Keypad Switch Composite Seat and Plastic Cap Design
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Solution Overview
Problem
Conventional keyswitch devices face high manufacturing costs and increased height due to the need for thick plastic or metal components, with plastic requiring iron lamination and metal requiring costly injection molding.
Innovation Solution
A keyswitch device with a supporting seat made of metal by stamping and a key cap of injection molded plastic, featuring a unique configuration with confining members and hooks to restrict horizontal movement and allow vertical movement, utilizing an elastic member to generate signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick plastic components are used to maintain required strength, then structural strength is improved, but manufacturing cost and overall height increase
Solution Approach 1:
The supporting seat combines plastic and iron materials to create a composite structure. The plastic base board provides the main structural form while the iron sheet laminate reinforces specific areas (bottom side and engaging parts) to achieve required strength with reduced overall thickness, thereby reducing the overall height of the keyswitch device while maintaining structural integrity
Solution Approach 2:
Instead of making the entire plastic component uniformly thick, the iron sheet is laminated only on the bottom side and specific engaging parts of the supporting seat where additional strength is needed. This localized reinforcement approach reduces overall material usage and height while maintaining required strength at critical locations
2Strength
If iron lamination is applied to plastic supporting seat to increase strength, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The iron sheet is laminated only on the bottom side and specific engaging parts of the plastic supporting seat rather than the entire component. This localized approach provides necessary strength reinforcement at critical areas while minimizing material usage and manufacturing complexity, thereby reducing overall manufacturing cost compared to full lamination or using solid metal components
3Strength
If metal supporting seat and key cap are made by injection molding, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The supporting seat uses a composite construction with a plastic base board and iron sheet laminate, while the key cap uses injection molded plastic with embedded metal reinforcing ribs. This composite approach achieves required structural strength through material combination and geometric reinforcement rather than using solid metal components, significantly reducing manufacturing cost while maintaining adequate strength
Solution Approach 2:
The supporting seat is divided into a plastic base board component and a separate iron sheet laminate component that are combined through lamination. This segmentation allows each material to be manufactured optimally (plastic by injection molding, iron by stamping) and then assembled, reducing overall manufacturing cost compared to creating a single solid metal component
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 results in a compact, stable, and cost-effective keyswitch device with reduced height and manufacturing costs while maintaining required strength and stability.
Implementation Method 1
an elastic member located between the key cap and the circuit board... When the key cap is moved downward, the elastic member deforms to press the circuit board so as to generate a corresponding signal
Data Source
AI summary
A keyswitch device includes a supporting seat, a key cap, a circuit board disposed on the supporting seat, and an elastic member located between the key cap and the circuit board. The supporting seat includes a base board and two first confining members that are formed on the base board and that are spaced apart from each other. The key cap includes a cap body and two first hooks that engage respectively the first confining members, thereby inhibiting the key cap to move in horizontal directions with respect to the supporting seat, and allowing the key cap to move vertically in a range equal to the height of the first blocking parts of the first confining members. When the key cap is moved downward, the elastic member deforms to press the circuit board so as to generate a corresponding signal.