protective film is integrated with the keycaps to form a unified structure. The film is stretched over the keycaps and fixed at the bottom surface, merging the protective function with the keycap structure itself, eliminating detachment issues while maintaining waterproof and dustproof efficacy
Solution Approach 2:
The protective film is nested within the keycap structure, with the film positioned inside the hollow portion of each keycap and secured at the bottom surface. This nesting approach ensures the film remains firmly attached while providing protection
2Reliability
If an adhesive unit is formed on the keycap to attach the protective film, then the protective film is fixed, but the tactile feel of depressing the keycap is adversely affected
Solution Approach 1:
The adhesive unit is completely removed from the design. Instead of using adhesive on the keycap surface, the protective film is mechanically secured by stretching it over the keycap and fixing it at the bottom surface, eliminating interference with tactile feedback
Solution Approach 2:
The protective film itself serves as the fixation mechanism through its flexibility. The film is stretched to conform to the keycap shape and secured at the bottom, using the film's own properties rather than additional adhesive materials, thus preserving tactile feel
3Reliability
If an adhesive unit with large thickness is used to attach the protective film, then the protective film is securely fixed, but the character, symbol or pattern printed on the keycap cannot be clearly viewed
Solution Approach 1:
The adhesive unit is completely removed from the design. The protective film is fixed without any adhesive layer between it and the keycap surface, eliminating the thickness issue that blocked visibility of printed characters and symbols
Solution Approach 2:
The protective film is used as a thin, transparent barrier that provides fixation through stretching and bottom-surface securing rather than through a thick adhesive layer, maintaining clear visibility of keycap designs
Data Source
AI summary
A keyboard device with a protecting function and a manufacturing method of the keyboard device are provided. Firstly, a mold is provided. Then, a frame material is placed into the mold to form a frame body, and a film material is placed into the mold to form a protective film. Consequently, the protective film is fixed on the frame body. After the mold is removed, a keyboard module is assembled with the frame body. Consequently, the keyboard device is manufactured. The protective film includes a sheet-like portion, plural connection portions and plural covering portions. The frame body includes plural spacer structures and plural perforations. The sheet-like portion is fixed on the plural spacer structures. The keyboard module includes a base plate and plural keys. The keycap is penetrated through the corresponding perforation and contacted with the corresponding covering portion.