Keyboard Housing Pivot Coupling and Hidden Fasteners

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Solution Overview

Problem

Conventional housing structures of electronic keyboard musical instruments face inefficiencies in assembly and maintenance due to separate upper and lower cases that are difficult to uncouple, leading to safety concerns and poor workability, and result in unsightly fastening mechanisms.

Innovation Solution

A housing structure with a pivotable upper case that can be easily mounted or dismounted from a lower case in a semi-open state, featuring protrusions and engagement holes that prevent unintentional dismounting and allow for safe and efficient assembly and maintenance, while also enabling the fastening of upper and lower cases with hidden fasteners for a natural appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If upper and lower cases are coupled by a hinge, then the housing can be opened for maintenance, but it is not easy to release the coupling to separate them

Engineering Contradiction:

Improveaccessibility for maintenanceVSAvoidease of separation

Core Design Contradiction:

Ease of repairVSEase of operation

Solution Approach 1:

The coupling mechanism is segmented into two independent parts: a hinge that enables opening/closing motion and a separate fastening mechanism (screws or clips) that secures the upper case to the lower case. This segmentation allows the hinge to maintain its opening function while the fastening mechanism can be independently released to separate the cases completely.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coupling system transitions from a static fixed connection to a dynamic multi-stage connection. The hinge provides initial dynamic opening capability, and the fastening mechanism can be engaged or disengaged based on operational needs, allowing the system to adapt between secured and separated states.

Inventive Principle:

Principle #15Dynamics

2Reliability

If upper and lower cases are fixed together by fastening means, then the housing is securely assembled, but the fastening means become visible from above creating inferior external appearance

Engineering Contradiction:

Improveassembly securityVSAvoidexternal appearance

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The fastening means are extracted from the visible exterior surface and relocated to the interior or side surfaces of the housing. Screws are positioned to be hidden within recesses or against the inner surfaces, while clips are integrated into the side walls, removing the unsightly fasteners from the top view while maintaining secure assembly.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fastening mechanism is nested within the housing structure itself. Screws are recessed into cavities within the upper or lower cases, and clips are embedded in the side walls, allowing the fastening function to be contained within the overall housing form rather than protruding from the exterior.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If upper and lower cases are fixed by screws inserted from below, then fastening is achieved, but cumbersome operations are required including turning cases upside down

Engineering Contradiction:

Improvefastening capabilityVSAvoidassembly time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

Instead of inserting screws from below the housing (requiring upside-down positioning), the fastening mechanism is inverted to allow screw insertion from above the housing. This inversion enables assembly operations to be performed with the housing in its normal upright position, eliminating the need to turn cases upside down and reducing assembly time.

Inventive Principle:

Principle #13The other way round (Inversion)

4Ease of manufacture

If positional accuracy between upper and lower cases is low, then assembly is simplified, but gaps between keyboard unit and side beds become nonuniform

Engineering Contradiction:

Improveassembly simplicityVSAvoidgap uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Positioning protrusions and corresponding positioning holes are provided on the upper and lower cases before final fastening. These preliminary positioning features guide the relative placement of the cases, ensuring correct alignment of the keyboard unit with side beds, and allow for easy assembly while achieving uniform gaps without requiring high precision in the final fastening operation.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS7902445B2Housing structure of electronic keyboard musical instrument

Publication Date: 2011.03.08 YAMAHA CORP

AI summary

A housing structure of an electronic keyboard musical instrument, in which a pivotable upper case can be mounted to and dismounted from a lower case when the upper case is in a semi-open state, thereby improving safety and the working efficiency at the time of assembly and maintenance. Pivot coupling parts each include an engagement protrusion comprised of a narrow-width portion and a wide-width portion. An upper case is formed with engagement holes each comprised of a narrow-width counterpart permitting the narrow-width portion to be inserted thereinto and a wide-width counterpart permitting the wide-width portion to be inserted thereinto. By moving the upper case, having a posture thereof corresponding to a mountable/dismountable angle range, in the direction in which the wide-width portions project, the wide-width portions can be inserted into and removed from the wide-width counterparts.