U.S. patent application number 13/623635 was filed with the patent office on 2013-06-27 for bonded keyboard and method for making the same.
This patent application is currently assigned to Apple Inc.. The applicant listed for this patent is Apple Inc.. Invention is credited to John M. Brock, Keith J. Hendren, Craig C. Leong, James J. Niu.
Application Number | 20130164068 13/623635 |
Document ID | / |
Family ID | 47505358 |
Filed Date | 2013-06-27 |
United States Patent
Application |
20130164068 |
Kind Code |
A1 |
Leong; Craig C. ; et
al. |
June 27, 2013 |
BONDED KEYBOARD AND METHOD FOR MAKING THE SAME
Abstract
A bonded keyboard and method for making the same are disclosed.
The bonded keyboard uses adhesive as the primary agent, and in some
embodiments, as the sole agent for coupling various components of
the keyboard stackup together. The keyboard stackup uses a skeletal
adhesive to couple a top case to a backcase assembly. In one
embodiment, the skeletal adhesive is an interconnected matrix of
ribs dimensioned to fit within the spacing existing between
adjacent keys, which are mounted on the backcase assembly. The
skeletal adhesive is fixed to the backcase assembly, occupies a
portion of the spacing that exists between keys, and the top case
is fixed to the top of the skeletal adhesive.
Inventors: |
Leong; Craig C.; (San Jose,
CA) ; Niu; James J.; (San Jose, CA) ; Brock;
John M.; (San Francisco, CA) ; Hendren; Keith J.;
(San Francisco, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Apple Inc.; |
Cupertino |
CA |
US |
|
|
Assignee: |
Apple Inc.
Cupertino
CA
|
Family ID: |
47505358 |
Appl. No.: |
13/623635 |
Filed: |
September 20, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61578687 |
Dec 21, 2011 |
|
|
|
Current U.S.
Class: |
400/496 ;
29/592.1 |
Current CPC
Class: |
H01H 2219/062 20130101;
Y10T 29/49105 20150115; H01H 13/88 20130101; H03K 17/98 20130101;
H01H 2227/01 20130101; H01H 2209/064 20130101; H01H 2229/028
20130101; H01H 2219/036 20130101; H01H 13/7065 20130101; H01H 3/125
20130101; H01H 13/023 20130101; H01H 13/703 20130101; Y10T 29/49002
20150115; H01H 2211/004 20130101 |
Class at
Publication: |
400/496 ;
29/592.1 |
International
Class: |
B41J 5/16 20060101
B41J005/16; H05K 13/00 20060101 H05K013/00 |
Claims
1. A bonded keyboard, comprising: a backcase assembly including a
feature plate, an adhesive layer and a membrane, the membrane
bonded to the feature plate with the adhesive layer; a plurality of
keys mounted on the backcase assembly and arranged in a
predetermined configuration such that spacing exists between
adjacent keys, the keys including outer keys that a define a
periphery; a skeletal double sided adhesive layer secured to the
backcase assembly and constructed to occupy a portion of the
spacing and a portion of the periphery; and a top case secured to
the skeletal double sided adhesive.
2. The keyboard of claim 1, wherein the skeletal adhesive layer
comprises a plurality of interconnected skeletal ribs.
3. The keyboard of claim 2, wherein a first portion of the skeletal
ribs has a first predetermined thickness and a second portion of
the skeletal ribs has a second predetermined thickness.
4. The keyboard of claim 1, wherein the skeletal adhesive layer
surrounds each one of the keys.
5. The keyboard of claim 1, wherein the skeletal adhesive layer
surrounds select groups of the keys.
6. The keyboard of claim 1, wherein the skeletal double sided
adhesive comprises a one-piece carrier.
7. The keyboard of claim 1, wherein skeletal double sided adhesive
has a thickness ranging between about 0.005 to 0.1 mm.
8. The keyboard of claim 1, wherein the skeletal double sided
adhesive does not interface with any of the keys.
9. The keyboard of claim 10, wherein the top case mimics the shape
of the skeletal double sided adhesive.
10. The keyboard of claim 1, further comprising at least one
fastener that couples the backcase assembly to the top case.
11. The keyboard of claim 2, wherein the top case comprises top
case skeletal ribs, wherein a thickness of the top case skeletal
ribs is at least as thick as a thickness of the skeletal ribs of
the skeletal adhesive.
12. A computing device, comprising: a bonded keyboard comprising: a
backcase assembly having top and bottom surfaces; a plurality of
keys mounted to the top surface of the backcase assembly, the keys
arranged such that spacing exists between adjacent keys; a skeletal
double sided adhesive layer mounted to the top surface of the
backcase assembly, the adhesive constructed to surround each key by
occupying a portion of the spacing existing between adjacent keys;
and a top case including a skeletal structure secured to the
adhesive layer.
13. The keyboard of claim 12, wherein the keys include outer keys,
and wherein the adhesive layer occupies a portion of a periphery
surrounding the outer keys.
14. The keyboard of claim 12, wherein each key has first and second
edges, wherein a minimum gap distance exist between edges and an
edge of the skeletal adhesive.
15. The keyboard of claim 12, wherein the backcase assembly is
operative to detect key strokes.
16. The keyboard of claim 12, further comprising fasteners to
couple the backcase assembly to the top case.
17. A method for assembling a keyboard, the method comprising:
mounting a plurality of keys to a backcase assembly; applying a
skeletal double sided adhesive layer to the backcase assembly, the
skeletal adhesive layer surrounding at least one of the keys; and
securing a top plate to the backcase assembly via the skeletal
adhesive, the top plate constructed to mimic construction of the
skeletal adhesive layer.
18. The method of claim 17, wherein the backcase assembly comprises
a feature plate, adhesive layer, and a membrane, the method further
comprising: securing the membrane to the feature plate with the
adhesive layer.
19. The method of claim 17, further comprising: using at least one
fastener to secure the top case to the back case assembly.
20. The method of claim 17, wherein the keys are arranged in a
predetermined configuration having a periphery defined by outer
keys and spacing exists between the outer keys and adjacent inner
keys and between adjacent inner keys, and the skeletal double
adhesive occupies a portion of the spacing and a portion of the
periphery.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/578,687, filed Dec. 21, 2011, the disclosure of
which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The disclosed embodiments relate generally to electronic
devices, and more particularly, to input devices for electronic
devices.
BACKGROUND OF THE DISCLOSURE
[0003] Many electronic devices typically include one or more input
devices such as keyboards, touchpads, mice, or touchscreens to
enable a user to interact with the device. These devices can be
integrated into an electronic device or can stand alone as discrete
devices that can transmit signals to another device either via
wired or wireless connection. For example, a keyboard can be
integrated into the housing of a laptop computer or it can exist in
its own housing.
[0004] It is often desirable to reduce the size of electronic
devices and minimize machining costs and manufacturing time of such
devices. For example, laptops may be designed to be as small and
light as possible, but input devices such as a keyboard may occupy
relatively large portions of the available interior space.
Accordingly, what is needed is an improved keyboard design.
SUMMARY OF THE DISCLOSURE
[0005] A bonded keyboard and method for making the same are
disclosed. The bonded keyboard uses adhesive as the primary agent,
and in some embodiments, as the sole agent for coupling various
components of the keyboard stackup together. The keyboard stackup
uses a skeletal adhesive to couple a top case to a backcase
assembly. In one embodiment, the skeletal adhesive is an
interconnected matrix of ribs dimensioned to fit within the spacing
existing between adjacent keys, which are mounted on the backcase
assembly. The skeletal adhesive is fixed to the backcase assembly,
occupies a portion of the spacing that exists between keys, and the
top case is fixed to the top of the skeletal adhesive.
[0006] In one embodiment, a bonded keyboard can include a backcase
assembly and several of keys mounted on the backcase assembly and
arranged in a predetermined configuration such that spacing exists
between adjacent keys. The keys can include outer keys that a
define a periphery. The backcase assembly can include a feature
plate, an adhesive layer and a membrane, the membrane bonded to the
feature plate with the adhesive layer. The keyboard also includes a
skeletal double sided adhesive layer secured to the backcase
assembly and constructed to occupy a portion of the spacing and a
portion of the periphery and a top case secured to the skeletal
double sided adhesive.
[0007] In another embodiment, a computing device has a bonded
keyboard including a backcase assembly having top and bottom
surfaces, several keys mounted to the top surface of the backcase
assembly, the keys arranged such that spacing exists between
adjacent keys, a skeletal double sided adhesive layer mounted to
the top surface of the backcase assembly, the adhesive constructed
to surround each key by occupying a portion of the spacing existing
between adjacent keys, and a top case including a skeletal
structure secured to the adhesive layer.
[0008] In another embodiment, a method for assembling a keyboard
includes mounting a plurality of keys to a backcase assembly,
applying a skeletal double sided adhesive layer to the backcase
assembly, the skeletal adhesive layer surrounding at least one of
the keys, and securing a top plate to the backcase assembly via the
skeletal adhesive, the top plate constructed to mimic construction
of the skeletal adhesive layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The above and other aspects and advantages of the invention
will become more apparent upon consideration of the following
detailed description, taken in conjunction with accompanying
drawings, in which like reference characters refer to like parts
throughout, and in which:
[0010] FIG. 1 shows an illustrative exploded view of bonded
keyboard 100 in accordance with an embodiment;
[0011] FIG. 2 shows a simplified top view of a feature plate n
accordance with an embodiment;
[0012] FIG. 3 shows a simplified illustrative top view of adhesive
layer 120 in accordance with an embodiment;
[0013] FIG. 4 shows a simplified illustrative top view of membrane
in accordance with an embodiment;
[0014] FIG. 5 shows a simplified top view of skeletal double sided
adhesive layer in accordance with an embodiment;
[0015] FIG. 6 shows an illustrative top view of top case in
accordance with an embodiment;
[0016] FIG. 7 shows an illustrative perspective view of a section
of keyboard including a key in accordance with an embodiment;
[0017] FIG. 8 is an illustrative cross-sectional view of the
keyboard of FIG. 7 in accordance with an embodiment;
[0018] FIG. 9 is an alternative illustrative cross-sectional view
of FIG. 7 in accordance with an embodiment;
[0019] FIG. 10 shows an illustrative top view of a section of a
keyboard in accordance with an embodiment;
[0020] FIG. 11 shows a perspective view of a computing device
having a keyboard incorporated therein in accordance with an
embodiment; and
[0021] FIG. 12 shows an illustrative flowchart for making a bonded
keyboard according to an embodiment.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0022] FIG. 1 shows an illustrative exploded view of bonded
keyboard 100 in accordance with an embodiment. Keyboard 100 is a
stackup (shown as stackup 102) of several components that are
connected together. Stackup 102 can include feature plate 110,
adhesive layer 120, membrane 130, keys 140, skeletal double sided
adhesive layer 150, and top case 160. Illustrative top views of
each component are shown in FIGS. 2-6. When keyboard 100 is
assembled, feature plate 110 may form the bottom of the stackup,
top case 160 forms the top of the stackup, and the other components
are sandwiched therebetween. In other embodiments, a backlight (not
shown) may form the bottom of the stackup, as it can be mounted
under feature plate 110. In yet another embodiment, a backlight can
be positioned between feature plate 110 and membrane 130. In a
further embodiment, a backlight can be integrated with feature
plate 110.
[0023] The components of keyboard 100 can be held together
primarily or exclusively with bonding, with minimal or no use of
fasteners. Bonding is achieved by adhesive layers 120 and 150.
Fasteners (not shown in FIGS. 1-6) assist in holding keyboard 100
together by coupling feature plate 110 to topcase 160. FIGS. 2-6
show fastener through-holes 170 through which fasteners are
inserted. A more detailed discussion of fasteners is discussed
below with reference to FIG. 10.
[0024] Adhesive layer 120 bonds feature plate 110 to the bottom
surface of membrane 130 and adhesive layer 150 bonds topcase 160 to
the top surface of membrane 130. Each one of keys 140 has a
mechanism (not shown) that secures it to membrane 130 and/or
feature plate 110. Using adhesive layers 120 and 150 as the primary
bonding agent simplifies construction of the stackup, reduces cost,
reduces thickness of the keyboard, minimizes or completely
eliminates use of fasteners, and enhances water proofing. An
additional benefit realized with the bonded keyboard is a reduction
of vibrations compared to contemporary keyboards built with a
substantial number of fasteners.
[0025] Turning now to FIGS. 2-6, each component of stackup 102 is
discussed in more detail. FIG. 2 shows a simplified top view of
feature plate 110. Feature plate 110 may form a bottom of stack 102
and may be operably connected to keys 140. For example, feature
plate 110 can include contacts (not shown) for conducting
electrical signals. As another example, feature plate 110 can
include anchoring points (not shown) for securing keys 140. Feature
plate 110 can optionally include fastener through-holes 170, as
shown. Through-holes 170 may be positioned on the periphery and in
a few locations of the interior portion of feature plate 110. The
number of through-holes 170 located in the interior portion is
substantially limited. This is in direct contrast to contemporary
keyboards, which have such through-holes distributed in substantial
numbers throughout the interior portion.
[0026] FIG. 3 shows a simplified illustrative top view of adhesive
layer 120. Adhesive layer 120 can be any suitable double sided
adhesive. For example, adhesive 120 can be a pressure sensitive
adhesive or a heat activated adhesive. In one embodiment, adhesive
120 can have a PET substrate with adhesive affixed on both sides.
Adhesive 120 can have a thickness ranging between 0.02 mm to 0.1
mm, or more particularly, between 0.03 mm to 0.05 mm. Adhesive
layer 120 can optionally include fastener through-holes 170. The
position of through-holes can align with through-holes 170 of
feature plate 110.
[0027] FIG. 4 shows a simplified illustrative top view of membrane
130. Membrane 130 can be sensing membrane that includes one or more
sensors (not shown) for detecting whether any of keys 140 have been
selected by a user. The sensors can be made from indium tin oxide
(ITO), for example. Membrane 130 can optionally include fastener
through-holes 170. The position of through-holes can align with
through-holes 170 of feature plate 110 and adhesive layer 120.
[0028] The collective combination of feature plate 110, adhesive
layer 120, and membrane 130 may be referred to herein as a backcase
assembly. The backcase assembly can be a sub-assembly made prior to
final assembly of keyboard 100.
[0029] Referring to FIG. 1, keys 140 can be any suitable keys for
use in a keyboard. Keys may, for example, use a scissor-based
support mechanism that couples a key cap to membrane 130 and/or
feature plate 110. The keys can be arranged in a predetermined
configuration of outer keys 141 that form a periphery and inner
keys 142 that exist within the periphery. Spacing exists between
all the keys.
[0030] FIG. 5 shows a simplified top view of skeletal double sided
adhesive layer 150. Adhesive layer 150 can be any suitable double
sided adhesive such as, for example, a pressure sensitive adhesive
or a heat activated adhesive. In other embodiments, adhesive layer
150 can be screen printed or pad printed, and can use wet or UV
curing. In one embodiment, adhesive 150 can have a PET substrate
with adhesive affixed on both sides. Adhesive 150 can have a
thickness ranging between 0.005 mm to 0.1 mm, or more particularly,
between 0.03 mm to 0.05 mm.
[0031] Adhesive layer 150 can optionally include fastener
through-holes 170. The position of through-holes can align with
through-holes 170 of feature plate 110, adhesive layer 120, and
membrane 130.
[0032] In one embodiment, as shown, the skeletal configuration of
adhesive layer 150--an interconnected series of skeletal ribs
154--is designed to surround each one of keys 140. That is,
adhesive layer 150 is dimensioned to fit into the spacing that
exists between each key. The thickness of the skeletal ribs can be
uniform or can vary. For example, the thickness of adhesive layer
150 between adjacent keys 140 (such as between regions 151 and 152)
can be a first predetermined thickness and the thickness of the
periphery of adhesive layer 150 (such as the region outside of
regions 151) can be a second predetermined thickness, where the
first predetermined thickness is greater than the second
predetermined thickness.
[0033] In another embodiment, not shown, the skeletal configuration
of adhesive layer 150 can be designed to selectively surround keys.
For example, as opposed to surrounding each key individually, layer
150 can surround a group of two or more keys. As a specific
example, if two keys are surrounded, no skeletal rib would exist
between the adjacent keys.
[0034] FIG. 6 shows an illustrative top view of top case 160. Top
case 160 can be part of an electronic device such as a laptop or it
can be part of a stand alone electronic device such as a wired
keyboard. Top case 160 includes skeletal ribs 164 dimensioned to
fit within the spacing between keys 140. The same spacing
uniformity or variance of the skeletal ribs discussed above in
connection with adhesive layer 150 applies to top case 160. Top
case 160 can also include an outer periphery region dimensioned to
surround keys 140. Top case 160 can optionally include fastener
through-holes 170. The position of through-holes can align with
through-holes 170 of feature plate 110, adhesive layer 120,
membrane 130, and adhesive layer 150.
[0035] Both adhesive 150 and top case 160 have structures that
mimic each other. This promotes a relatively strong bond between
the backcase and top case 160 because the shape of skeletal
adhesive 150 maximizes bonding adhesion between the two. Thus, this
can eliminate or substantially reduce the use of fasteners to
couple the keyboard stackup together.
[0036] Reference is now made to FIGS. 7-10 to show spatial
relationships of various components as they are stacked up to form
keyboard 100. FIG. 7 shows an illustrative perspective view of a
section of keyboard 100 including a key 140. FIG. 7 also shows the
stackup of feature plate 110, adhesive layer 120, membrane 130, and
adhesive layer 150.
[0037] FIG. 8 is an illustrative cross-sectional view of keyboard
100 taken along line 8-8 of FIG. 7. This cross-sectional view shows
that gaps 810 exist between the edges of key 140 and top case 160.
Gaps 810 ensures that key 140 travels freely without interference
from top case 160. Gaps 810 may be equidistant or different on both
sides of key 140. In addition, gaps 820 exist between skeletal
adhesive layer 150 and the edge of key 140. Gap 820 ensures key 140
travels freely and does not get stuck to the adhesive.
[0038] Skeletal rib 861 of top case 860 has width, Wtp, as shown,
and skeletal rib 851 of adhesive layer 850 has width, Wa, as shown.
The width of skeletal rib 861 can be at least the same width of
skeletal rib 851 or greater. Such sizing ensures that adhesive
layer 150 cannot be seen, even after top case 160 has been applied
thereto. The sizing also accounts for differences in manufacturing
and assembly tolerances. As shown in FIG. 8, skeletal rib 861
overhangs both sides of skeletal rib 851. It is understood that rib
861 need not overhang rib 851 in this fashion. In another
embodiment, rib 861 may overhang one side of rib 851, but both ribs
851 and 861 are substantially aligned at the other side.
[0039] FIG. 9 is an alternative illustrative cross-sectional view
taken along line 8-8 of FIG. 7. In FIG. 9, fastener 910 is shown
coupling feature plate 110 to top plate 160 by passing through
feature plate 110, adhesive layer 120, membrane 130, adhesive 150,
and top plate 160. In particular, fastener can pass through
fastener through-holes 170 of each component. Fastener 910 can be
any suitable mechanism for coupling objects together. For example,
fastener 910 can be a screw or pin.
[0040] FIG. 10 shows an illustrative top view of a section of a
keyboard in accordance with an embodiment. Several buttons 140 are
shown positioned in apertures of top case 160. Skeletal adhesive
150, shown with dotted lines, surrounds the apertures of top case
160. As discussed above, adhesive 150 is dimensioned such that top
case 160 completely covers adhesive 150.
[0041] FIG. 11 shows a perspective view of a computing device 1100
having a keyboard 1102 incorporated therein. Computing device 1100
can be any suitable computing device, such as, for example, a
laptop computer, a desktop computer, a telephone, smart phone, or
gaming device. Keyboard 1102 can be integrally formed within
computing device 1100. In other embodiments, a keyboard according
to an embodiment can be separate from the computing device and can
stand alone as a self-contained device. For example, a keyboard may
be a communication interface such as, for example, a wired keyboard
or a wireless keyboard that can transmit data to and from a
computing device.
[0042] FIG. 12 shows an illustrative flowchart for making a bonded
keyboard according to an embodiment. Starting at step 1210, a
plurality of keys are mounted to a backcase assembly. For example,
the keys can keys 140 discussed above in connection with FIGS.
1-10, and the backcase assembly can include a feature plate,
adhesive, and a sensor membrane. At step 1220, a skeletal
double-sided adhesive layer can be applied to the backcase
assembly. The skeletal adhesive layer can surround at least one of
the keys. For example, the skeletal adhesive can be skeletal
adhesive 150 shown in FIGS. 1, 5, 8, and 10. At step 1230, a top
plate is secured to the backcase assembly via the skeletal
adhesive. The top plate is constructed to mimic construction of the
skeletal adhesive layer such that when it is applied to the top of
skeletal adhesive, a strong adhesive bond is formed and the
adhesive layer if fully covered by the top case.
[0043] It is understood that the order in which the bonded keyboard
can vary from that order described above in connection FIG. 12. The
bonded keyboard can be constructed using any approach. For example,
the skeletal adhesive can be applied to the top plate first, and
the combination can then be applied to the backcase assembly.
[0044] The described embodiments of the invention are presented for
the purpose of illustration and not of limitation.
* * * * *