PATENT DOCUMENT

Publication Number: US-10796863-B2
Application Number: US-201514826590-A
Country: US
Kind Code: B2

Title: Fabric keyboard

Abstract:
An input device, such as a keyboard, includes one or more keys that each includes a keycap operable to move within an aperture of a frame to activate a switch and fabric disposed over the frame and keycap. A first region of the fabric is bonded to the keycap and a second region of the fabric is bonded to the frame. The first region may be an embossed region and the second region may be an unembossed region. The fabric may dampen sound from within the keyboard, such as noise related to movement of the keycap, activation of the switch, and so on. The fabric may also form a barrier that restricts passage of contaminants into the aperture and/or other portions of the input device.

Claims:
We claim: 
     
       1. An input device, comprising:
 a frame defining an aperture and a frame flange extending from the aperture; 
 a keycap within the aperture and operable to move with respect to the frame, the keycap comprising a top surface projecting above the aperture and a keycap flange laterally extending from the keycap and operable to contact the frame flange to block movement of the keycap relative to the aperture; 
 a switch positioned under the keycap; and 
 a fabric disposed over the frame and the keycap and comprising:
 a first region bonded to the top surface of the keycap using adhesive; 
 a second region bonded to the frame using adhesive; and 
 a set of sidewalls connected to the first region and the second region, the set of sidewalls having a height less than a total distance between the top surface and the keycap flange of the keycap; 
 
 wherein the set of sidewalls extends downward beneath the frame and upward along a side of the keycap when the keycap is not traveling to permit the keycap to travel without stretching the fabric or exerting force on the keycap. 
 
     
     
       2. The input device of  claim 1 , wherein
 the fabric further includes a set of embossed regions; and 
 the second region is between adjacent embossed regions of the set of embossed regions. 
 
     
     
       3. The input device of  claim 1 , wherein the keycap flange is configured to engage an inner surface of the frame flange when the keycap is unactuated. 
     
     
       4. The input device of  claim 1 , wherein the set of sidewalls surround the keycap. 
     
     
       5. The input device of  claim 1 , wherein at least one embossed region further comprises a rounded corner connecting the first region with the set of sidewalls. 
     
     
       6. The input device of  claim 1 , wherein the height of the set of sidewalls corresponds to a travel distance of the keycap. 
     
     
       7. The input device of  claim 1 , wherein the keycap flange contacts the frame to restrict lateral movement of the keycap with respect to the switch. 
     
     
       8. The input device of  claim 1 , wherein the switch biases the keycap upwards. 
     
     
       9. The input device of  claim 1 , further comprising:
 an illuminator positioned under the fabric; wherein 
 the fabric allows passage of light from the illuminator. 
 
     
     
       10. The input device of  claim 9 , wherein:
 the first region includes a legend; and 
 the light from the illuminator illuminates the legend. 
 
     
     
       11. The input device of  claim 1 , wherein the fabric is slack during vertical movement of the keycap with respect to the switch. 
     
     
       12. The input device of  claim 11 , wherein a portion of the fabric restricts passage of a contaminant into the aperture. 
     
     
       13. The input device of  claim 1 , wherein the fabric further comprises:
 an embossed region including a side wall of the set of sidewalls, the side wall forming a U-shaped depression; and 
 an unembossed region adjacent the embossed region; 
 wherein the fabric is configured to bias upward the keycap. 
 
     
     
       14. The input device of  claim 13 , further comprising an illuminator, wherein light emitted from the illuminator shines through a portion of the keycap and the embossed region. 
     
     
       15. The input device of  claim 14 , wherein the keycap includes an opaque material that blocks passage of the light. 
     
     
       16. The input device of  claim 13 , wherein the fabric restricts passage of a contaminant into the aperture. 
     
     
       17. The input device of  claim 13 , wherein the fabric restricts lateral movement of the keycap with respect to the switch. 
     
     
       18. The input device of  claim 1 , wherein the set of sidewalls form a depression around the keycap relative to the second region when the keycap is in an undepressed state. 
     
     
       19. The input device of  claim 13 , wherein the U-shaped depression is formed in a portion of the fabric extending downward beneath the frame and extending upward along a side of the keycap.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a nonprovisional patent application of and claims the benefit of U.S. Provisional Patent Application No. 62/037,947, filed Aug. 15, 2014 and titled “Fabric Keyboard,” the disclosure of which is hereby incorporated herein by reference in its entirety. 
    
    
     FIELD 
     This disclosure relates generally to input devices, and more specifically to keyboards having a fabric component. 
     BACKGROUND 
     Many electronic devices utilize input devices to receive commands or other interactions from users. In some cases, such input devices may also provide output to that may or may not be associated with received inputs. One common, widely-used input device is a keyboard. 
     Keyboards may include one or more keys, each of which may have a legend or legends thereon that indicate the input provided when the key is pressed. Sample legends are one or more letters, numbers, signs, symbols, or other characters. 
     In various cases, mechanisms that allow the keys to move may produce noise. Such mechanisms may require a particular amount of force to move sufficiently to provide an input, and may provide a particular tactile feel when pressed. These components and/or other components of the keys may be vulnerable to entry of contaminants such as dust, food, other particles, water, and/or other liquids, since each key&#39;s keycap typically protrudes upward through a plate or case, thereby permitting entry of foreign matter around the edges of the keycaps. 
     SUMMARY 
     The present disclosure describes systems, apparatuses, and methods related to fabric input devices such as fabric keyboards. An input device including keys that move within apertures of a frame may be covered by a fabric bonded to the keys and frame. The fabric may dampen sound from within the input device and form a barrier that restricts passage of contaminants. In various implementations, the fabric may include embossed areas or structures bonded to tops of keycaps of the keys and unembossed areas bonded to the frame. Sides of the keycaps may not be bonded to the embossed areas such that unbonded portions of the fabric are able to bend and/or buckle during keycap movement. In some implementations, the fabric and/or flanges of the keycaps and/or the frame around the apertures may restrict movement of the keycaps in various directions. 
     In various embodiments, an input device may include a frame with an aperture, a keycap at least partially within the aperture and operable to move with respect to the frame, a switch positioned under the keycap that is activated by vertical movement of the keycap with respect to the switch, and a fabric disposed over the frame and keycap with a first region bonded to the keycap and a second region bonded to the frame. 
     In some embodiments, a keyboard may include a fabric having embossed regions with rounded corners and an unembossed region, a frame with apertures, and keys. Each key may include a top hat configuration keycap operable to move within one of the apertures and a switch positioned under the top hat configuration keycap that is activated by vertical movement of the top hat configuration keycap with respect to the switch. A planar upper or top surface of the top hat configuration keycap of each key may be bonded to one of the embossed regions and the frame may be bonded to the unembossed region. 
     In one or more embodiments, a method for manufacturing an input device may include: embossing a fabric to create embossed structures and an unembossed area; bonding a frame to one of the unembossed area using a first adhesive, the frame including an aperture; and bonding a top of a keycap of a key to one of the embossed structures using a second adhesive, leaving sides of the keycap unbonded, wherein the key includes the frame, the keycap positioned at least partially within the aperture, and a switch positioned under the keycap that is activated by vertical movement of the keycap with respect to the switch. 
     It is to be understood that both the foregoing general description and the following detailed description are for purposes of example and explanation and do not necessarily limit the present disclosure. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate subject matter of the disclosure. Together, the descriptions and the drawings serve to explain the principles of the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a sample system including an example fabric keyboard. 
         FIG. 2  is a cross-sectional view of a key of the fabric keyboard of  FIG. 1 , taken along diagonal line A-A of  FIG. 1 . 
         FIG. 3  illustrates the key of  FIG. 2  during a center press. 
         FIG. 4  illustrates the key of  FIG. 2  during a side press. 
         FIG. 5  is an exploded view of the key of the fabric keyboard of  FIG. 1 . 
         FIGS. 6A-6D  illustrate a first example of assembly of an individual key that may be backlit by an illuminator. 
         FIGS. 7A-7F  illustrate a second example of assembly of an individual key that may be backlit by an illuminator. 
         FIG. 8  shows the view of the system of  FIG. 1  with the cover rolled up. 
         FIG. 9  is a graph illustrating various force and displacement curves for a fabric-covered keycap and certain constituent portions thereof. 
         FIG. 10  is a flow chart illustrating one sample method for manufacturing the example fabric keyboard of  FIG. 1 .  FIG. 11  is a simplified diagram of a fabric having a side section extending downward beneath a frame before extending upward along the side of the keycap. 
     
    
    
     DETAILED DESCRIPTION 
     The description that follows includes sample systems, methods, and apparatuses that embody various elements of the present disclosure. However, it should be understood that the described disclosure may be practiced in a variety of forms in addition to those described herein. 
     The present disclosure describes systems, apparatuses, and methods related to fabric input devices, such as fabric keyboards, that are suitable for use with various electronic devices. An input device may include a frame, multiple keys that generate inputs when pressed, and fabric (or multiple layers of fabric) overlying the keycaps and, optionally, some portion of the frame. Each key may further include a keycap that is operable to move within an aperture of the frame, a switch (such as a dome switch) activated when the keycap depresses sufficiently far, and a support mechanism that biases the key away from the switch in its resting state, but collapses or otherwise contracts when the keycap is pressed so that the keycap may actuate the switch. 
     Part of the fabric may be bonded to the keycap and a second part of the fabric may be bonded to the frame. Generally, the portion of the fabric bonded to the keycap is raised above, and forms a raised feature with respect to, the portion of the fabric that is bonded to the frame. This may be referred to herein as an “embossed” feature, area, or the like. The use of the term “embossed” does not imply or require any particular method for forming a corresponding feature or area. Rather, an embossed area, feature or the like may be formed by any suitable process or mechanism, including heat forming, molding, stamping, crimping, weaving, or the like. Some embossed areas or structures discussed herein have one or more sidewalls connecting the raised region to the lower region; such sidewalls may be generally perpendicular to one of or both the raised and lower regions, although this is not necessary. 
     The fabric may be slack, or excess fabric may be contained, between the part bonded to the keycap and the part bonded to the frame. The fabric may be sufficiently slack that it does not pull on the keycap or otherwise exert force on the keycap either while the keycap is in a rest state or during the keycap&#39;s travel. 
     The fabric may dampen sound from within the keyboard, such as noise related to movement of the keycap, activation of the switch, and so on. The fabric may also form a barrier that restricts passage of contaminants (such as dust, food, or other particles and/or water and/or other liquids) into the aperture and/or other portions of the input device. Put another way, a top section of fabric may be bonded to the keycap and side sections of fabric (e.g., that portion of fabric overlapping the sides of the keycap or otherwise extending from the top section) may be unbonded, such that the side sections are operable to bend and/or buckle during movement of the keycap. Thus, the fabric is not in tension during the movement, but instead is slack. In some cases, the height of the side sections and thus the height of the embossed area may be related to the travel distance of the keycap such that higher embossed area heights may be configured for keycaps with longer travel distances. 
     In some implementations, the keys or keycaps may utilize a “top hat configuration.” A “top hat” key may have a keycap with a typically planar upper (or top) surface and side walls extending downwardly from the upper surface. The keycap may further define one or more flanges that extend outwardly from the side walls; in some embodiments, a continuous annular ring or plate structure may be used instead of one or more flanges. Such a configuration may be referred to as a “top hat” because the keycap shape and/or profile resembles a simplified top hat. 
     The keycap may be biased upward by the switch, or otherwise supported by the switch, when force is not exerted downward upon the keycap. The frame may include flanges or other features that are operable to interact with flanges of the keycap to restrict upward movement of the keycap so that the keycap does not exit the aperture. The flanges of the keycap may also interact with the aperture or another feature of the frame to restrict lateral movement of the keycap. The keycap may include a top surface that projects above the aperture when force is not exerted downward upon the keycap and is flush with the aperture and/or enters the aperture when force is exerted downward. The region of the fabric bonded to the keycap may be bonded to the top surface of the keycap. In such implementations, the fabric may further restrict lateral movement and/or other movement of the keycap. 
     The fabric may be embossed to include one or more embossed areas or embossed structures and one or more embossed areas. In such a case, the region of the fabric bonded to the keycap may be an embossed area. In various implementations, the embossed area may include a top section and side sections positioned perpendicular to the top section. 
     In various implementations, fabric of various characteristics may be selected based on interaction with the switch and/or other such factors. For example, the material composing the fabric (such as nylon, elastane, polyester, and/or other such material) may be selected such that a force curve involved in activating the switch is not significantly altered and/or to deliberately alter the force curve involved in activating the switch. By way of another example, in cases where the fabric includes an embossed area formed into a shape with one or more rounded corners, the radius of the curved corner may be selected to not significantly alter the force curve and/or to deliberately alter the force curve involved in activating the switch. The smaller the radius of curved corners may cause the embossed area to have more self-supporting stiffness and thus increasingly affect the force curve, whereas the larger the radius, the less self-supporting stiffness and less effect to the force curve. Alternately, the keycap may have non-rounded, pointed corners which may have even more self-supporting stiffness and thus affect the force curve more than rounded corners. 
     In some implementations, the keys may include one or more illuminators. For example, one or more illuminators (such as one or more light emitting diodes or “LEDs”) may be positioned under the keycap, on the keycap, and so on. In such cases, the fabric, keycap, and/or other components may be configured such that the illuminator is operable to illuminate the key, a legend (such as a letter, number, symbol, glyph, and/or other pattern) on a surface of the key, and so on. For example, the fabric may be permeable to light but the keycap may not be such that light from an illuminator positioned under the keycap is operable to shine around the keycap and out of the fabric to illuminate an area around the key. By way of another example, a portion of the fabric corresponding to a legend on a surface of the keycap may be permeable to light whereas other portions of the fabric are not (such as where the fabric includes a light permeable layer covered by a non-light permeable layer such as paint or fabric where the area of the non-light permeable layer corresponding to the legend removed by laser etching or other process, the fabric includes a non-light permeable material with a light permeable and/or light transmissive material woven and/or otherwise positioned in the area of the legend, and so on) such that an illuminator positioned under the fabric is operable to illuminate the legend. 
     Although the present disclosure is illustrated and described in the context of a fabric keyboard, it is understood that this is an example. In various implementations, the techniques of the present disclosure may be utilized in various other fabric input devices (such as a fabric covered button) without departing from the scope of the present disclosure. 
       FIG. 1  shows a sample system  100  including an example fabric keyboard  101 , such as the fabric keyboard generally discussed above and described in more detail below. As illustrated, the system  100  includes an electronic device  104  and a cover  105  that includes or otherwise incorporates a fabric keyboard  101  and is configured to removably attach to the electronic device  104 . 
     As further illustrated in  FIG. 1 , the fabric keyboard  101  may include one or more keys  102 . Each key  102  is covered by a fabric  106 . As previously discussed, the fabric  106  may be a single piece of material or may be formed from multiple pieces of material. Further, the fabric  106  may be bonded to each key  102  (or more particularly, a keycap of each key) and to the cover  105  in order to form a barrier against ingress of foreign material. A sample structure of an individual key  102  and fabric  106 , including the interaction between the two and their related structural configuration, is discussed in more detail below with respect to  FIGS. 2-3 . 
     In some implementations the keys  102  may include one or more rounded corners, each having a radius  103 . The radius  103  may affect the stiffness of the fabric at the respective area of the fabric keyboard  101 . Rounded corners with a smaller radius  103  (or non-rounded corners) may result in stiffer fabric portions whereas rounded corners with a larger radius  103  may result in less stiff fabric portions. 
       FIG. 2  is a cross-sectional view of a key  102  of the fabric keyboard  101  of  FIG. 1 , taken along diagonal line A-A of  FIG. 1 . As illustrated, a fabric  201  may be bonded (such as by adhesive  202 ) to the top surface of a keycap  205  and to a frame  204  (such as by adhesive  203 ). The frame  204  may define an aperture  218  in or through which the keycap  205  may move. Movement of the keycap  205  (illustrated as vertical movement) may activate a dome switch by deforming a dome  210  to touch or otherwise connect to a contact  213 . The dome  210  and contact  213  may be positioned on a substrate  215  such as a printed circuit board (PCB). 
     The dome  210  may be held in place on the substrate  215  by a switch block  211  that may be bonded to the substrate  215  (such as by adhesive  212 ). The switch block  211  may hold the dome  210  in place by providing a barrier that prevents movement of the dome  210 . As illustrated, the switch block  211  may prevent lateral motion of the dome  210 . In some implementations, the switch block  211  may perform other functions, such as implementations where the switch block  211  operates as and/or includes a light guide. 
     In some implementations, the key  102  may include one or more illuminators  214 , such as one or more LEDs. Although  FIG. 2  illustrates the illuminator  214  as positioned below the keycap  205 , it is understood that this is an example. In various implementations such an illuminator  214  may be otherwise positioned, such as positioned on top of the keycap  205  and/or integrated into the keycap  205 . In some implementations, an illuminator  214  may be offset from the key  102  so that the illuminator  214  illuminates into the key  102 . In such an implementation, a light guide may reorient light received by the illuminator  214 . 
     In various implementations, the substrate  215  may be rigid. However, in other implementations the substrate  215  may be flexible such that the fabric keyboard  101  of  FIG. 1  and/or other such keyboard including a key such as the key  102  may be flexible. This may enable the fabric keyboard  101  to be folded, bent, rolled up, and/or otherwise manipulated. 
     In some embodiments, the substrate  215  may be formed into substantially rigid sections or regions, each of which may be associated with a number of keys  102 . As one example, each row of the fabric keyboard  101  may be placed atop or otherwise associated with its own substantially rigid section. These substantially rigid sections may be connected by one or more flexible links (such as links made of rubber, elastomer, and/or other flexible material). In such embodiments, though one or more portions of the fabric keyboard  101  may be rigid, the flexible links connecting such rigid portions may enable the fabric keyboard  101  to be folded, bent, rolled up (such as is shown in  FIG. 1B ), and/or otherwise manipulated in various ways. For example, each row (or a group of rows) of the fabric keyboard  101  may have a rigid substrate but the rows may be connected to each other by one or more flexible links. This configuration may provide stability for users attempting to type on the fabric keyboard  101  while still enabling the fabric keyboard  101  to be rolled up, flexed, and/or otherwise manipulated along axes provided by the flexible links. The fabric keyboard  101  may also be used when rolled to prop the electronic device  104  on a surface at an angle. Additionally or alternatively, the flexible links may extend across one or more columns of the fabric keyboard  101  enabling the fabric keyboard  101  to flex in more than one direction. 
     Still with respect to  FIG. 2 , the fabric  201  may be embossed to include one or more embossed regions (or embossed structures)  206  and one or more unembossed regions  209 . At least a part of the embossed region  206  may be bonded to the keycap  205  and the unembossed region  209  may be bonded to the frame  204 . As further illustrated, the embossed region  206  may include a top section  208  and side sections  207  that are perpendicular to the top section  208 . The top section  208  may be bonded to the top surface of the keycap  205  and the side sections  207  may be unbonded such that the side sections  207  are able to buckle and/or bend during movement of the keycap  205 . In some cases, the bonded area is less than the total area of either the top of the keycap  205  or the top section  208  of the embossed region  206 . This may ensure unrestricted movement of the side sections  207  and prevent the fabric  201  from being in substantial tension during movement of the keycap  205 . 
     The height of the side sections  207  may be related to the distance that the keycap  205  travels to deform the dome  210 . For example, the embossed region  206  may be over embossed such that the side sections  207  are able to buckle and/or bend during travel of the keycap  205  and not require the fabric  201  to stretch in order to allow such movement, and also to prevent the fabric from exerting force on the keycap. Higher side sections  207  may be configured for keycaps  205  with longer travel distances. Likewise, the side sections  207  may extend downward beneath the frame  204  before extending upward along the side of the keycap  205 , thereby forming a U-shaped depression  250  around some or all of a key. This depression may permit the keycap to travel without stretching the fabric or exerting force on the keycap  205 . See  FIG. 11 . 
     By utilizing the embossed region  206  to allow for keycap  205  travel, stress upon the dome switch of the key  102  may be avoided because the embossed region  206  may prevent stretching of the fabric  201  from exerting unwanted force on the keycap  205 . In particular, the side sections  207  may prevent the fabric  201  from exerting unwanted force on the keycap  205  or exerting force on the dome switch. 
     The keycap  205  may be biased upward or otherwise supported by the dome  210  portion of the switch when force is not exerted downward upon the keycap  205 . The top surface of the keycap  205  may project above the aperture  218  when the keycap  205  is not subjected to any external force (e.g., is in a rest state) but may be flush with the aperture  218  and/or enter the aperture  218  when an external force is exerted downward on the keycap  205 . In some embodiments, the fabric  201  may also bias (or assist in biasing) the keycap  205  upward. That is, the relative stiffness of the fabric  201  and/or the amount of fabric used in the side section  207  may essentially pull the keycap to its rest state. 
     As also illustrated, the keys  102  may take, or have in cross-section, a top hat configuration. Such a top hat configuration may enable the keys  102  to be activated by center presses, side presses, and so on as the top hat configuration may restrict motion of the keycap  205  during a side press such that the keycap  205  deforms the dome  210  (illustrated in  FIG. 4 ) the same as during a center press (as illustrated in  FIG. 3  and discussed below). The top hat configuration may include a flange or protrusion  217  that extends from all portions of the keycap sidewalls, or a series of separate flanges/protrusions  217  that each extend from a different portion of the keycap sidewalls. 
     Further, portions of the frame  204  defining a perimeter around the aperture  218  may include flanges  216  that extend into the aperture  218 . The flanges  216  may be operable to contact and block movement of the flanges  217  of the keycap  205  to restrict upward movement of the keycap  205  so that the keycap  205  does not exit the aperture  218 . The flanges  217  of the keycap  205  may also contact the perimeter of the frame  204  around the aperture  218 , blocking further movement of the flanges  217 , to restrict lateral movement of the keycap  205 . The fabric  201  may also restrict lateral movement and/or other movement of the keycap  205 . 
     As illustrated, the fabric  201  may cover the aperture  218 . In some cases, the fabric  201  may function to dampen sound from within the keyboard and/or emanating through the aperture  218  and/or other components of the key  102 , such as noise produced during movement of the keycap  205 . In various cases, the fabric  201  may also form a barrier that may restrict passage of contaminants into the aperture, such as dust, food, or other particles and/or water and/or other liquids. This may protect components such as the dome  210  or the contact  213  from corrosion and/or other damage and/or prevent such contaminants from otherwise interfering with operation of the key  102 . 
     Returning again to  FIG. 2 , although the key  102  is illustrated and described above as having a top surface formed of the fabric  201 , it is understood that this is an example. In some implementations, an element such as a key pad may be placed over the fabric  201 . This may provide the appearance of a typical keyboard key while still enabling the use of the fabric  201  for purposes of key  102  operations, sound dampening, contaminant barrier, and so on. 
     Further, although the key  102  is illustrated and described as directly engaging the keycap  205  and the dome switch, it is understood that this is an example. In various implementations one or more other mechanisms may positioned between the keycap  205  and the dome switch (which may be a switch other than a dome switch) without departing from the scope of the present disclosure. For example, in such implementations the key  102  may include one or more movement mechanisms such as a butterfly mechanism, a scissor mechanism, and/or any other such key movement mechanism. These movement mechanisms may limit the upward and/or downward motion and position of the keycap or key, as well as biasing the key or keycap away from the dome switch (or otherwise toward a surface of the input device) when the key is not under a load. In other embodiments, one or both of the dome switch and fabric may serve to similarly limit keycap/key motion and bias the keycap/key. 
     Additionally, although the fabric  201  is illustrated and described above as being embossed and not being in tension during movement of the keycap  205 , it is understood that this is an example. In various implementations, the fabric  201  may be formed of an elastic material without embossed areas  206  and that stretches to allow movement of the keycap  205 , which may stretch in the absence of force applied to the keycap  205  to allow the keycap  205  to project above the frame  204 . In some such implementations a material may be used for the fabric  201  such that stretching of the fabric  201  does not cause the keycap  205  to put excessive stress on the dome  210 , such as the stretching of the fabric  201  putting stress in excess of that necessary to deform the dome  210  when force is not exerted on the keycap  205  thus causing unintentional activation and/or improper operation of the key  102 . 
     Still with respect to  FIG. 2 , as discussed above the key  102  may include one or more illuminators  214 . In such cases, the fabric  201 , keycap  205 , and/or other components may be configured such that the illuminator  214  is operable to illuminate the key  102 , a legend (such as a letter, number, symbol, glyph, and/or other pattern) on a surface of the key  102 , and so on. 
     For example, the fabric  201  may be permeable to light (such as being formed of clear and/or translucent nylon) but the keycap  205  may not be. As such, light from the illuminator  214  positioned under the keycap  205  may be operable to shine around the keycap  205  and out of the fabric  201  to illuminate an area around the key  102 . 
     By way of another example, a portion of the fabric  201  corresponding to a legend on a surface of the key  102  may be permeable to light whereas other portions of the fabric  201  are not such that the illuminator  214  positioned under the fabric  201  is operable to illuminate the legend. In some example cases, the fabric  201  may include a light permeable layer (such as clear and/or translucent polyester) covered by a non-light permeable layer (such as opaque paint or polyester) where the area of the non-light permeable layer corresponding to the legend removed by laser etching or other process. In other example cases, the fabric  201  may include a non-light permeable material (such as opaque nylon) with a light permeable (such as clear polyester) and/or light transmissive material (such as fiber optic material) woven and/or otherwise positioned in the area of the legend. 
     In various implementations, use of an illuminator  214  to backlight the key  102  may result in a “hotspot,” or a brighter area of illumination of the surface of the key  102  corresponding to the location of the illuminator  214  surrounded by a dimmer area of illumination corresponding to the area around the illuminator  214 . To mitigate the occurrence of such a hotspot by using the illuminator  214  to backlight the key  102 , a cover may be positioned over the illuminator  214  between the illuminator  214  and the keycap  205 . Such a cover may cause light emitted by the illuminator  214  to diffuse evenly throughout the aperture  218  as opposed to directly toward the keycap  205 , resulting in uniform illumination through the surface of the key  102  without a hotspot. In such implementations, the frame  204  may be formed of an opaque material so light emitted by the illuminator  214  of the key  102  is prevented from entering adjacent keys  102 . 
     In some implementations, such a cover or “roof” may extend from a portion of the switch block  211  proximate to the illuminator  214  to fully or partially cover the illuminator  214 . In some embodiments of such an implementation, the switch block  211  may include a light guide panel or similar structure that receives light from the illuminator  214  and diffuses the received light more uniformly throughout the aperture  218 . For example, the illuminator  214  may be a side-firing LED that emits light toward the light guide panel included in the switch block  211  which is then diffused throughout the aperture  218  by the light guide panel. 
       FIG. 3  illustrates the key  102  of  FIG. 2  during a center press. As illustrated, an external force  301  exerted on the embossed region  206  may move the entire keycap  205  such that the center of the keycap  205  deforms the dome  210  to connect with the contact  213 . During such movement, the side sections  207  may buckle and/or bend to allow such movement without causing the fabric  201  to stretch and/or putting the fabric  201  in tension. 
       FIG. 4  illustrates the key  102  of  FIG. 2  during a side press. As illustrated, an external force  401  exerted on a right side the embossed region  206  may push the right side of the keycap  205  such that the center of the keycap  205  deforms the dome  210  to connect with the contact  213 . During such movement, the side sections  207  may buckle and/or bend to allow such movement without causing the fabric  201  to stretch and/or putting the fabric  201  in tension. Also during such movement, the flanges  217  may contact and be blocked by the perimeter of the frame  204  around the aperture  218 , the flanges  216 , the substrate  215 , and/or other structures due to rotation or pivoting of the keycap, which may still cause deformation of the dome  210  despite being pressed on a side instead of the center. 
       FIG. 5  is an exploded view of the key  102  of the fabric keyboard  101  of  FIG. 1 . As illustrated, the contact  213  (and in some implementations the illuminator  214 ) may be positioned on the substrate  215 . The dome  210  may be placed on the substrate  215  and held in place by adhering the switch block  211  to the substrate  215  with the adhesive  212 . The keycap  205  may be positioned under the frame  204  in the aperture  218 , biased against the frame by the dome  210 , and the frame  204  may be coupled to the substrate  215 . Then, the unembossed region  209  of the fabric  201  may be bonded to the frame  204  by the adhesive  203  and the embossed region  206  of the fabric  201  may be bonded to the top surface of the keycap  205  by the adhesive  202 . 
     Although a particular order of assembly is discussed above with respect to  FIG. 5 , it is understood that this is an example. In various implementations, the above discussed components and/or other components may be differently assembled and/or assembled in different orders without departing from the scope of the present disclosure. 
     In various implementations, fabric  201  of various characteristics may be selected based on interaction with the dome  210  and/or other such factors. For example, the material composing the fabric  201  (such as nylon, elastane, polyester, and/or other such material) may be selected such that a force curve involved in deforming the dome  210  is not significantly altered and/or to deliberately alter the force curve involved in deforming the dome  210 . 
     In some implementations, keys  102  may be configured to require a particular force curve in order to have a pleasing “feel” when operated by a user. If the dome  210  itself is configured with the appropriate force curve and if the fabric  201  significantly changes that force curve, the key  102  may no longer have the pleasing feel. As such, where the dome  210  is already configured with the appropriate force curve, the fabric  201  and/or the embossed region  206  may be configured such that the fabric  201  does not significantly change the force curve. 
       FIGS. 6A-6D  illustrate a first example of assembly of an individual key  602  that may be backlit by an illuminator.  FIG. 6A  illustrates a top view of an example keycap  605 . In this example, the keycap  605  may be formed of an opaque material and include a window  640  formed of clear, translucent, or other material that allows passage of light; the resulting illumination level of the key  602  corresponding to the amount of light allowed through the utilized material where less opaque materials allow result in brighter illumination and more opaque materials result in dimmer illumination. Forming the keycap  605  of an opaque material with a window  640  may allow for use of a material for the window  640  that may not be suitable for construction of the keycap  605  (insofar as it may otherwise be insufficiently strong or durable) while allowing use of a material for the keycap  605  that is suitable for keycap  605  construction but does not allow the passage of light. As one example, the window  640  may be formed from clear polyurethane and the keycap  605  from opaque polyvinyl chloride. However, in various other implementations the entire keycap  605  may be formed of a clear, translucent, or other material that allows passage of light and may not utilize a window  640 . 
       FIG. 6B  illustrates the keycap  605  of  FIG. 6A  after the addition of a legend  641 . The legend  641  may be formed of an opaque material, such as black paint, black printing, or other opaque material.  FIG. 6C  illustrates an assembled key  602  after the surface of the keycap  605  of  FIG. 6B  is covered with fabric  601  (such as by bonding the fabric  601  to the top of the keycap  605  using adhesive) and a legend  642  is formed on the fabric  601  (such as by printing). The legend  642  may allow the key  602  to be identified even when not backlit or when not sufficiently backlit for the illuminator to be seen (such as when a level of ambient light, like daylight, is high enough that illumination from backlighting is not visible). 
       FIG. 6D  illustrates the assembled key  602  of  FIG. 6C  when backlit. As illustrated, light from underneath the key  602  (such as light emitted by an illuminator positioned inside the key) shines out through the fabric  601  (which may allow the passage of light) around the legend  642 . As illustrated, the legend  641  and/or the legend  642  may block the passage of light such that the area occupied by the legend  642  is not illuminated. 
     However, it is understood that this is an example and other configurations are possible without departing from the scope of the present disclosure. For example, in various implementations the legend  641  may be omitted and only the legend  642  may block the passage of light (and/or allow less passage of light than the surrounding fabric  601  such that the legend  642  is illuminated more dimly than the surrounding fabric  601 ). 
     By way of another example, in some implementations the legend  641  may be formed by covering the window  640  except for the area occupied by the legend  641  with opaque material (and/or by covering the entire window  640  with the opaque material and then removing, such as by etching, laser etching, and/or other process, the opaque material in the area of the legend  641 ) such that the legend  642  is illuminated and light is prevented from passing through the fabric  601  in the area around the legend  642 . In such an example, the legend  641  may have dimensions larger than that of the legend  642 , resulting in an illuminated outline of the legend  642  if the legend  642  does not allow the passage of light or an illuminated legend  642  with a more brightly illuminated outline of the legend  642  if the legend  642  allows less passage of light than the fabric. 
       FIGS. 7A-7F  illustrates a second example of assembly of an individual key  702  that may be backlit by an illuminator.  FIG. 7A  illustrates a top view of an example keycap  705 . In this example, the keycap  705  may be formed of a clear, translucent, or other material that allows passage of light.  FIG. 7B  illustrates the keycap  705  of  FIG. 7A  after the addition of first coating  750 . The first coating  750  may be formed of a material that allows the passage of light, such as a white or appropriately colored paint or print.  FIG. 7C  illustrates the keycap  705  of  FIG. 7B  after the addition of second coating  751 . The second coating  751  may be formed of an opaque material, such as black paint or print. As illustrated, the second coating  751  may entirely cover the first coating  750 .  FIG. 7D  illustrates the keycap  705  of  FIG. 7C  after the keycap  705  is covered with fabric  701  (such as by bonding the fabric  701  to the top of the keycap  705  using adhesive).  FIG. 7E  illustrates an assembled key  702  after a portion of the fabric  701  and the second coating  751  are removed (such as by etching, laser etching, and/or other processes) to expose a portion of the first coating  750  to form a legend  752 . In implementations where the fabric  701  is bonded to the keycap  705  using adhesive, the adhesive may be reflowed after the portions of the fabric  701  and second coating  751  are removed in order to ensure that the remaining portions of the fabric  701  remain adequately bonded to the keycap  705 . 
       FIG. 7F  illustrates the assembled key  702  of  FIG. 7E  when backlit. As illustrated, light from underneath the key  702  shines out through the first coating  750  in the area of the legend  752 , the remaining portions of the second coating  751  and/or the fabric  701  blocking the passage of light such that the area around the legend  752  is not illuminated. 
     In various implementations, the color and/or opacity of the first coating  750  may be used to tune the illuminated light. For example, less opaque materials may be used for the first coating  750  to cause in brighter illumination whereas more opaque materials may be used to cause dimmer illumination. By of another example, white colored material may be used for the first coating  750  to cause the illumination to appear white whereas a different colored material (such as blue) may be used to cause the illumination to appear another color (such as blue). 
     However, it is understood that  FIGS. 7A-7F  are examples and other configurations are possible without departing from the scope of the present disclosure. For example, in various implementations the first coating  750  may be omitted and the second coating  751  may be directly applied to the keycap  705 . 
       FIG. 8  illustrates the sample system  100  of  FIG. 1 , but with the cover  105  (and flexible keyboard  101 ) rolled up. The cover  105  and/or portions thereof may be flexible. As illustrated in  FIG. 8 , the cover  105  may include rigid sections connected by flexible links and the cover  105  may be rolled up and/or otherwise manipulated the rigid sections with respect to each other along the flexible links. Such flexibility in the cover  105  may allow the cover  105  to be rolled up such that the cover  105  can occupy a smaller area when the electronic device  104  is being used without removal of the cover  105 . 
     Further, such flexibility may enable the cover  105  to partially cover the screen instead of entirely covering or uncovering. Portions of the fabric keyboard  101  may be exposed when the cover  105  partially covers the screen. Such exposed portions of the fabric keyboard  101  may be utilized to provide input to the electronic device  104  while the screen is partially covered. Moreover, such flexibility may enable the cover  105  to be rolled or otherwise manipulated to function as a stand and prop the electronic device  104  at an angle on a surface. 
     The cover  105  may attach to the electronic device  104  in one or more positions where the screen is covered and/or one or more positions where the screen is uncovered. For example, the cover  105  may attach to the electronic device  104  using one or more magnets. In some cases, coupling the magnets may electrically connect contacts of the cover  105  and the electronic device  104  to enable communication between the fabric keyboard  101  and electronic device  104 . The fabric keyboard  101  may be disposed on an internal or external surface of the cover  105  and may be utilized to provide input to the electronic device  104  when the cover  105  is not covering the screen. 
     The illustrated system  100  is but one example system. In various implementations, the fabric keyboard  101  may be incorporated into the electronic device  104  instead of being removably attachable via the cover  105  without departing from the scope of the present disclosure. Further, in various implementations the electronic device  104  may be any kind of electronic device (such as a desktop computing device, a mobile computing device, a tablet computing device, a smart phone, a cellular telephone, a wearable device, a digital media player, and/or any other electronic device). 
     Moreover, although the fabric keyboard  101  is illustrated and described as being included in the cover  105 , the fabric keyboard  101  may be implemented in a variety of different ways. In various implementations, the fabric keyboard  101  may be incorporated into a variety of different items. For example, a case operable to contain, enclose, and/or otherwise hold the electronic device  104  may include the fabric keyboard  101 . By way of another example, an item of apparel (such as a jacket, pants, purse, bag, and so on) or other accessory may include a fabric input device with a number of fabric covered buttons (such as five or other numbers of fabric covered buttons) that is operable to wirelessly communicate with an electronic device such as a smart phone stored in a pocket or compartment of (and/or otherwise proximate to) the item of apparel. 
     Additionally, though the fabric keyboard  101  is illustrated and described as a keyboard, it is understood that this is an example. In various implementations, the fabric keyboard  101  may be any kind of fabric input device (such as a fabric covered button) without departing from the scope of the present disclosure. 
       FIG. 9  is a graph illustrating: a force and displacement curve  901  for of the dome  210  of the key of  FIG. 2 ; a force and displacement curve  902  for the fabric of the key of  FIG. 2 ; and the resultant force and displacement curve  903  of the combination of the dome  210  and the fabric  201  of the key  102  of  FIG. 2 . As illustrated, the fabric  201  in this example is configured to operate as a low modulus/constant force spring with a force curve that is relatively low such that the resultant force curve is not significantly different from that of the dome  210  alone. 
     However, in other implementations the dome  210  may not itself be configured completely with the appropriate force curve. In such an implementation, the fabric  201  may be configured to more significantly change that force curve such that the resultant force curve has the appropriate feel. 
     The force curve  902  of the fabric  201  may be related to the material(s) used to form the fabric  201  (i.e., the force required to move the fabric), the height and/or other configuration of embossed areas  206  (i.e., the force required to move the embossed structures), and/or other such factors. For example, as discussed above, the fabric  201  may include embossed areas  206  with one or more rounded corners defined by a radius  103 . In such examples, the radius  103  may be selected to not significantly alter the force curve and/or to deliberately alter the force curve involved in activating the dome  210 . The smaller the radius  103  may cause the embossed area to have more self-supporting stiffness and thus increasingly affect the force curve whereas the larger the radius  103  the less self-supporting stiffness and less effect to the force curve. Alternatively, in examples where it is desired to significantly affect the force curve, non-rounded, pointed corners which may have even more self-supporting stiffness and thus affect the force curve more than rounded corners may be utilized. 
       FIG. 10  is a method diagram illustrating a method  1000  for manufacturing an input device. This method may manufacture the fabric keyboard  101  of  FIG. 1 . 
     The flow may begin and proceed to block  1001  where a fabric may be embossed to create one or more embossed regions and one or more unembossed regions. The flow may then proceed to block  1002  where a frame is bonded to one of the unembossed regions. Each frame may include an aperture. Next, the flow may proceed to block  1003  where a keycap of a key is bonded to one of the embossed regions. The key may include the frame, the keycap which is operable to move vertically with respect to the frame while at least partially within the aperture, and a switch positioned under the keycap that is activated by the vertical movement of the keycap. The key may be one of a number of keys. 
     For example, in various embodiments manufacture of an input device may include placing a fabric in a mold. Closing the mold may emboss the fabric to create embossed regions and unembossed regions. Material, such as plastic, may be injected into the mold to create a frame with a number of apertures where the frame is bonded to the unembossed regions of the fabric by the injection molding. Alternately, the embossed fabric may be moved to a second injection mold and material injected therein. Individual keycaps may be placed in the apertures and bonded to the embossed regions of the fabric (which may have been removed from the injection mold), such as using adhesive. It should be understood that this is but one way of making an embossed fabric and related key structure; other methods may be used to emboss fabric and/or bond the fabric to a keycap and/or frame. 
     However, it is understood that this is an example. In various other implementations, a number of keys each with a respective frame (or respective frame portion of a unified frame that includes multiple apertures), a respective keycap operable to move within an aperture of the respective frame, and a switch positioned under the respective keycap that is activated by vertical movement of the keycap, may be assembled. The fabric may be embossed to create embossed and unembossed regions. The frame of each key may be bonded to an unembossed region and the keycap of each key may be bonded to an embossed region. 
     Although the method  1000  is illustrated and described above as including particular operations performed in a particular order, it is understood that this is an example. In various implementations, various orders of the same, similar, and/or different operations may be performed without departing from the scope of the present disclosure. 
     For example, block  1001  illustrates and describes assembly of the keys as a single step. However, in various implementations assembly of the keys may involve a series of operations. For instance, in a first example operation the keycap may be positioned in the aperture and in a second example operation the switch may be positioned under the keycap. 
     As described above and illustrated in the accompanying figures, the present disclosure describes systems, apparatuses, and methods related to fabric input devices such as fabric keyboards. An input device may include one or more keys that each includes a keycap that is operable to move within an aperture of a frame to activate a switch and fabric disposed over the frame and keycap. A first region of the fabric may be bonded to the keycap and a second region of the fabric may be bonded to the frame. The fabric may dampen sound from within the keyboard and/or emanating through the aperture, such as noise related to movement of the keycap, activation of the switch, and so on. The fabric may also form a barrier that restricts passage of contaminants into the aperture and/or other portions of the input device. 
     It should be appreciated that a variety of modifications and variations may be made to any structure, portion of a structure, or method described herein. For example, although the key  102  is illustrated and described above as having a top surface formed of the fabric  201 , it is understood that this is an example. In some implementations, an element such as a key pad may be placed over the fabric  201 . This may provide the appearance of a typical keyboard key while still enabling the use of the fabric  201  for purposes of key  102  operations, sound dampening, contaminant barrier, and so on. 
     Further, although the key  102  is illustrated and described as directly engaging the keycap  205  and the dome switch, it is understood that this is an example. In various implementations one or more other mechanisms may positioned between the keycap  205  and the dome switch (which may be a switch other than a dome switch) without departing from the scope of the present disclosure. For example, in such implementations the key  102  may include one or more movement mechanisms such as a butterfly mechanism, a scissor mechanism, and/or any other such key movement mechanism. These movement mechanisms may limit the upward and/or downward motion and position of the keycap or key, as well as biasing the key or keycap away from the dome switch (or otherwise toward a surface of the input device) when the key is not under a load. In other embodiments, one or both of the dome switch and fabric may serve to similarly limit keycap/key motion and bias the keycap/key. 
     Additionally, although the fabric  201  is illustrated and described above as being embossed and not being in tension during movement of the keycap  205 , it is understood that this is an example. In various implementations, the fabric  201  may be formed of an elastic material without embossed areas  206  and that stretches to allow movement of the keycap  205 , which may stretch in the absence of force applied to the keycap  205  to allow the keycap  205  to project above the frame  204 . In some such implementations a material may be used for the fabric  201  such that stretching of the fabric  201  does not cause the keycap  205  to put excessive stress on the dome  210 , such as the stretching of the fabric  201  putting stress in excess of that necessary to deform the dome  210  when force is not exerted on the keycap  205  thus causing unintentional activation and/or improper operation of the key  102 . 
     With respect to the present disclosure, the specific order or hierarchy of steps in the methods disclosed are examples of sample approaches. In other embodiments, the specific order or hierarchy of steps in the method can be rearranged while remaining within the disclosed subject matter. The accompanying method claims present elements of the various steps in a sample order, and are not necessarily meant to be limited to the specific order or hierarchy presented. 
     Manufacture of fabric input devices and/or operation of such fabric input devices described in the present disclosure may utilize a computer program product, or software, that may include a non-transitory machine-readable medium having stored thereon instructions, which may be used to program a computer system (or other electronic devices) to perform a process according to the present disclosure. A non-transitory machine-readable medium includes any mechanism for storing information in a form (e.g., software, processing application) readable by a machine (e.g., a computer). The non-transitory machine-readable medium may take the form of, but is not limited to, a magnetic storage medium (e.g., floppy diskette, video cassette, and so on); optical storage medium (e.g., CD-ROM); magneto-optical storage medium; read only memory (ROM); random access memory (RAM); erasable programmable memory (e.g., EPROM and EEPROM); flash memory; and so on. 
     It is believed that the present disclosure and many of its attendant advantages will be understood by the foregoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components without departing from the disclosed subject matter or without sacrificing all of its material advantages. The form described is merely explanatory, and it is the intention of the following claims to encompass and include such changes. 
     While the present disclosure has been described with reference to various embodiments, it will be understood that these embodiments are illustrative and that the scope of the disclosure is not limited to them. Many variations, modifications, additions, and improvements are possible. More generally, embodiments in accordance with the present disclosure have been described in the context or particular embodiments. Functionality may be separated or combined in blocks differently in various embodiments of the disclosure or described with different terminology. These and other variations, modifications, additions, and improvements may fall within the scope of the disclosure as defined in the claims that follow.

Metadata:
Filing Date: 20150814
Publication Date: 20201006
Grant Date: 20201006
Priority Date: 20140815
Inventors: STRINGER, CHRISTOPHER J.
COSTER, DANIEL J.
SHAFFER, BENJAMIN A.
COUSINS, Benjamin A.
KUNA, MELODY
CORBIN, SEAN S.
BROCK, JOHN M.
MURPHY, ROBERT S.
WILSON, JR., THOMAS W.
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2223/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/83", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2221/058", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/044", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/88", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2219/048", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/7065", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/86", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/704", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1662", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1662", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/86", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2221/058", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1662", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2219/048", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/83", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2223/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/88", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/7065", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2223/044", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/704", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 54015216