Sealed Key Assembly Using Elastic Frame Compression
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Solution Overview
Problem
Existing key designs lack waterproof and dustproof functions, leading to component damage and increased manufacturing costs due to the use of two-color injection molding processes.
Innovation Solution
A key device design featuring a housing, soft material layer, and key component with an elastic frame that squeezes a soft packing ring, eliminating the need for two-color injection molding by integrating waterproof and dustproof features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-color injection molding process is used to directly inject TPU and other elastomers into a rigid housing, then waterproof and dustproof functions are achieved, but manufacturing cost increases due to higher die cost
Solution Approach 1:
The patent divides the key device into separate components: a rigid housing, a soft material layer, and a key component with elastic frame. This segmentation allows each component to be manufactured independently using standard single-color injection molding, eliminating the need for expensive two-color dies while maintaining waterproof functionality through the layered structure
Solution Approach 2:
The patent uses composite material construction by combining a rigid housing material with a soft material layer (TPU or other elastomers) and an elastic frame. This composite approach achieves both waterproof performance and cost-effectiveness by utilizing the properties of different materials in separate, independently manufactured components
2Reliability
If a two-color injection molding process is used to form keys, then waterproof function is achieved, but device complexity increases due to process burden
Solution Approach 1:
The key device is segmented into multiple independently manufactured components (housing, soft material layer, key component) that are assembled together. This simplifies the manufacturing process by eliminating complex two-color injection molding while achieving waterproof functionality through the layered assembly structure
Solution Approach 2:
The soft material layer and key component are prepared separately in advance with pre-formed structures (such as pre-formed elastic frames and soft packing rings). This preliminary preparation simplifies the final assembly process and eliminates the need for complex multi-material injection molding operations
3Reliability
If keys are formed by two-color injection molding, then waterproof design is achieved, but key flexibility decreases making keys hard and inflexible
Solution Approach 1:
The patent applies local quality by using a soft material layer (TPU or elastomer) specifically at the key contact areas and elastic frame portions that require flexibility, while the housing remains rigid. This localized softness provides both waterproof sealing and comfortable flexible key operation
Solution Approach 2:
The key device combines rigid housing material with soft elastomeric materials (TPU or other elastomers) in the key component and soft material layer. This composite construction provides both the structural integrity needed for waterproofing and the local flexibility required for comfortable key operation
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
Provides effective waterproof and dustproof protection while reducing manufacturing costs by avoiding the use of two-color injection molding, enhancing user comfort with flexible key components.
Implementation Method 1
The elastic frame is connected with the key body and squeezes the soft material layer
Data Source
AI summary
The disclosure provides a key device including a housing, a soft material layer, and a key component. The housing has at least one first assembly hole. The soft material layer is disposed on the housing and has at least one second assembly hole. The key component includes at least one key body and an elastic frame. The key body is exposed to the housing through the second assembly hole and the first assembly hole correspondingly. The elastic frame is connected with the key body and squeezes the soft material layer. The key device of the disclosure has waterproof and dustproof functions and may effectively reduce the cost.