BONDED KEYBOARD AND METHOD FOR MAKING THE SAME
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.
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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 INVENTIONThe disclosed embodiments relate generally to electronic devices, and more particularly, to input devices for electronic devices.
BACKGROUND OF THE DISCLOSUREMany 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.
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 DISCLOSUREA 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.
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.
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.
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.
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:
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
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.
Turning now to
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.
Referring to
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.
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.
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.
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.
Reference is now made to
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
It is understood that the order in which the bonded keyboard can vary from that order described above in connection
The described embodiments of the invention are presented for the purpose of illustration and not of limitation.
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.
Type: Application
Filed: Sep 20, 2012
Publication Date: Jun 27, 2013
Applicant: Apple Inc. (Cupertino, CA)
Inventor: Apple Inc. (Cupertino, CA)
Application Number: 13/623,635
International Classification: B41J 5/16 (20060101); H05K 13/00 (20060101);