Modular Keyboard Keystone Assembly for Automated Disassembly

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Solution Overview

Problem

Conventional portable information handling systems are difficult to break down efficiently for recycling and reuse, due to their complex designs and reliance on screws, which hinder automated disassembly and increase costs associated with material separation.

Innovation Solution

A modular keyboard design for portable information handling systems that couples components without screws, using a single keystone assembly for automated assembly and disassembly, and incorporating a keyboard membrane with integrated sensors and a printed circuit board to eliminate internal cables.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional portable information handling systems use screws to assemble components, then the system structure is robust and stable, but the system becomes difficult to break down for recycling and reuse

Engineering Contradiction:

Improvesystem structure stabilityVSAvoiddisassembly efficiency

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The keyboard is divided into separate modular components: a keyboard assembly with keys and a separate lattice structure. These modules can be easily detached from each other and from the housing, enabling efficient disassembly for recycling while maintaining structural integrity during use through precise geometric interlocking.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces traditional mechanical screw-fastening systems with a geometric interlocking mechanism based on complementary shapes (protrusions and recesses). This substitution eliminates screws entirely, allowing components to be securely assembled through shape-matching while enabling tool-free disassembly by reversing the insertion motion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If conventional designs use dozens of screws to assemble components, then the system is robust, but the cost of breakdown for recycling exceeds the value of reusable materials

Engineering Contradiction:

Improvesystem robustnessVSAvoidrecycling value

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent extracts and eliminates all screws and cable connectors from the system architecture. Components are designed to interface through direct geometric coupling, removing the need for fastening hardware and electrical cable assemblies. This extraction simplifies the system to its essential functional connections, making disassembly trivial and preserving maximum material value for recycling.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The keyboard membrane, key switches, and lattice structure are merged into an integrated modular assembly that functions as a single replaceable unit. This merging eliminates the need for multiple separate fasteners and connectors, reducing the number of disassembly steps and maximizing the recoverable value of the integrated component package.

Inventive Principle:

Principle #5Merging (Combining)

3Volume of moving object

If conventional portable systems use specialized housing arrangements with screws, then the system optimizes interior space usage, but the system becomes difficult to break down at end-of-life

Engineering Contradiction:

Improveinterior housing space utilizationVSAvoidsystem breakdown ease

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The housing and components are segmented into standardized modules with uniform geometric interfaces. This segmentation allows tight packing and optimal space utilization while ensuring that each module can be independently removed and reconfigured, facilitating easy breakdown and potential reuse in different system configurations.

Inventive Principle:

Principle #1Segmentation

4Manufacturing precision

If conventional designs use cables and connectors of different lengths and types, then the components interface correctly within the housing, but reuse of components in new use models becomes difficult

Engineering Contradiction:

Improvecomponent interface precisionVSAvoidcomponent reuse adaptability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent implements universal geometric interfaces that can accommodate multiple component types and configurations. The standardized protrusion-recess coupling mechanism works across different component sizes and functions, allowing precise interfacing while enabling the same interface standard to serve multiple purposes and component variants, thus facilitating reuse in diverse applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12223119B2Portable information handling system modular keyboard having removable lattice and keys

Publication Date: 2025.02.11 DELL PROD LP

AI summary

A portable information handling system is assembled and disassembled by a keystone assembly that couples at an upper surface of the portable housing to overlap a keyboard assembly that covers processing components disposed in the portable housing. The keyboard assembly includes a membrane having plural input sensors, each aligned with a key assembly having a key cap coupled with a scissors to a holder plate, the holder plate configured to couple to a coupling extension extending up from a housing cover upper surface. A flexible planar sheet couples between the membrane and plural keys so that a lifting force applied to the flexible planar sheet separates the plural keys from the housing cover.