MXPA06014939A - Thin keypad assemblies and components for electronics devices and methods - Google Patents

Abstract

A keypad assembly, the keypad assembly including a keycap layer 110 having multiple user interface key caps flexibly coupled to a carrier portion, a luminescent layer 120 disposed toward a backside of the plurality of key cap layer, the luminescent layer carrying a plurality of switch domes aligned with a corresponding one of the plurality of key caps of the key cap layer. In some embodiments, a backing material is applied to a backside of the user interface keycaps.

Description

THIN KEYBOARD ASSEMBLIES AND COMPONENTS FOR ELECTRONIC DEVICES AND METHODS FIELD OF THE INVENTION The present disclosure relates generally to input devices, and very specifically to keyboard assemblies and keyboard components, for example, keyboard assemblies and components for use in super-thin applications, e.g., wireless communications devices, and corresponding methods.

BACKGROUND OF THE INVENTION In the past, keyboards in cellular radiotelephone devices have comprised a multiple layer structure having a large part of a piece that is relatively thick, thereby limiting the thinness of the devices in which the keyboard is integrated. Typical keyboards include a user interface that forms the keys accessible to the user, which are often interconnected by means of a network. The keys are aligned on a corresponding contact dust cover mounted on a carrier made of Mylar or some other carrier material. The carrier and boot assembly are placed in a layer of switch contact circuitry. To provide the illumination of the keyboard, a luminescent layer is placed between the dust carrier and the keys. However, the luminescent layer includes cuts through which the piston portions of the keys can have contact with the dust covers to operate the switches in the circuit layer. This configuration lacks luminescence directly below or behind the keys where it is most desired. Instead, the keys are illuminated indirectly by scaed light, part of which emanates from circumferential areas surrounding the keys. The various aspects, features and advantages of the description will be more apparent to those skilled in the art at the time of careful consideration of the following Detailed Description with the accompanying figures described below.

BRIEF DESCRIPTION OF THE FIGURES Figure 1 is an exemplary keyboard assembly. Figure 2 is an exemplary key layer. Figure 3 is another layer of exemplary keys.

Figure 4 is a tab that holds the exemplary key layer. Figure 5 is a part view of an exemplary key layer assembly. Figure 6 is a part diagram of an exemplary contact / luminescent dust cover layer. Figure 7 is an exemplary luminescent layer having color portions. Figure 8 is a sectional view of a portion of an exemplary keyboard assembly. Figure 9 is a sectional sectional view of another exemplary keyboard assembly.

DETAILED DESCRIPTION OF THE INVENTION Figure 1 illustrates a part view of an exemplary keypad assembly 100 generally comprising a user interface key layer assembly 110, a contact dust / luminescent layer 120 assembly and a keyboard circuitry 130 layer. exemplary keyboard assembly 100 and variations thereof, which will be more apparent from the following analysis, have applications in portable electronic devices, for example, calculators, personal organizers, personal digital assistants, wireless and connected communications devices including cell phones, portable computing machines, among other devices. The exemplary key assembly layer 110 generally comprises a key layer having a plurality of user interface keys flexibly coupled to a carrier or carrier portions. Figure 5 illustrates an exemplary key layer 510. In one embodiment, each key is flexibly coupled to the carrier along at least one side of the key, and other remaining sides of the key are separated from other keys and / or Carrier portions through a space, thus allowing the keys to be flexible in response to the user's tactile touch action. In another modality, each of a plurality of user interface keys are coupled to the carrier by means of a flexible carrier portion positioned along no more than one side of the corresponding user interface key, in which other sides of each key of user interfaces are separated from neighboring keys and / or carrier portions by a space. Figure 2 illustrates an exemplary key assembly layer 200 seen from the user interface side thereof. The exemplary keyboard assembly layer 200 includes a plurality of keys, for example, the "7" key 210, the "0" key 212, and the "9" key 214 flexibly coupled by intermediate carrier portions 211 and 213. Figure 2 also illustrates the space between adjacent keys and between keys and carrier potions. For example, there is a space 220 between the key 210 and the key "*" 216. The same space 220 separates the key 216 from the carrier portion 211. In Figure 2, at least some of the plurality of keys and some of the carrier portions form a unitary element, for example, keys 210, 212, 214 and carrier portions 211 and 213. Figure 3 illustrates another exemplary key assembly layer 300 also seen from the user interface side thereof. exemplary key assembly 300 includes a plurality of keys, for example, the "7" key 310, the "0" key 312, and the? 9"key 314 flexibly coupled to intermediate carrier portions 311 and 313. The assembly layer of keys of Figure 3 is distinguished from Figure 2 by means of a carrier portion or portions 316 and 318 along the side sides of the plurality of user interface keys. The exemplary lateral carrier portions 316 and 318 interconnect all rows of keys, for example, the row containing the "1", "5" and "3" keys and the row containing the "4", "8" and "6", thus forming a unitary element comprising the plurality of keys and carrier portions. Figure 3 also illustrates spaces between adjacent keys and between keys and carrier portions. For example, there is a space 320 between the key 310 and the key of the number "4" 322. The space 320 also extends between the key 310 and the carrier portion 316. Figure 5 illustrates a view in parts of an assembly layer. of exemplary keys 500 comprising a key layer 510, and a flexible network 520 applied to the back of the key layer. In one embodiment, the key layer including the plurality of user interface keys flexibly coupled to the carrier is formed from a single sheet material, for example, stainless steel, or aluminum, or phosphor bronze, copper alloy or some other appropriate metallic material. In an exemplary embodiment, the key layer is of SS304 stainless steel quality. In other embodiments, the key layer is formed of a synthetic or composite material with appropriate stiffness and flexibility characteristics. In some embodiments, the plurality of keys is defined by the formation of spaces in a stamping process or in some other process of removal of material, for example, by chemical or laser recording, cutting of high speed fluid, etc. In other modalities, the keys are formed in a molding or casting process or some other manufacturing process. In one embodiment, the key layer is no more than 1.5mm thick, and in an exemplary super slim keyboard application, the key layer is between about 0.2 and about 0.3 mm thick. However, these exemplary ranges are not intended to be limited. Next, other exemplary ranges are analyzed. In Figure 1, the exemplary key assembly layer 110 comprises a plurality of clamping tabs projecting from the side portions of the keyboard layer. Figure 4 is a more detailed view of an exemplary fastening tab 400. The fastening tab 400 includes a first flange 410 extending from a side carrier portion 404 of the key., and a second flange 420 extending from the first flange. The fastening tab is preferably formed unitarily with the keys and the carrier of a single sheet material, although in other embodiments, the fastening tabs may be added through some fastening means. Figure 4 illustrates a curved corner portion 412 between the first flange and the second flange. In some embodiments, the corner portion 412 is formed along a thin portion 414 of the sheet material from which the fastening tab is fabricated. The thin portion 414 facilitates the formation of the corner portion and can be formed by etching or some other process. Figure 4 also illustrates a corner portion 416 between the side carrier portion and the first flange 410. In one embodiment, the corner portion 416 is thin to facilitate bending and provide continuity of an edge portion 402 along the length of the lateral carrier portion 404. Unlike conventional keyboard assemblies that must be installed from inside electronic device housings, the keyboard assemblies comprising the exemplary key layers described herein can be installed from outside the housing of the device , and may be attached to the housing by means of retaining tabs. In some embodiments, the flexible portion of the carrier that flexibly couples the plurality of user interface keys to the carrier portion is relatively thin compared to other portions of the carrier and / or keys. In Figure 3, for example, the carrier portion 330, between the "1" and 5"keys, has a reduced thickness to provide increased flexibility.The amount of thinness of any carrier depends on many factors, including, among others, the thickness and stiffness of the sheet material from which the carrier and keys are formed, desired tactile performance, etc. In one embodiment, the thin carrier portion is formed by etching or by some other material removal process applied to the surface of the sheet material from which the key layer is formed In one embodiment, a flexible network interconnects at least some of the plurality of user interface keys.The flexible network generally saves the space between the plurality of keys of the user interface. user interface and the space between the keys and any carrier portion, for example, the side carrier portions 316 and 318 in Figure 3. The flexible network generally pre it comes that debris enters the space between the keys, and in some modalities, is part of the outer layer of keys. In one embodiment, the flexible network interconnecting the plurality of user interface keys comprises a material different from the material of the user interface keys. In an exemplary embodiment, the flexible network is a resilient material, for example silicone. More generally, in other embodiments, the flexible network may be some other elastomeric material. In one embodiment, the flexible network is formed of a translucent material that allows the emanation of background illumination from the luminescent layer, which is discussed below. The flexible network can be transparent or colored to provide contrast in relation to the keys. In some embodiments, the flexible material is doped with the materials to provide special effects, and / or may be covered with ink or other coloration. Figure 5 illustrates the exemplary key assembly layer 500 comprising the key layer 510 described above, and a flexible network 520 applied to a back side of the key layer. Exemplary flexible network 520 may be molded, for example, injection molded or insert molded or otherwise deposited on the back side of the key layer. In one embodiment, the flexible network material protrudes in the space between the keys and any carrier portion, and in some embodiments, the flexible network forms part of the visible outer layer of the keys. In Figure 5, the exemplary flexible network 520 is fairly applied to the carrier and partially to the keys, leaving portions of keys exposed for the application of another reinforcing material which is discussed below. In other embodiments, the flexible network may be a flexible network film placed on or applied to an outer surface of the key layer. In another alternative embodiment, the flexible network and the plurality of user interface keys comprise a common material that forms the unitary element. According to this alternative embodiment, the flexible network is formed from sheet material from which the key layer is formed. In one embodiment, portions of the flexible network, between the keys and any carrier portion, are formed by reducing the thickness of the portions of the sheet material, for example, by recording. In this embodiment, the removed portion of the sheet material forms the space between the individual keys, and the reduced thickness portion of the sheet material also forms the flexible network that saves the space. In an exemplary key layer assembly, a reinforcement material is placed on the back of the corresponding keys. In some embodiments, the reinforcement material provides rigidity for the keys, particularly in applications where the keys are relatively thin and also in modalities where the key material is not rigid enough to provide the desired tactile performance. In the exemplary embodiment of Figure 5, the reinforcing material portions 530 are placed on the corresponding keys of the key layer 510, for example, the rear portion 502 is applied to the keys 512. In some embodiments, the material of reinforcement is different from the material that constitutes the flexible network. For example, the flexible web may be an elastic or relatively resilient material, and the reinforcing material may be a relatively rigid or hard material. In an exemplary embodiment, the reinforcement material is a TOYOLAC 900 Series material. In some embodiments, the reinforcement material is doped with materials to provide special effects, and / or may be covered with ink or other coloration. In an exemplary application process, the reinforcing material is applied to a back side of a plurality of keys, for example, flexible keys interconnected by means of a carrier portion. In embodiments where multiple user interface keys are flexibly coupled to one or more carrier portions, a flexible network is applied to the back of the key layer. In one embodiment, the flexible network is applied to the back of the key layer. The flexible network can be applied by means of any application process, for example, an insert molding process. In an alternative embodiment, the resilient material is first applied to the key, such that the resilient material forms a wall portion that surrounds the portion of the key where the reinforcing material is desired. The reinforcing material is then applied to the portion of the key surrounded by the wall portion of resilient material, wherein the wall portion of resilient material acts the reinforcing material applied to the key. In another alternative embodiment, the reinforcement material is part of the flexible network placed on the back of the keys. In some embodiments, some or all of the keys have graphics placed thereon to indicate functionality and / or provide other information associated with the corresponding key. The graphic can be printed or marked on the keys. In other embodiments, the embossed or rotogravure graphic is applied to the keys, for example, to a key such as the xx5"key, or to all the keys to provide a tactile interface. Figures 2 and 3 comprise keys that include graph slits, exemplary graph slits include alphanumeric characters and other functional symbols suitable for use in an application of the communications device., the reinforcement material of the key covers or fills the graphic gap. In one embodiment, the reinforcing material is a clear or colored translucent material that allows light to emanate from a luminescent layer, placed under the keys, as will be discussed below. According to a related aspect of the description, the reinforcing material placed in the graphic slit can be used to capture portions of the graph that would otherwise require support structure or be susceptible to displacement. These reproduced graphic portions include, for example, the central portions of the numbers "0", "4", "6", "8" etc. A tactile interface may be formed on some or all of the keys as discussed above, or allowing part of the reinforcing material to protrude through the graphic slot beyond the surface of the key. The tactile interface can also be produced through the process of embossing or rotogravure. According to another process for manufacturing the key layer assembly, the function of the identification key or graphic is recorded on a relatively thin metal sheet, for example, a thickness between 0.2mm and 0.3mm. Next, a hard translucent plastic material is molded to the back of the metal sheet where the keys will be defined. Next, the perimeters of the keys are recorded in the thin sheet. And then the flexible network is formed around the perimeter of the keys, as discussed above. The flexible network allows the keys to move independently, and also prevents the keys from being raised. As a final step, the keys may be subjected to finishing operations to polish the cosmetic surface and / or to remove excessive molding of the key layer material. In Figure 1, the contact / luminescent dust cover layer 120 comprises a luminescent layer, for example, an electro-luminescent layer. In the exemplary embodiment, the luminescent layer functions as a carrier for a formation of switch covers aligned with the corresponding keys of the key layer. Figure 6 is a diagram in parts of an exemplary contact / luminescent dust cover assembly 600. The exemplary assembly comprises a luminescent layer 610. In one embodiment, the luminescent layer 610 is an electro-luminescent layer, e.g., the lamp Flexible electro-luminescent Durel DFLX-665 manufactured by Rogers Corporation, Durel Division, Chandler, Arizona. In other embodiments, the luminescent layer may comprise other luminescent materials. In one embodiment, the luminescent layer is colored or painted to provide color background illumination. In Figure 7, the exemplary luminescent layer includes a green color or dye portion 702 and a red color or dye portion 704. The exemplary green and red portions may be located behind the ON or SEND keys, and OFF or END respectively. In other modes, other colors can be used in these and other keys. Figure 6 also illustrates a layer of adhesive 620, for example, a printed adhesive, which is adhered to one side of the luminescent layer 610. A contact dust cover 630 arrangement is also included with the contact / luminescent dust cover layer. adhered to the luminescent layer 610 by means of the adhesive layer 620 in alignment with the corresponding keys. Alternatively, the dust covers 630 may be adhered to the luminescent layer 610 by discrete amounts of adhesive, without the requirement of the exemplary adhesive layer. In other embodiments, the contact dusters may be coupled to the luminescent layer through other fastening means. Carrying the dust covers in the luminescent layer eliminates the need for a dedicated carrier, for example, the Mylar layer, used in conventional designs. In the exemplary mode, the contact dust guard 630 is adhered to a back part of the luminescent layer 610 by means of the intermediate adhesive layer. In one embodiment, the luminescent layer is a malleable material that fits around the dome surface of the contact boot, thereby ensuring sufficient adhesion with the adhesive layer. In an alternative embodiment, the dust covers may be placed between the luminescent layer and some other layer. The placement of the contact dust covers on the back of the luminescent layer ensures that the light emanates from the luminescent layer directly behind the keys. In an alternative embodiment, the contact dusts are located in a front part of, or on top of the luminescent layer. The use of a clear or translucent contact dust cover will reduce any obstruction, by the dust cover, of light emanating directly from the back of the keys. In the exemplary embodiment, the contact dusters include a connector support 632, which provides good tactile performance by ensuring that the point without protrusions of the dust cover is actuated. In other embodiments, the protrusion may be located within or in the reinforcement material placed on the keys. In alternative embodiments, the luminescent layer includes cutting portions that house the contact seals or portions thereof, thereby reducing the thickness of the assembly resulting from the stacking of the layer. In other embodiments, a conventional carrier layer, for example, a Mylar layer, carries the contact dust covers. The contact dust cover layer is positioned so that the dust covers adhered or otherwise secured to it are aligned with corresponding switches in a layer of keyboard circuitry. In Figure 1, the carrier of the exemplary luminescent layer 120 is positioned so that the plurality of contact dusts, for example, dust covers 122 and 124, positioned thereon, are positioned on the corresponding switches, for example, the switch 132 and 134, in the circuitry layer 130. The assembly resulting from the keypad assembly 110, the contact / luminescent dust cap layer 120 and the circuitry layer provide a relatively compact keyboard assembly having an overall thickness between approximately 1.0 mm and 5.0 mm. In Figure 8, a sectional portion of an exemplary key assembly 800 comprises an exemplary key assembly that incorporates the features described above. The section portion of FIG. 8 corresponds, for example, to a section through the directional cursor controller 230 and the selection key 232 in FIG. 2. A key layer 802 includes a selection key 803 and an input of directional cursor controller 805 corresponding to the selection key 232 and cursor controller 230 of FIG. 2. The exemplary key layer is approximately 0.15mm and includes a surface coating 806, for example, urethane. The selection key includes a chart slit filled with a translucent material 805 to allow light to pass from a backlight source, discussed below. A base film 810, which is preferably transparent, is co-molded between the upper and lower silicone films 812 and 814, respectively. The upper layer of the key is adhered to the base film by a layer of glue 816. A luminescent layer 820 functions as a dust carrier. An exemplary dust cap 822 is located below the key 803. A piston 824 is positioned between the key 803 and dust boot 822. The piston may be part of, or be attached to, the dust boot or the structure opposite the dust boot. The overall thickness of the exemplary keyboard layer is less than about 1.2mm. In Figure 9, another exemplary keyboard assembly 900 comprises a key layer including a first key 902 and a second key 904. A flexible network portion 906 is positioned between the adjacent keys 902 and 904 and other neighboring keys. A reinforcing material 908 is placed on a back side of the key 902 and protrudes through a graphic slit in the key, as illustrated. A piston 912 is formed integrally with the reinforcing material of a contact dust boot under the key 902. A luminescent layer 920 is positioned below the key layer assembly. The exemplary luminescent layer 920 functions as a carrier for contact dusts 922, which are adhered thereto by means of an intermediate adhesive layer 924. as discussed above. The luminescent layer and dust covers are placed on a circuit board 930, which is mounted in a housing 940. Although the present description and the best modes of the inventions have been described in a manner which establish possession thereof by the inventors and allows those skilled in the art to manufacture and use the same, it will be understood and appreciated that there are many equivalent to the exemplary embodiments described herein and that modifications and variations can be made thereto without departing from the scope and spirit of the inventions, they will be limited not by the exemplary modalities, but by the appended claims.

Claims (31)

NOVELTY OF THE INVENTION Having described the present invention, consider as a novelty and, therefore, priority is claimed as contained in the following: CLAIMS

1. - A keyboard, the keyboard comprises: a plurality of user interface keys, the plurality of user interface keys separated by spaces at least on some sides thereof; a carrier portion interconnecting the plurality of user interface keys, the plurality of user interface keys flexibly coupled to the carrier portion, and the plurality of user interface keys and the carrier portion constitute a unitary element; a flexible network that interconnects at least some of the plurality of user interface keys.

2. The keyboard according to claim 1, characterized in that the plurality of user interface keys and the carrier portion are formed of a metal material.

3. - The keyboard according to claim 1, characterized in that the plurality of user interface keys and the carrier portion have a thickness no greater than 1.5 nm.

4. The keyboard according to claim 1, characterized in that: the flexible network and the plurality of user interface keys comprise a common material and form a unitary element, the flexible network has a thickness less than a thickness of the keys of user interface.

5. The keyboard according to claim 1, characterized in that the flexible network interconnecting the plurality of user interface keys comprises an elastic material different from a material of the user interface keys.

6. - The keyboard according to claim 5, characterized in that the flexible network is placed on a back of at least some of the plurality of user interface keys.

7. The keyboard according to claim 5, characterized in that the flexible network is a resilient material, and the unitary element is a metal material.

8. - The keyboard according to claim 1, further comprising a rigid reinforcement material placed on a back of at least some of the plurality of user interface keys.

9. The keyboard according to claim 8, further comprising: the plurality of user interface keys are metallic, the rigid rear side is a plastic material, the flexible network interconnecting the plurality of user interface keys is an elastic material.

10. A keyboard assembly, the keyboard assembly comprising: a plurality of keys flexibly coupled to a carrier portion, the plurality of keys has a user interface side and a back side, the plurality of user interface keys and the carrier portion constitutes a unitary element; a luminescent layer placed in the direction of the back of the plurality of keys, the luminescent layer carrying a plurality of contact dusts, the plurality of contact dials aligned, each, with a corresponding key of the plurality of keys.

11. The keyboard assembly according to claim 10, characterized in that: the luminescent layer carries a plurality of contact dusts placed between the plurality of contact dust covers and the. plurality of keys flexibly coupled to the carrier portion.

12. The keyboard assembly according to claim 11, further comprising a layer of keyboard circuitry, the luminescent layer carries the plurality of contact dust covers placed between the layer of keyboard circuitry and the plurality of keys flexibly coupled to each other. the carrier portion, the plurality of contact dims placed between the keyboard circuitry layer and the luminescent layer.

13. The keyboard assembly according to claim 11, further comprising a resilient material placed in spaces separating the plurality of keys.

14. The keyboard assembly according to claim 11, further comprising a translucent material placed in spaces separating the plurality of keys.

15. - The keyboard assembly according to claim 11, further comprising: a translucent and resilient network interconnecting the plurality of keys.

16. The keyboard assembly according to claim 11, further comprising a reinforcing material placed on a back of at least some of the plurality of keys.

17. - The keyboard assembly according to claim 11, characterized in that at least one of the plurality of keys includes a graphic slit.

18. The keyboard assembly according to claim 17, further comprising the graphic slit covered by a translucent material.

19. A keyboard assembly, the keyboard assembly comprising: a user interface layer that includes a plurality of keys; a luminescent layer placed below the user interface layer, the luminescent layer carrying a plurality of contact dusts on one side thereof, the plurality of contact dials aligned with a corresponding key of the plurality of keys and the user interface layer.

20. - The keyboard assembly according to claim 19, further comprising the luminescent layer placed between the plurality of contact dust covers and the keys of the user interface layer.

21. The keyboard assembly according to claim 19, further comprising: a layer of keyboard circuitry, the luminescent layer placed between the layer of keyboard circuitry and the plurality of keys flexibly coupled to the carrier portion, the plurality of contact dust covers placed between the keyboard circuitry layer and the luminescent layer.

22. - The keyboard assembly according to claim 19, characterized in that a translucent material is placed in spaces that separate the plurality of keys of the user interface layer.

23. - A keyboard, the keyboard comprises: a plurality of user interface keys, the plurality of user interface keys separated by spaces at least on some sides thereof; a carrier portion interconnecting the plurality of user interface keys, a flexible portion of the carrier flexibly coupling each of the plurality of user interface keys to the carrier portion, the flexible carrier portion positioned along no more than one side of the corresponding user interface key, other sides of each of the user interface keys separated from the neighboring keys by a space, the plurality of user interface keys and the carrier portion forming a unitary element.

24. - The keyboard according to claim 23, characterized in that the unitary element is a metal material of not more than 1.5 mm in thickness.

25. - The keyboard according to claim 23, characterized in that the keys are flexibly coupled to the carrier portion along relatively thin portions of the unit element.

26.- The keyboard according to claim 23, characterized in that a resilient material saves the space between the keys and the carrier, the resilient material more flexible than the flexible portion of the carrier.

27. A method for making a keyboard, the method comprising: forming a plurality of user interface keys flexibly coupled to a carrier from a single sheet material; save the space between the plurality of user interface keys with a resilient material.

28. The method according to claim 27, further comprising applying a reinforcement material to a back of the user interface keys before saving the space between the plurality of user interface keys with the resilient material.

29. The method according to claim 28, further comprising capturing the reinforcement material applied to the back of the user interface keys with the resilient material that saves the space between the plurality of user interface keys.

30. The method according to claim 28, which further comprises forming a graphic slit in at least one of the user interface keys, covering the graphic slit with the reinforcing material.

31. The method according to claim 30, further comprising capturing a portion of the user interface keyboard located within the slit with the reinforcement material. 32.- A method for making a keyboard, the method comprises: applying a resilient material to a layer of keys comprising a plurality of user interface keys flexibly coupled to the carrier portions; applying a reinforcing material to a rear portion of the plurality of user interface keys; Capture the reinforcement material applied to the back of the user interface keys with the resilient material. The method according to claim 32, further comprising: applying the resilient material to the key so that a portion of the key is surrounded by a wall portion of resilient material, applying the reinforcing material to the portion of the key surrounded by a wall portion of resilient material, capture the reinforcement material applied to the back of the user interface keys with the wall portion of resilient material. 34.- The method according to claim 32, characterized in that the application of the resilient material to the key layer includes applying the resilient material to spaces between the user interface keys.

35. - The method according to claim 32, further comprising forming the plurality of user interface keys flexibly coupled to the carrier from a unitary metal sheet material.