Thin Keyboard Membrane Structure for Waterproof Tactile Keys
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Solution Overview
Problem
Conventional keyboard membranes are thick, lack wear resistance, and fail to provide effective waterproof and dustproof protection, leading to poor tactile feedback and increased risk of invalid keystrokes.
Innovation Solution
A thin, thermoplastic wear-resistant keyboard membrane with a concave-convex structure, comprising a wear-resistant polyurethane surface layer and a ductile thermoplastic polyurethane inner layer, designed to wrap around a key module, providing a waterproof and dustproof barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional membrane is used to protect the keys, then the keys are covered and protected, but the membrane cannot provide waterproof and dustproof functions for the keyboard
Solution Approach 1:
The membrane extends from a traditional 2D surface layer to a 3D structure with a peripheral edge that wraps around the sides of the key module. This dimensional extension creates a barrier that prevents water and dust from entering along the edges, achieving waterproof and dustproof protection while maintaining reliable coverage of the keys.
Solution Approach 2:
The invention uses a flexible membrane with a peripheral edge that can wrap around the key module contours. This flexible thin film structure conformally covers the keys and extends to wrap the peripheral surfaces, creating an effective seal against water and dust penetration while maintaining the protective function.
2Manufacturing precision
If a conventional membrane is used, then key coverage is provided, but the membrane is thick causing poor molding effect and cracking at concave-convex parts
Solution Approach 1:
The invention changes the thickness parameter of the membrane from conventional thick (0.5mm or more) to thin (0.03-0.1mm). This parameter change enables the membrane to be properly molded into concave-convex shapes without cracking, as the thin membrane can flex and conform to complex geometries without the stress concentration that causes cracking in thicker materials.
Solution Approach 2:
The thin membrane structure (0.03-0.1mm thickness) is inherently more flexible and adaptable to complex shapes. This thin film can be molded into precise concave-convex parts with good surface finish and without the cracking defects that plague thicker membranes, achieving excellent manufacturing precision.
3Ease of operation
If a conventional thick membrane is used, then key coverage is achieved, but adjacent concave-convex parts are pulled against each other causing poor handfeel and inaccurate keystroke stroke
Solution Approach 1:
The invention reduces the membrane thickness parameter from conventional thick (0.5mm or more) to thin (0.03-0.1mm). This parameter reduction eliminates the pulling and tension between adjacent concave-convex parts that occurs in thick membranes. The thin membrane responds accurately to key presses without deformation, providing excellent handfeel and precise keystroke registration.
4Duration of action of stationary object
If a conventional membrane surface is used, then key protection is provided, but the surface is not wear-resistant and becomes sticky and dirty over time
Solution Approach 1:
The invention uses a composite material structure with a wear-resistant polyurethane layer (20-80 micrometers thick) as the surface layer and a thermoplastic polyurethane layer as the base layer. This composite structure combines the wear resistance and surface stability of polyurethane with the molding and flexibility properties of thermoplastic materials, creating a durable surface that resists sticking and dirt accumulation over time.
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 membrane is lightweight, thin, and soft, offering excellent elasticity, ductility, and wear resistance, ensuring accurate keystrokes, improved tactile feedback, and enhanced durability against water and dust.
Implementation Method 1
comprising a wear-resistant polyurethane layer and a thermoplastic polyurethane layer
Implementation Method 2
the thermoplastic polyurethane layer... with ductility and elasticity
Data Source
Figure 1~2
Figure 3
Figure 3A
AI summary
A keyboard membrane, which is a thin sheet molded object thermoformed by a thermoplastic wear-resistant molding membrane, comprising a plurality of concave-convex parts, the concave-convex part comprises a plurality of upwardly protruding pressing parts, each of the pressing parts has a top wall and a peripheral wall extending downward from a periphery of the top wall; the keyboard membrane is disposed on a key module with keys; each of the pressing parts is connected with one of the keys of the key module; a periphery of the keyboard membrane has a peripheral edge extending outward from the pressing part, and the peripheral edge wraps the key module to form a waterproof and dustproof keyboard.