Patent Publication Number: US-10325733-B2

Title: Key button and method of manufacturing the same

Description:
PRIORITY 
     This application claims priority under 35 U.S.C. § 119(a) to a Korean Patent Application filed in the Korean Intellectual Property Office on Jul. 26, 2013 and assigned Serial No. 10-2013-0088512, the entire disclosure of which is incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Disclosure 
     The present disclosure generally relates to a key button, and more particularly, to a key button and a method of manufacturing the same. 
     2. Description of the Related Art 
     Recently, a touch screen device, for simultaneously performing input and output, has been used as a data input and output means in an electronic device. The touch screen device may display an input button of a switch type on its display screen. If a user touches a displayed switch, the touch screen device receives corresponding data. 
     In addition to the above-described data input means of a software type, the electronic device may perform functions, such as a function for providing a sense of touch to the user, a power on/off function, a function for performing conversion to its wake-up mode or its sleep mode, a function for adjusting volume, a function for quickly jumping from a current page to a predetermined basic page, etc. In order to perform these functions, the electronic device may have at least one physical key button to be operated by the user. 
     A part of this physical key button, for example, a part of a key top, is installed in a key hole formed in a case frame of the electronic device to protrude from the case frame. The key button is a mechanical type key for pressing a switching means installed in the electronic device by an actuator which protrudes in a direction from the key top to an internal side of the electronic device. 
     This switching means electrically connects with a circuit board installed in the electronic device. The switching means is disposed in a pressing range of the above-described actuator and performs a switching operation selectively by a pressing operation of the actuator. Accordingly, a metal dome, for selectively connecting carbon contacts, is mainly used as the switching means. This metal dome provides a sense of a click to the user as well as a switching function when being pressed by the actuator. 
     The key button used in this physical key button device is installed such that at least a part of it protrudes from the case frame of the electronic device. A soft touch of the protruding key button as well as excellent aesthetics is important to the marketability and competitiveness of the electronic device. 
     Therefore, it is considerably important to design the key button to have the excellent aesthetic value as well as a soft touch in the electronic device. 
     SUMMARY OF THE INVENTION 
     An aspect of the present disclosure is to solve at least the above-mentioned problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present disclosure is to provide a key button and a method of manufacturing the same. 
     Another aspect of the present disclosure is to provide a key button having an excellent aesthetic value and a soft touch and a method of manufacturing the same. 
     Another aspect of the present disclosure is to provide a key button having an excellent aesthetic value and a soft touch while keeping a conventional working method and a method of manufacturing the same. 
     Another aspect of the present disclosure is to provide a key button having an excellent aesthetic value and a soft touch without a separate additional working procedure and a method of manufacturing the same. 
     In accordance with an aspect of the present disclosure, a key button is provided. The key button includes an upper surface, a side surface formed at a certain height along a border of the upper surface, and at least two worked surfaces formed to have a certain slope in a boundary portion between the side surface and the upper surface, wherein at least one first worked surface and at least one second worked surface are formed such that a shortest distance between the upper surface and the side surface differs from each other. 
     In accordance with another aspect of the present disclosure, an electronic device is provided. The electronic device includes a case frame and at least one key button installed in the case frame such that a part thereof is exposed at a portion of the case frame, wherein at least the one key button includes an upper surface, a side surface formed at a certain height along a border of the upper surface, and at least two worked surfaces formed to have a certain slope in a boundary portion between the side surface and the upper surface, and wherein at least one first worked surface and at least one second worked surface are formed such that a shortest distance between the upper surface and the side surface differs from each other. 
     In accordance with another aspect of the present disclosure, a method of manufacturing a key button is provided. The method includes preparing a basic material including an upper surface, and a side surface formed at a certain height along a border of the upper surface, forming at least two worked surfaces by working the key button using a working tool to have a certain slope along a boundary portion between the side surface and the upper surface of the prepared basic material, and adjusting an amount of offset of the working tool such that a shortest distance between the upper surface and the side surface of at least one first worked surface and at least one second worked surface while forming at least the two worked surfaces are different from each other. 
     In accordance with another aspect of the present disclosure, an electronic device is provided. The electronic device includes a case frame and a longitudinal key button installed in the case frame such that a part thereof is exposed at a portion of the case frame, wherein the longitudinal key button includes an upper surface, a side surface formed at a certain height along a border of the upper surface, a pair of first worked surfaces formed between the side surface and the upper surface to have a certain slope in positions which are opposite to each other in a longitudinal direction of the longitudinal key button, and a pair of second worked surfaces formed between the side surface and the upper surface to have a certain slope in positions which are opposite to each other in a width direction of the longitudinal key button, and wherein a shortest distance between the upper surface and the side surface of the pair of first worked surfaces is formed to be greater than that of a shortest distance of the pair of second worked surfaces. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects, features and advantages of certain embodiments of the present disclosure will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a perspective view of an electronic device having a key button according to an embodiment of the present disclosure; 
         FIG. 2  is a detailed perspective view of a key button according to an embodiment of the present disclosure; 
         FIG. 3  is a plan view of a key button according to an embodiment of the present disclosure; 
         FIGS. 4A and 4B  illustrate a method of working a basic material by a tool according to another embodiment of the present disclosure; 
         FIG. 5  illustrates a worked key button applied to a case frame according to an embodiment of the present disclosure; 
         FIG. 6  illustrates a worked key button applied to a case frame according to another embodiment of the present disclosure; 
         FIG. 7  illustrates a worked key button applied to a case frame according to another embodiment of the present disclosure; 
         FIG. 8  illustrates a worked key button applied to a case frame according to another embodiment of the present disclosure; and 
         FIG. 9  illustrates a worked key button applied to a case frame according to another embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE PRESENT INVENTION 
     Embodiments of the present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the disclosure in unnecessary detail. 
     In explaining various embodiments of the present disclosure, a description will be given for an electronic device, including a touch screen device, in which a key button is installed to be exposed to the outside at a certain place of its external surface. However, the electronic device may be, but is not limited to, any electronic device, such as a Personal Digital Assistant (PDA), a laptop computer, a mobile phone, a smart phone, a netbook, a Mobile Internet Device (MID), a Ultra Mobile Personal Computer (UMPC), a tablet PC, a navigation device, a Moving Picture Experts Group (MPEG) layer 3 (MP3) player, and the like, each including at least one key button whose part as a data input means is installed in a case frame to protrude from the case frame. 
     In explaining various embodiments of the present disclosure, the electronic device may also include a general device in addition to the key button used as the data input means. Also, the electronic device may have a structure of a key button shape which is not a data input means and is installed to protrude to the outside. 
       FIG. 1  is a perspective view of an electronic device for providing a key button according to an embodiment of the present disclosure. 
     Referring to  FIG. 1 , the electronic device  100  has a case frame  101  which forms its appearance. A display module  102  is installed on a front surface of the electronic device  100 . The display module  102  may be a touch screen device, in which a touch panel and a Liquid Crystal Display (LCD) module are installed together, for simultaneously performing data input and output. A speaker device  103  may be installed on the display module  102 . A microphone device  104  may be installed at a lower side of the display module  102 . 
     In accordance with an embodiment of the present disclosure, a key button  10  may be installed at a side surface of the case frame  101  of the electronic device  100 . The key button  10  is installed such that a part is exposed to the outside and protrudes from the case frame  101 . The key button  10  may be used, for example, as a volume key button of the electronic device  100 , or as a key button for mode conversion for performing conversion to a sleep mode or a wake-up mode of the electronic device  100 . The key button  10  may also be applied to a home button  105  disposed in a front surface of the electronic device  100 , or may be disposed in various regions of the electronic device, such as shown by a circular dotted line in  FIG. 1 . 
     In accordance with one embodiment of the present disclosure, although a part of this key button  10  is exposed to the outside of the electronic device  100 , the key button  10  is configured not only to have an excellent aesthetic value, but also to prevent the user from feeling any sharpness to this end when touching the key button  10 . A corner of the key button  10  (including a side surface) does not protrude in principle from the case frame  101 . During manufacture, the corners of the key button  10  protrude equally from the case frame  101 , and an amount of offset by a working tool is increased to reduce an amount of protrusion of a narrow width interval of the corners and side surfaces of the key button  10 . 
     Hereinafter, a description will be given for a method of shaping and working the key button  10  according to an embodiment of the present disclosure. 
       FIG. 2  is a detailed perspective view of a key button according to one embodiment of the present disclosure. 
     Referring to  FIGS. 1 and 2 , the key button  10  includes an upper surface  12  having a certain size and a side surface  11  formed to provide a certain height along a border of the upper surface  12 . Worked surfaces  13  to  16 , each of them having a certain slope, are beveled to remove sharpness of the corner portions where the upper surface  12  contacts with the side surface  11 . 
     In an embodiment of the present disclosure, the key button  10  has a certain length. The worked surfaces  13  to  16  include the first worked surface  13  formed in a longitudinal direction of the key button  10  and the second worked surface  14  formed opposite to the first working surface  13 . The worked surfaces  13  to  16  include the third worked surface  15  and the fourth worked surface  16  which are formed in a width direction at opposite ends of the key button  10 . A worked surface with which the side surface  11  and the upper surface  12  of the key button  10  come in contact is formed to have a closed curve for closing the upper surface  12  by continuously forming the first closed surface  13 , the second closed surface  14 , the third closed surface  15 , and the fourth worked surface  16 . The third worked surface  15  and the fourth worked surface  16  which are formed in the width direction of the key button  10  are formed as a shape curved in a direction to the outside. Accordingly, a width portion of the upper surface  12  and a width portion of the side surface  11  which are extended from the third worked surface  15  and the fourth worked surface  16  have a natural curved shape. 
     In one embodiment of the present disclosure, the key button  10  includes a first portion  151  which is a point ending in a direction to one end of the first worked surface  13  where the curve shape of the third worked surface  15  starts. The key button also includes a second portion  152  which is a point where the curved shape of the third worked surface  15  ends and the second worked surface  14  starts. The key button  10  also includes a third portion  161  which is a point ending in a direction at the other end of the first worked surface  13 , in which the curved shape of the fourth worked surface  16  starts, and a fourth portion  162  which is a point in which the curved shape of the fourth worked surface  16  ends and the second worked surface  14  starts. 
     In the embodiment of the present disclosure, a portion curved in a width direction of the key button  10  provides a relatively sharp sense of touch to a user in comparison with a longitudinal direction of the key button  10 . The bigger a portion exposed from the case frame  101  among side surfaces of the key button  10  is, the greater a relative sharp sense of touch is provided to the user. 
     In the embodiment of the present disclosure, a portion having a relatively narrow width of the key button  10  (or a side portion having a greater amount of exposure from the case frame  101 ) is formed as a worked surface having a shortest distance. The shortest distance has a worked surface which is longer than those of other worked surfaces by increasing an amount of offset in a direction to the inside of a closed curve formed by the worked surfaces and working the portion when processing the portion using a working tool. 
     The “shortest distance” means the shortest distance of the worked surface between the upper surface  12  and the side surface  11  of the key button  10 . 
     During forming of the worked surfaces, although an amount of offset of the working tool may change, because the key button  10  is moved in only a horizontal direction (x direction), the shortest distance of the worked surface may change but a slope does not changed. 
     The third worked surface  15  and the fourth worked surface  16  which have a relative narrow width have a greater shortest distance than the shortest distance of the first worked surface  13  and the second worked surface  14  by increasing an amount of offset by the working tool. A portion where an amount of offset of the key button  10  is increased may remove sharpness felt by the user because an exposed portion of the side surface  11  of the key button  10  installed in the case frame  101  is reduced. 
     In an embodiment of the present disclosure, the key button  10  is formed of metal materials. In this case, worked surfaces are formed using a separate working tool. A description will be given for a working method using the working tool below. 
     In an embodiment of the present disclosure, the key button  10  is formed of plastic materials. In this case, the key button  10  is formed by an injection method using a metal die which is formed where an amount of offset of a worked surface in which the side surface  11  of the key button  10  has a greater exposure from the case frame  101 , and/the worked surface has a relatively narrow width. 
     In another embodiment of the present disclosure, the key button  10  may also be formed of glass materials. 
       FIG. 3  is a plan view of a key button according to an embodiment of the present disclosure. 
     Referring to  FIGS. 2 and 3 , the first to fourth worked surfaces  13  to  16  for connecting a longitudinal direction L with a width direction W of the key button  10  are formed. The first worked surface  13  and the second worked surface  14  are formed in the longitudinal direction (L direction). The third worked surface  15  and the fourth worked surface  16  are formed in the width direction (W direction). The first worked surface  13 , the second worked surface  14 , the third worked surface  15 , and the fourth worked surface  16  connect to each other and form a closed curve. In this case, the third worked surface  15  and the fourth worked surface  16  which have a relatively narrow width and are formed as a curved shape towards the outside are formed so that the shortest distance d is increased. A feeling of sharpness may be removed by increasing this shortest distance. A degree of exposure of the side surface  11  may be reduced from the case frame  101 . 
     In accordance with one embodiment of the present disclosure, the third worked surface  15  is formed by increasing an amount of offset by a working tool, and may be defined as a portion which is converted from the longitudinal direction to the width direction of the key button  10 . That is, the third worked surface  15  is defined from the first portion  151 , which is here the first worked surface  13  transitions to the third worked surface  15 , to the second portion  152  which is where the third worked surface  15  transitions to the second worked surface  14 . The fourth worked surface  16  is also formed by increasing an amount of offset by the working tool, and may be also defined as a portion which is converted from the longitudinal direction to the width direction of the key button  10 . That is, the fourth worked surface  16  is defined from the third portion  161 , which is where the first worked surface  13  transitions to the fourth worked surface  16 , to the fourth portion  162  which is where the fourth worked surface  16  transitions to the second worked surface  14 . 
     In accordance with an embodiment of the present disclosure, the third worked surface  15 , from the first portion  151  to the second portion  152 , is worked by an amount of offset which is greater than that of the first worked surface  13 , and has an equal shortest distance along its entire surface. The third worked surface  15  alternatively may also have the shortest distance which is worked by a variable amount of offset, such as being gradually increased, gradually decreased, or gradually decreased after being gradually increased. 
     The fourth worked surface  16 , from the third portion  161  to the fourth portion  162 , also has an amount of offset which is greater than that of the first worked surface  13 , and has an equal shortest distance worked along its entire surface. The fourth worked surface  16  alternatively may also have the shortest distance which is worked by a variable amount of offset, such as being gradually increased, gradually decreased, or gradually decreased after being gradually increased. 
     In accordance with one embodiment of the present disclosure, the shortest distance formed according to an increased amount of offset may be formed to be symmetric or asymmetric in a horizontal or vertical direction. 
       FIGS. 4A and 4B  illustrate a method of working a basic material by a working tool according to an embodiment of the present disclosure. 
     Referring to  FIG. 4A , a contact surface  21  of a working tool  20  for cutting a basic material  40  may be implemented as a straight line type. In accordance with an embodiment of the present disclosure, the basic material  40  may be a metal or glass material and may include an upper surface and a side surface which has a certain height along a border of the upper surface. A portion with which the upper surface and the side surface come in contact may be implemented as a sharp corner shape. The contact surface  21  of the working tool  20  comes in contact with this corner to form the above-described worked surface. 
     In accordance with an embodiment of the present disclosure, the working tool  20  may be moved in only a horizontal direction (X-axis direction), without being moved in a vertical direction. An additional process for moving a working tool in a Z-axis may be implemented using a separate working device for separate three-dimensional working. However, a key button in which an amount of offset is increased in a corresponding worked surface, to be identical to a three-dimensional working method, may be obtained by the present disclosure as the working tool  20  is moved in an X-axis direction. 
     Referring to  FIG. 4B , a contact surface  31  of a working tool  30  for cutting a basic material  40  may be implemented as a curve shape. In this case, also, the working tool  30  is moved in only an X-axis direction. A key button may be worked by increasing an amount of offset in a corresponding worked surface of the key button. 
     In accordance with one embodiment of the present disclosure, when a contact surface of the working tool  20  is a straight line, a worked surface of a key button may be formed as a plane. When a contact surface of the working tool  30  is a curved shape curved in the center direction of the working tool  30 , a worked surface of a key button may be formed as a curved surface which protrudes upwardly. 
       FIGS. 5 to 9  illustrate a worked key button applied to a case frame according to various embodiments of the present disclosure. 
     Referring to  FIGS. 2 and 5 , the key button  10  is worked by increasing an amount of offset of a working tool from the first portion  151  to the second portion  152 , thus increasing the shortest distance. In accordance with one embodiment of the present disclosure, a contact surface of the working tool is formed as a straight line. Accordingly, the third worked surface  15  is formed as a plane. When this key button  10  is mounted on the case frame  101 , it may be formed to have the same shortest distance from the first portion  151  to the second portion  152  of the third worked surface  15  irrespective of an amount of exposure of the side surface  11  of the key button  10 , which is exposed from the case frame  101 . The key button  10  has the same shortest distance from the first portion  151  to the second portion  152  through a portion denoted by dotted circle A. In this case, there is no difference in the shortest distance, although a degree in which the side surface  11  of the key button  10  is exposed from the case frame  101  differs. 
     Referring to  FIGS. 2 and 6 , the key button  10  is worked by increasing an amount of offset of a working tool from the first portion  151  to the second portion  152  of the third worked surface  15 , thus increasing the shortest distance. In accordance with one embodiment of the present disclosure, a contact surface of the working tool is formed as a curved shape. Accordingly, the third worked surface  15  is formed to have a curved surface which protrudes upwardly. An amount of offset of the working tool is increased more in a portion denoted by dotted circle B portion and the key button  10  is worked while increasing an amount of offset of the working tool and working the key button  10 . An exposure distance d1 of the portion B which is at the center portion of the side surface  11  of the key button  10  is less than a corresponding portion of  FIG. 5  from the case frame  101 . A sharp sense of touch may be removed by minimizing this exposure of the side surface  11  of the key button  10 . 
     Referring to  FIGS. 2 and 7 , the key button  10  is worked by increasing an amount of offset of a working tool from the first portion  151  to the second portion  152  of the third worked surface  15 , thus increasing the shortest distance. In accordance with one embodiment of the present disclosure, a contact surface of the working tool is formed as a curved shape. Accordingly, the third worked surface  15  is formed to have a curved surface which protrudes upwardly. The shortest distance of the third worked surface  15  is changed by asymmetrically adjusting an amount of offset of the working tool to be different from the above-described embodiments. The shortest distance is increased by increasing an amount of offset of the working tool for a portion denoted by the dotted circle C of  FIG. 7 , which is a side portion and the most exposed portion from the case frame  101  of the key button  10 . Accordingly, as shown in  FIG. 7 , the side surface  11  of the portion C of the key button  10  is relatively less exposed at distance d2 than a corresponding portion of  FIG. 6  from the case frame  101 . 
     Referring to  FIGS. 2 and 8 , the key button  10  is installed in a boundary portion between two case frames  101  and  107 . In this case, because a portion denoted by the dotted circle D, which is the boundary portion between the two case frames  101  and  107  among side surfaces of the key button  10 , is relatively more exposed, a feeling of sharpness may be felt by a user. Accordingly, when working the key button  10  using a working tool with a straight line, the shortest distance may be increased by increasing an amount of offset in the portion D. Therefore, the side surface  11  of the key button  10  worked by increasing an amount of offset in the D portion D is relatively less exposed than a corresponding portion of the key button  10  when working the key button  10  by a same amount of offset. For this reason, a soft sense of touch is provided by the user in the corresponding portion. 
     Referring to  FIGS. 2 and 9 , the key button  10  is installed in a boundary portion between two case frames  101  and  107 . In this case, because a portion denoted by the dotted circle E, which is the boundary portion between the two case frames  101  and  107  among side surfaces of the key button  10 , is relatively more exposed, a feeling of sharpness may be felt by a user. Accordingly, when working the key button  10  using a working tool, the shortest distance may be increased by increasing an amount of offset in the portion E. A contact surface of the working tool is formed as a curved shape in  FIG. 9  in comparison with the contact surface of the working tool having a straight line in  FIG. 8 . Accordingly, in common with  FIG. 8 , although a same amount of offset by the working tool is applied to the portion E, the side surface  11  of the key button  10  is formed so as to not be more exposed than a corresponding portion of  FIG. 8 . 
     In accordance with various embodiments of the present disclosure, an amount of offset by the working tool may be changed according to a degree in which the side surface (corner) of the key button protrudes from the case frame. An amount of offset by the working tool may be increased in a portion which has a greater amount of protrusion in which the side surface of the key button protrudes from the case frame. 
     In accordance with various embodiments of the present disclosure, when the side surface (corner) of the key button has a same amount of offset, an amount of offset of an interval having a narrow external shape of the key button may be increased. 
     In accordance with various embodiments of the present disclosure, the electronic device provides an excellent aesthetic value and a soft touch to the user by removing a protruding sharp portion of the key button without a separate additional procedure. 
     While the present disclosure has been particularly shown and described with reference to certain embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present disclosure as defined by the appended claims.