Metal Wire Scissor Mechanism for Compact Keyboard Button Assembly
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Solution Overview
Problem
Conventional keyboard button structures face high mold costs, time-consuming assembly, and structural weaknesses due to plastic materials, which hinder compact design requirements.
Innovation Solution
A button structure comprising a key cap, first and second supporting members made from metal or flexible materials with bending portions, and an elastomer, allowing for cross-connected movements to support the key cap and reduce assembly complexity and weight, while maintaining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plastic scissor structure is used, then button structure can be assembled, but mold cost is high and assembly process is time-consuming
Solution Approach 1:
The patent combines two separate plastic stands and their connecting axes into a single metal wire structure. The metal wire is bent to form both supporting legs and the connecting pivot points in one continuous piece, eliminating the need for separate molding and assembly of multiple components. This merging of parts directly reduces assembly time and eliminates mold costs while maintaining the scissor mechanism's functionality.
Solution Approach 2:
The metal wire serves multiple functions simultaneously: it provides structural support, acts as the scissor mechanism linkage, and forms the pivot connection points through its bent sections. This multi-functional design replaces what would traditionally require separate components (support structures, linkages, and pivot joints), simplifying manufacturing and assembly while reducing overall part count.
2Strength
If plastic material is used for scissor structure, then assembly is simple, but strength is inadequate and thickness must be increased
Solution Approach 1:
The patent changes the material parameter from plastic to metal wire, fundamentally altering the strength-to-thickness ratio. Metal wire provides superior tensile and bending strength compared to plastic, allowing the structure to achieve the same or higher strength levels with significantly reduced thickness. This material parameter change enables thinner, more compact button structures without compromising structural integrity.
Solution Approach 2:
The invention creates a composite structure by combining metal wire with an elastomer. The metal wire provides rigid structural support and leverage, while the elastomer adds flexibility and shock absorption. This composite approach allows the use of thinner metal wire than would be required for a purely rigid structure, as the elastomer compensates for stress and prevents brittle failure.
3Volume of moving object
If plastic scissor structure is used, then manufacturing is straightforward, but overall button height increases affecting compact design
Solution Approach 1:
By merging the supporting legs and pivot connections into a single bent metal wire, the patent eliminates the need for separate plastic components and their associated molding operations. This consolidation reduces the overall height of the button structure by removing unnecessary material and simplifying the stack-up, while the manufacturing complexity is reduced through the use of simple wire bending operations instead of multi-step molding and assembly processes.
4Reliability
If conventional scissor structure with short axis is used, then assembly is possible, but the axis easily breaks during assembly
Solution Approach 1:
The patent eliminates the separate short axis component by integrating the pivot function directly into the bent sections of the continuous metal wire. The wire is bent to form loops or hooks that naturally serve as pivot points, removing the weak connection point that would otherwise require a separate axis. This integration dramatically improves reliability by eliminating the failure point while simplifying the assembly process to require only wire forming operations.
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 simplifies assembly, reduces mold costs, and achieves a compact design by using lightweight, high-strength materials that prevent horizontal wavering and uneven stress, enhancing the overall structure's durability and aesthetics.
Implementation Method 1
The elastomer is located below the key cap and supports the key cap. The key cap is able to move up and down through operations of the first supporting member, the second supporting member and the elastomer.
Implementation Method 2
The first supporting member has a first bending portion and a second bending portion. The second supporting member has a third bending portion and a fourth bending portion.
Data Source
AI summary
A button structure includes a key cap, a first supporting member, a second supporting member, an elastomer and a base plate. The first supporting member has a first bending portion and a second bending portion. The second supporting member is cross-connected with the first supporting member. The second supporting member has a third bending portion and a fourth bending portion. The third bending portion passes through the first bending portion and abuts an inside of the first bending portion. The second bending portion passes through the fourth bending portion and abuts an inside of the fourth bending portion. The elastomer below the key cap supports the key cap. The base plate is for supporting the first supporting member, the second supporting member and the elastomer. The key cap is able to move up and down through operations of the first supporting member, the second supporting member and the elastomer.