Membrane-Sealed Keyboard Structure for Spill and Dust Protection
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Solution Overview
Problem
Conventional keyboards are vulnerable to contaminants like dust and liquids, which can damage internal electronics and obstruct key movement, and they often have design issues such as misaligned keycaps and noisy visual appearance due to manufacturing tolerances.
Innovation Solution
A keyboard design featuring a flexible membrane that covers the electronics unit and key structures, providing a waterproof and spill-proof surface, with a composite membrane combining mesh and elastomeric materials for toughness and fluid resistance, and aligning features to ensure proper keycap alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If keys are spaced apart to provide key definition, then key definition is improved, but liquid and particles can pass through gaps into the keyboard
Solution Approach 1:
A flexible membrane material is positioned between the keycaps and the internal components, extending across the entire keyboard surface including between keys. This membrane acts as a barrier that prevents liquids and particles from passing through the gaps between keys while maintaining the spaced-apart key configuration for proper key definition.
2Shape
If keys are spaced apart to provide key definition, then key definition is improved, but solid contaminants can lodge under keys and obstruct movement
Solution Approach 1:
The flexible membrane creates a continuous barrier surface that prevents solid contaminants like dust, dirt, and food crumbs from lodging under the keys. The membrane extends across the entire keyboard surface, blocking the pathways that would otherwise allow contaminants to reach internal components while preserving key spacing for proper definition.
3Ease of operation
If separate switches and domes support each keycap, then key movement is enabled, but manufacturing tolerances cause misalignment and noisy visual appearance
Solution Approach 1:
The flexible membrane serves as a unified support structure that underlies all keycaps simultaneously. By having the membrane extend continuously across the keyboard and provide support to multiple keycaps, the system reduces the cumulative effect of manufacturing tolerances on keycap alignment, creating a more visually consistent appearance while still allowing individual key movement through membrane flexibility.
4Ease of operation
If conventional keyboard structures are used, then key movement is enabled, but internal electronics are vulnerable to damage from contaminants
Solution Approach 1:
The flexible membrane acts as a protective barrier that prevents contaminants from reaching internal electronics while allowing key movement. The membrane is positioned between the keycaps and the internal components including electronics, creating a sealed environment that protects vulnerable electronics from liquid ingress and contaminant exposure.
5Object-affected harmful factors
If a continuous membrane surface is used, then contaminant ingress is prevented, but key definition may be reduced
Solution Approach 1:
The flexible membrane is configured to extend across the entire keyboard surface, creating a continuous barrier that prevents contaminant ingress. The membrane's flexibility allows it to conform to the key structure while maintaining continuity, and the membrane can be positioned or designed to maintain visual key definition through its interaction with the keycap structures.
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 flexible membrane effectively prevents contaminant ingress, maintains a smooth and consistent visual appearance, reduces noise, and enhances key definition while protecting internal components from damage.
Implementation Method 1
A flexible membrane extends over the electronics unit and over the upper surface, with the flexible membrane being attached to the downward-facing wall of the housing
Implementation Method 2
The flexible membrane effectively prevents contaminant ingress, maintains a smooth and consistent visual appearance, reduces noise, and enhances key definition while protecting internal components from damage
Implementation Method 3
a composite membrane combining mesh and elastomeric materials for toughness and fluid resistance
Implementation Method 4
the sidewall or bottom wall can have a vent passage connecting the internal cavity to an external atmosphere surrounding the housing, with the vent passage being configured to redirect external water away from the electronics unit
Data Source
AI summary
Keyboards and other input devices are provided with at least one flexible layer that extends over or under the keycaps. The flexible layer spans interkey spaces and lies between inner and outer keycaps. The flexible layer prevents intrusion of invasive material to the keyboard mechanisms and simplifies the appearance of the keyboard area. Some flexible layers help align keycaps by connecting inner and outer keycaps or by providing a mechanical connection interface for the keycaps. Some membranes used in the flexible layer have a layered or composite construction that increases durability and tear resistance by attaching or infusing a mesh material or other tough material to a less durable, elastic material.