Flexible Circuit Waterproof Keyboard With Sealed Air Chambers

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Solution Overview

Problem

Conventional human interface devices, such as keyboards, are vulnerable to liquid and solid particle exposure, leading to malfunction and destruction, and fail to withstand disinfection and extreme temperatures, posing health risks due to contamination and infection concerns.

Innovation Solution

A waterproof keyboard design featuring a flexible circuit with multiple sealed air chambers and a hermetically sealed housing, eliminating the need for external vents and using biaxially-oriented polyethylene terephthalate layers and an adhesive tape layer to create a fully sealed environment, along with a controller for visual indicators and a magnetic connector plug for sealing the connection port.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional keyboard designs are used, then tactile feedback and switch operation are achieved, but the device is vulnerable to liquid damage and contamination

Engineering Contradiction:

Improveliquid resistanceVSAvoidliquid exposure vulnerability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a flexible circuit board enclosed within a sealed membrane structure that allows key actuation while preventing liquid ingress. The membrane acts as a flexible barrier that maintains tactile feedback functionality while providing waterproof protection, directly resolving the contradiction between reliability and liquid exposure vulnerability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The keyboard is divided into sealed segments or chambers, with each key switch area isolated by the membrane structure. This segmentation prevents liquid from reaching the electrical components while maintaining the tactile feedback mechanism, addressing the reliability issue without compromising the harmful factor resistance.

Inventive Principle:

Principle #1Segmentation

2Reliability

If conventional keyboard structures are used, then key actuation and tactile feedback are provided, but the device cannot withstand harsh cleaning agents and disinfection

Engineering Contradiction:

Improvesanitization resistanceVSAvoidcleaning agent exposure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sealed membrane enclosure protects the internal electronics from harsh cleaning agents and disinfectants. The membrane structure allows the keyboard to be sanitized without exposing vulnerable components, enabling reliable operation after repeated exposure to harsh chemicals.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The membrane structure can be replaced if degraded, providing a cost-effective solution for maintaining sanitization resistance. This approach allows the keyboard to withstand repeated disinfection cycles while maintaining reliability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If sealed waterproof structure is implemented, then liquid resistance is improved, but tactile feedback and switch operation may be compromised

Engineering Contradiction:

Improvewaterproof capabilityVSAvoidtactile feedback quality

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The flexible membrane is specifically designed to transmit tactile feedback forces from key actuation to the user's fingers while maintaining the waterproof seal. The membrane's flexibility and elastic properties allow it to deform during key press and return to its original shape, providing tactile feedback without compromising waterproof capability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The membrane structure dynamically responds to key actuation forces, deforming during press and recovering afterward. This dynamic behavior maintains both the sealed waterproof structure and the tactile feedback mechanism, resolving the contradiction between waterproof capability and ease of operation.

Inventive Principle:

Principle #15Dynamics

4Ease of operation

If vented structure is used for key operation, then tactile feedback is maintained, but liquid ingress is enabled

Engineering Contradiction:

Improvekey actuation functionalityVSAvoidliquid protection

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The flexible membrane replaces the need for vents or openings in traditional keyboards. It provides a continuous sealed barrier that allows key actuation through its elastic deformation while completely preventing liquid ingress, eliminating the need for any openings that would compromise waterproofing.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentEP4379764A1Waterproof keyboard with flexible keyboard circuit and related methods

Publication Date: 2024.06.05 SEAL SHIELD LLC

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AI summary

A waterproof keyboard includes a housing having keyboard buttons, and a flexible keyboard circuit carried within the housing. The flexible keyboard circuit includes a first polymer layer, and an electrically conductive material layer on the first polymer layer to define switches and connections. The switches are aligned with the keyboard buttons. The flexible keyboard circuit also includes a second polymer layer over the first polymer layer and the electrically conductive material layer, and an adhesive layer between the first polymer layer and the second polymer layer and defining sealed air chambers. Subsets of the switches are respectively within the sealed air chambers. The waterproof keyboard also includes a controller to be coupled to the flexible keyboard circuit.