Keyswitch Horizontal Return Mechanism for Thin Profile
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Solution Overview
Problem
Conventional keyboards face limitations in miniaturization due to height requirements for spring or rubber dome return mechanisms, and existing thin keyboards lack tactile and audible feedback, are complex and costly to manufacture, and prone to dust entry and keycap dislodgment.
Innovation Solution
A key assembly using a novel return mechanism with flexible rods and a tapered protrusion on the keycap, where a vertical keypress forces the protrusion to flex the rods horizontally, providing tactile and audible feedback, and a snap-back action for keycap return, reducing height and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spring or rubber dome return mechanisms are used, then the keyboard provides tactile and audible feedback, but the keyboard height increases
Solution Approach 1:
The patent converts the vertical motion of keycap depression into horizontal motion of the flexible rod. When the keycap is pressed downward, the tapered protrusion converts this vertical force into horizontal flexing of the flexible rod, which then snaps back horizontally to propel the keycap upward. This dimensional transformation allows the return mechanism to operate in a different plane, reducing the vertical space required.
Solution Approach 2:
Instead of using a vertical spring or dome that compresses in the same direction as keycap depression, the patent uses a horizontal flexible rod that flexes perpendicular to the keycap motion. The flexible rod is pre-bent and stores energy in a horizontal plane, then releases this energy horizontally to drive the keycap back to its original position, inverting the traditional vertical return mechanism.
2Length of moving object
If scissor mechanism is used for keycap support, then the keyboard achieves thin profile, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent removes the complex scissor mechanism entirely and replaces it with a simplified structure consisting of a support plate with grooves and flexible rods. The flexible rods are simply inserted into grooves in the support plate, eliminating the need for complex interlocking scissor components while maintaining the thin profile through the horizontal flexing action.
Solution Approach 2:
The patent changes the operational parameters of the return mechanism from vertical compression (springs, domes) to horizontal flexing. The flexible rod is designed with specific curvature and material properties that allow it to flex horizontally when subjected to vertical keycap depression, providing the return function with different mechanical parameters that simplify the overall structure.
3Length of moving object
If magnet-based return mechanism is used, then the keyboard achieves thin profile, but the manufacturing cost and complexity increase due to multiple magnets per key
Solution Approach 1:
The patent replaces the magnetic field-based return mechanism with a purely mechanical flexible rod system. Instead of using magnetic attraction and repulsion forces that require precisely positioned magnets in both the keycap and base, the flexible rod uses elastic deformation and snap-back action to provide the return force, eliminating the need for multiple magnets per key and simplifying manufacturing.
Solution Approach 2:
The flexible rod is a simple, inexpensive mechanical component that can be easily manufactured and replaced if needed. Unlike precision-machined magnet assemblies or complex scissor mechanisms, the flexible rod is a simple elastic element that can be produced at low cost through conventional manufacturing methods, making the overall keyboard more cost-effective.
4Length of moving object
If thin keyboard overlay with elastomer keys is used, then the keyboard achieves thin profile, but the tactile feedback is limited and lacks crispness
Solution Approach 1:
The patent uses a tapered protrusion on the keycap that converts vertical depression into horizontal motion of the flexible rod. The curved or tapered geometry of this protrusion is essential for transforming the direction of force, allowing the vertical keypress to effectively flex the horizontal flexible rod, thereby generating the snap-back action that provides crisp tactile feedback.
Solution Approach 2:
The flexible rod's snap-back action creates a rapid mechanical vibration or impact when it propels the keycap back to its original position. This sudden movement generates the crisp tactile sensation and audible click that characterize high-quality mechanical keyboards, replacing the muted, gradual return of elastomer-based overlays with a dynamic, responsive mechanical action.
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
Enables a thin, cost-effective keyboard with enhanced tactile and audible feedback, improved durability, and reduced manufacturing complexity, while maintaining keycap stability and preventing dust entry.
Implementation Method 1
Located within the support plate are two flexible rods position substantially parallel to each other. The underside of the movable keycap has a tapered protrusion position a top of the two flexible rods. The preloaded spring tension between the flexible rods and the movable keycap keeps the movable keycap level within the support plate. A vertical keypress forces the tapered protrusion on the underside of the movable keycap to flex the flexible rods horizontally.
Implementation Method 2
A vertical keypress forces the tapered protrusion on the underside of the movable keycap to flex the flexible rods horizontally. The proportional increased in strength require to further depress the keycap provides the user a resistance feel or pre-actuation cue.
Data Source
AI summary
Described herein are thin keyboard and thin keyboard overlay, as well as novel key assembly for uses on keyboards and keyswitches. The key assembly includes a top plate, a movable keycap, a support plate and flexible rods embedded in the support plate acting as springs. The underside of the movable keycap has at least one or several tapered protrusions which are located above the flexible rods. A vertical downward force on the movable keycap will enable the protrusion to flex the rods horizontally, thus creating a spring like mechanism that will return the movable keycap to its original position once the vertical force is removed.