Nylon Keyboard Enclosure for Harsh Environments
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Solution Overview
Problem
Existing keyboard enclosures for computers in quick serve restaurant environments are prone to damage due to harsh conditions, requiring time-consuming and potentially damaging disassembly for cable installation, and suffer from corrosion and failure of metal dome buttons.
Innovation Solution
A lightweight keyboard enclosure made of injection molded nylon with a secure snap-fit assembly for the PCB, embossed buttons, and a secure cable management system to prevent disconnection, along with a flexible keypad cover for protection and easy mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a two-piece metal enclosure shell is used for the keyboard, then the enclosure provides structural strength and durability, but it becomes heavy and subject to corrosion in harsh kitchen environments
Solution Approach 1:
The patent changes the material parameter from metal to polymer (specifically polycarbonate or similar durable plastic), transforming the enclosure from metal construction to polymer construction. This material substitution eliminates corrosion susceptibility while maintaining structural integrity through carefully engineered wall thicknesses and reinforcement features in the polymer housing.
Solution Approach 2:
The patent employs composite construction by integrating multiple functional elements into the polymer enclosure structure, including integrated cable management features, mounting provisions, and structural reinforcement elements embedded within or attached to the polymer housing. This composite approach achieves metal-like durability without the corrosion problems.
2Strength
If metal dome buttons are used on the keypad membrane, then the buttons provide tactile feedback and durability, but they break apart after repeated presses and cause serial connection failures
Solution Approach 1:
The patent replaces the durable but failure-prone metal dome buttons with inexpensive, simple membrane switches that can be easily replaced. The membrane switch construction uses printed conductive traces on flexible substrate rather than mechanical metal domes, eliminating the breakdown issue while accepting that the entire keypad membrane may need periodic replacement as a low-cost component.
Solution Approach 2:
The patent substitutes the mechanical metal dome button system with an electrical membrane switch system. Instead of relying on mechanical metal dome deformation and contact, the solution uses printed conductive pathways on flexible plastic layers that make electrical contact when pressed, eliminating mechanical wear and breakage of metal components.
3Ease of operation
If the PS/2 cable is installed through a slot in the enclosure shell, then the cable connection is achieved, but disassembly of the two-piece enclosure is required which is time-consuming and can damage the PCB
Solution Approach 1:
The patent incorporates preliminary action by pre-configuring the cable access mechanism during enclosure manufacturing. The cable access feature is built into the enclosure structure before final assembly, allowing cables to be routed through pre-formed openings or channels without requiring disassembly of the enclosure halves. This preliminary structuring eliminates the need for time-consuming disassembly and reassembly operations.
Solution Approach 2:
The patent merges the cable management function directly into the enclosure structure itself. Rather than having separate cable access mechanisms or requiring enclosure disassembly, the cable routing features (such as integrated cable glands, grommets, or molded-in cable channels) are combined with the enclosure housing, allowing cable installation without separating the enclosure halves.
4Strength
If the keyboard enclosure is made of metal, then it provides structural rigidity and protection, but it is heavy and corrodes in harsh kitchen environments
Solution Approach 1:
The patent changes the fundamental material parameter from metal to polymer, specifically selecting high-strength polymers like polycarbonate that offer an favorable strength-to-weight ratio. This material parameter change simultaneously reduces weight while maintaining or improving structural rigidity through the polymer's inherent properties and structural design features.
Solution Approach 2:
The patent may employ segmentation by dividing the enclosure into modular sections or using thin-walled structural panels with strategic reinforcement ribs. This segmentation allows the use of lighter polymer materials while achieving required structural rigidity through distributed reinforcement rather than solid metal construction, reducing overall weight while maintaining strength.
Data Source
AI summary
A keyboard/keyboard enclosure is provided. The keyboard/keyboard enclosure includes front and rear shells removably connected together and made of a polymer material such as Nylon 6. A keypad is positioned on the front surface of the front shell. The rear shell includes a cutout and a removable hatch covering the cutout.