One-Piece Keyboard Key Module Housing Design
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Solution Overview
Problem
Existing keyboard key modules are complex, costly, and difficult to replace, with a lack of efficient guidance for the key plunger during actuation and inadequate feedback mechanisms.
Innovation Solution
A simplified mechanical key module design featuring a one-piece module housing with a snap-fit plunger retention system, a solderless connection to the circuit substrate, and integrated feedback mechanisms for reliable actuation and feedback, allowing for easy replacement and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a multi-part housing design is used for the key module, then assembly flexibility is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple housing components (housing body, contactor housing, guide elements) into a single integrated module housing made of thermoplastic material. This one-piece construction eliminates the need for separate parts and assembly steps, directly resolving the contradiction by reducing device complexity while maintaining manufacturing efficiency through injection molding.
Solution Approach 2:
The module housing serves multiple functions simultaneously: it provides structural support, guides the key plunger, houses the contactor, and integrates fastening elements. This multi-functionality consolidates what would traditionally require multiple separate components, reducing overall device complexity while maintaining ease of manufacture.
2Reliability
If a complex fastening system is used to secure the key module to the circuit substrate, then connection reliability is improved, but ease of replacement deteriorates
Solution Approach 1:
The patent segments the keyboard system into independently replaceable key module units, each with its own integrated housing and fastening elements. This allows individual key modules to be removed and replaced without affecting other keys, maintaining connection reliability through dedicated fastening features while dramatically improving ease of replacement for users.
Solution Approach 2:
The module housing includes pre-integrated fastening elements (such as clips or lugs) that are formed during manufacturing. These preliminary-built fastening features enable tool-free attachment and detachment, providing reliable connection during use while allowing easy replacement when needed, resolving the contradiction between reliability and ease of repair.
3Stability of the object's composition
If traditional guidance mechanisms are used for the key plunger, then plunger stability is improved, but device complexity and cost increase
Solution Approach 1:
The patent integrates guide elements directly into the module housing structure, eliminating the need for separate guide rods, bushings, or external guidance mechanisms. The housing itself provides the guidance surfaces that constrain and stabilize the key plunger during actuation, achieving plunger stability while reducing device complexity and part count.
Solution Approach 2:
The module housing is made from thermoplastic material that provides flexible yet precise guidance surfaces. These molded-in guide features offer sufficient stability for plunger movement without requiring rigid metal guides or complex mechanical constraints, reducing complexity while maintaining functional stability.
4Reliability
If soldered connections are used between the key module and circuit substrate, then electrical connection reliability is improved, but ease of replacement and material selection deteriorate
Solution Approach 1:
The patent replaces traditional soldered electrical connections with mechanical contact systems. The contactor elements make direct mechanical contact with contact surfaces on the circuit substrate, eliminating the need for soldering. This provides sufficient electrical connection reliability for key switching while enabling tool-free removal and replacement of key modules, and allows use of materials that cannot withstand soldering temperatures.
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 solution provides a durable, cost-effective, and user-replaceable key module with improved plunger guidance and feedback, enhancing the reliability and usability of keyboard keys.
Implementation Method 1
The elastic means can be designed as a compression spring. The elastic means can function as a return spring for the button module.
Implementation Method 2
The elastic means can bring about a linear force-displacement curve during the actuation movement. Alternatively, the elastic means can have a progressive spring characteristic.
Implementation Method 3
The plunger stop and housing stop may be shaped to allow a snap fit between the key plunger and the module housing to retain the key plunger in the module housing.
Data Source
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AI summary
The invention relates to a key module (110) for a keyboard. The key module (110) has a key lifter (220). The key lifter (220) has a coupling section (322) for coupling a key cap for the key module (110). The key lifter (220) has at least one guide section (326, 328) for guiding a translational actuation movement of the key lifter (220) between a rest position and an actuation position. The key lifter (220) has at least one lifter stop (324) for limiting the actuation movement. The key module (110) also has a trigger element (350) for triggering a switch signal of the key module (110) in response to the actuation movement. The trigger element (350) can be attached to the key lifter (220). The key module (110) additionally has a module housing (230), wherein the module housing (230) is formed as a single piece. The module housing (230) has at least one positioning protrusion (334) for positioning the key module (110) on a circuit substrate of the keyboard. The module housing (230) is designed to receive the key lifter (220) in a movable manner in order to allow the actuation movement of the key lifter (220) relative to the module housing (230). The module housing (230) has at least one housing stop (332) for resting against the at least one lifter stop (324) of the key lifter (220) in the rest position of the key lifter (220). The key module (110) additionally has an elastic means (340). The elastic means (340) is designed to pre-tension the key lifter (220) into the rest position in an assembled state of the key module (110).