PATENT DOCUMENT

Publication Number: US-10864686-B2
Application Number: US-201816138955-A
Country: US
Kind Code: B2

Title: Continuous carbon fiber winding for thin structural ribs

Abstract:
Embodiments are directed to a keyboard or other input structure having a continuous fiber material. In one aspect, the continuous fiber material is disposed in a layered fiber pattern under tension. The continuous fiber material is continuous in that it is not broken or severed within the webbing. Heat and pressure are then applied to form a structural web. The resulting structural web may be stronger than a webbing of conventional materials yet with reduced relative weight.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a display portion comprising a display; and 
 a base portion pivotally coupled to the display portion and comprising:
 a housing; 
 a key web defining an aperture having four sides and comprising:
 a matrix material; and 
 a continuous carbon fiber strand extending along at least two sides of the aperture and encapsulated in the matrix material; and 
 
 a keyboard coupled to the housing and comprising a keycap positioned at least partially in the aperture. 
 
 
     
     
       2. The electronic device of  claim 1 , wherein:
 the key web defines multiple additional apertures; and 
 the keyboard further comprises a respective additional keycap positioned in each respective additional aperture. 
 
     
     
       3. The electronic device of  claim 1 , wherein the continuous carbon fiber strand at least partially defines each of the four sides. 
     
     
       4. The electronic device of  claim 1 , further comprising a conductive conduit encapsulated at least partially in the matrix material. 
     
     
       5. The electronic device of  claim 4 , wherein the conductive conduit conductively couples a first component of the electronic device with a second component of the electronic device. 
     
     
       6. The electronic device of  claim 1 , wherein:
 the keyboard further comprises:
 a substrate; and 
 a key assembly coupled to the substrate and movably supporting the keycap above the substrate; and 
 
 the key web is attached to the substrate. 
 
     
     
       7. The electronic device of  claim 6 , wherein:
 the matrix material is a first matrix material; 
 the substrate comprises a second matrix material at least partially encapsulating a reinforcing material; and 
 the first and second matrix materials are co-cured to define a unitary matrix structure. 
 
     
     
       8. The electronic device of  claim 1 , wherein the electronic device is a notebook computer. 
     
     
       9. The electronic device of  claim 1 , further comprising a light-transmissive fiber encapsulated at least partially in the matrix material. 
     
     
       10. The electronic device of  claim 9 , wherein the light-transmissive fiber is configured to emit light from a surface of the key web. 
     
     
       11. The electronic device of  claim 5 , wherein the key web further comprises an electrical connector conductively coupled to the conductive conduit and configured to couple to the first component of the electronic device. 
     
     
       12. The electronic device of  claim 1 , further comprising a flexible cover attached to the key web. 
     
     
       13. The electronic device of  claim 12 , wherein:
 the key web defines a recess; and 
 a portion of the flexible cover is captive in the recess. 
 
     
     
       14. The electronic device of  claim 12 , wherein the keycap is attached to the flexible cover. 
     
     
       15. The electronic device of  claim 1 , wherein:
 the base portion further comprises a substrate positioned below the key web; and 
 the key web is attached to the substrate. 
 
     
     
       16. The electronic device of  claim 1 , wherein the continuous carbon fiber strand is of non-uniform diameter. 
     
     
       17. The electronic device of  claim 1 , wherein the key web further comprises a plurality of fiber segments at least partially encapsulated in the matrix material and extending across the aperture. 
     
     
       18. The electronic device of  claim 17 , wherein the keycap is supported by the plurality of fiber segments. 
     
     
       19. The electronic device of  claim 18 , wherein the plurality of fiber segments are configured to:
 deform in response to an actuation force applied to the keycap; and 
 return the keycap to an unactuated position upon removal of the actuation force. 
 
     
     
       20. The electronic device of  claim 1 , wherein:
 a first side of the aperture is defined by a first wall; 
 a second side of the aperture is defined by a second wall; 
 the first wall includes a first number of segments of the carbon fiber strand; and 
 the second wall includes a second number of segments of the carbon fiber strand that is different than the first number of segments.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application is a nonprovisional patent application of and claims the benefit of U.S. Provisional Patent Application No. 62/563,027, filed Sep. 25, 2017 and titled “Continuous Carbon Fiber Winding for Thin Structural Ribs,” the disclosure of which is hereby incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The described embodiments relate generally to input devices for computing systems. More particularly, the present embodiments relate to structures used in a keyboard of an electronic device. 
     BACKGROUND 
     Structures used in electronic devices may include relatively thin or narrow portions which define apertures, such as found in structural webbing for keyboards. Such structures are prone to structural failure at aperture edges due to reduced width and/or thickness. In electronic devices, design parameters may require relatively light weight with relatively strong structure. Traditional webbings are made of aluminum. Webbings made of carbon fiber laminate may promise a comparatively stronger yet lighter weight design than aluminum. However, if the apertures of the webbing are stamped from a carbon fiber laminate sheet, the fibers are indiscriminately severed which structurally weakens the web. For example, the webbing may become structurally weak at aperture edges due to, for example, cutting of fibers and/or minimal to no continuous fiber materials adjacent the aperture. 
     SUMMARY 
     In one embodiment, a method of forming a structural web for an electronic device is disclosed. The method may include placing a first end of a continuous fiber material within a first retention channel of a mold, the mold having multiple retention channels defining multiple apertures; laying the continuous fiber material within the first retention channel; laying the continuous fiber material within a second retention channel; repeatedly layering the continuous fiber material in a pattern to form a layered fiber web surrounding each of the multiple apertures; heating the layered fiber web; and compressing the layered fiber web, thereby forming the structural web. 
     In one aspect, laying the continuous fiber material in the first and second retention channels is performed while the fiber is under tension; the continuous fiber material is a single continuous carbon fiber; the first retention channel extends along a first axis; and the second retention channel extends along a second axis transverse to the first axis. In one aspect, the first retention channel extends along an axis; the second retention channel extends along the axis; laying the continuous fiber material within the first retention channel comprises laying the continuous fiber material in a first direction; and laying the continuous fiber material within the second retention channel comprises laying the continuous fiber material in a second direction that is opposite to the first direction. In one aspect, the method of forming a structural web for an electronic device further comprises applying an adhesive to each of the multiple retention channels. In one aspect, laying the continuous fiber material is performed under tension with a positioning tool. In one aspect, the continuous fiber material has a varying dimension. In one aspect, the continuous fiber material is a pre-impregnated fiber material. 
     In another embodiment, a method of forming a structural web for an electronic device is disclosed. The method may include engaging a mold comprising multiple retention channels with a tool, the tool configured to position and stretch a continuous carbon fiber material; attaching an end of the continuous carbon fiber material to a portion of a first retention channel of the multiple retention channels; stretching the continuous carbon fiber material along a length of the first channel; stretching the continuous carbon fiber material along additional retention channels of the multiple retention channels to form a layered fiber web; compressing the layered fiber web; and heating the layered fiber web while compressing the layered fiber web. 
     In one aspect, the mold comprises a tow fixture disposed in the first retention channel; and the continuous carbon fiber material is attached to the tow fixture. In one aspect, an adhesive is applied to the multiple retention channels before the end of the continuous carbon fiber material is secured. In one aspect, at least a portion of the layered fiber web comprises multiple segments of the continuous carbon fiber material adjacent and bonded to one another. In one aspect, the continuous carbon fiber material has a first diameter along a first segment within the first retention channel; the continuous carbon fiber material has a second diameter along a second segment within a second retention channel. In one aspect, the first retention channel is positioned along a major axis of the mold; and the second retention channel is positioned along a minor axis of the mold. In one aspect, the carbon fiber is stretched along the first retention channel a first number of times and stretched along the second retention channel a second number of times, the first number greater than the second number. 
     In another embodiment, a structural web for an electronic device may include a single continuous fiber material defining multiple apertures, the single continuous fiber material layered with itself to form a layered fiber web comprising layered walls surrounding each of the multiple apertures, wherein: the layered fiber web is heated and compressed to form the structural web. 
     In one aspect, the layered fiber web forms a planar structure defining multiple apertures. In one aspect, the layered fiber web comprises: a first layered wall; and a second layered wall adjacent the first layered wall; wherein the first layered wall is formed from a greater amount of the single continuous fiber material than the second layered wall. In one aspect, the single continuous fiber material is pre-impregnated with a resin; and the single continuous fiber material is configured to adhere to itself upon application of heat or pressure. In one aspect, the single continuous fiber material is of non-uniform diameter. In one aspect, the layered fiber web further comprises a tow fixture at each corner of the layered fiber web. 
     In another embodiment, an electronic device may include a display portion comprising a display and a base portion pivotally coupled to the display portion. The base portion may include a housing a keyboard coupled to the housing. The keyboard may include a key web comprising a continuous carbon fiber defining an aperture and encapsulated in a matrix material and a keycap positioned at least partially in the aperture. The aperture may be defined by four walls and the continuous carbon fiber may at least partially define each of the four walls. The key web may define multiple additional apertures and the keyboard may further include a respective additional keycap positioned in each respective additional aperture. 
     The electronic device may further include a conductive conduit encapsulated at least partially in the matrix material. The conductive conduit may conductively couple a first component of the electronic device with a second component of the electronic device. 
     The keyboard may further include a substrate and a key assembly coupled to the substrate and movably supporting the keycap above the substrate. The key web may be attached to the substrate. The matrix material may be a first matrix material, the substrate may include a second matrix material at least partially encapsulating a reinforcing material, and the first and second matrix materials may be co-cured to define a unitary matrix structure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  illustrates one example of an electronic device with a structural web; 
         FIG. 2  illustrates another example of an electronic device with a structural web; 
         FIG. 3A  is a sample exploded view of portions of a keyboard of an electronic device with a structural web; 
         FIG. 3B  is a sample exploded view of portions of a keyboard of another electronic device with a structural web; 
         FIG. 4A  illustrates a sample mold used to manufacture a structural web; 
         FIG. 4B  illustrates the sample mold of  FIG. 4A  engaged with a fiber roll in a first state; 
         FIG. 4C  illustrates the sample mold of  FIG. 4A  engaged with a fiber roll in a second state; 
         FIG. 4D  illustrates the sample mold of  FIG. 4A  engaged with a fiber roll in a third state; 
         FIG. 4E  illustrates the sample mold of  FIG. 4A  engaged with a finished fiber web; 
         FIG. 4F  illustrates a finished structural web manufactured using the sample mold of  FIG. 4A ; 
         FIG. 5A  illustrates another sample mold used to manufacture a structural web; 
         FIG. 5B  illustrates the sample mold of  FIG. 5A  engaged with a fiber roll; 
         FIG. 6  illustrates another sample mold engaged with a fiber roll; 
         FIG. 7  illustrates another sample mold engaged with a fiber positioning tool; 
         FIG. 8  is a flow chart that describes a method of manufacturing a structural web; 
         FIG. 9  is a flow chart that describes another method of manufacturing a structural web; 
         FIG. 10A  is a partial cross-sectional view of a portion of an example electronic device with a structural web; 
         FIG. 10B  is a partial cross-sectional view of a portion of an example electronic device with a structural web; 
         FIG. 10C  is a partial cross-sectional view of a portion of an example electronic device with a structural web; 
         FIG. 10D  is a partial cross-sectional view of a portion of an example electronic device with a structural web; 
         FIG. 11A  is a partial cross-sectional view of an example electronic device with a structural web; 
         FIG. 11B  is a partial cross-sectional view of an example electronic device with a structural web; 
         FIG. 11C  is a partial cross-sectional view of an example electronic device with a structural web; 
         FIG. 11D  is a partial cross-sectional view of an example electronic device with a structural web; 
         FIG. 12A  is a partial cross-sectional view of an example electronic device with a structural web, showing a key in an unactuated state; 
         FIG. 12B  is a partial cross-sectional view of an example electronic device with a structural web, showing the key of  FIG. 12A  in an actuated state; 
         FIG. 13A  is a partial view of an example structural web; 
         FIG. 13B  is a partial cross-sectional view of a device with the structural web of  FIG. 13A , showing a key in an unactuated state; 
         FIG. 13C  is a partial cross-sectional view of the device shown in  FIG. 13B , showing the key in an actuated state; 
         FIG. 14A  is a partial view of an example structural web and substrate; 
         FIG. 14B  is a partial cross-sectional view of an example device with the structural web of  FIG. 14A ; 
         FIG. 14C  is a partial cross-sectional view of an example device with the structural web of  FIG. 14A ; 
         FIG. 15A  is a partial view of an example device with a structural web; 
         FIG. 15B  is a detail view of the structural web of  FIG. 15A ; 
         FIG. 16  illustrates an example structural web with conductive conduits; 
         FIG. 17  is a sample exploded view of an example device having a structural web; and 
         FIG. 18  is a partial view of a structural web having vent features. 
     
    
    
     The use of cross-hatching or shading in the accompanying figures is generally provided to clarify the boundaries between adjacent elements and also to facilitate legibility of the figures. Accordingly, neither the presence nor the absence of cross-hatching or shading conveys or indicates any preference or requirement for particular materials, material properties, element proportions, element dimensions, commonalities of similarly illustrated elements, or any other characteristic, attribute, or property for any element illustrated in the accompanying figures. 
     Additionally, it should be understood that the proportions and dimensions (either relative or absolute) of the various features and elements (and collections and groupings thereof) and the boundaries, separations, and positional relationships presented there between, are provided in the accompanying figures merely to facilitate an understanding of the various embodiments described herein and, accordingly, may not necessarily be presented or illustrated to scale, and are not intended to indicate any preference or requirement for an illustrated embodiment to the exclusion of embodiments described with reference thereto. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     The following disclosure generally relates to structures used in electronic devices, such as housings, plates and reinforcing constructs, attachments (such as bosses, protrusions, detents, and the like), and so on. Certain embodiments may take the form of structures which include relatively thin or narrow portions that define apertures, such as a keyboard web or plate (also referred to herein as a “structural web,” “key web,” or simply “web”). Key webs include multiple apertures to allow placement of keys or keycaps, typically from below the key web. The key may protrude or project beyond an upper surface of the web to allow access by a user. The apertures of the structural webbing are defined by relatively narrow and/or thin ribs of the structural webbing. 
     In portable electronic devices, such as laptop computers, key webs may provide structural rigidity to the overall device. For example, a key web may essentially define part of a top wall of a housing of a laptop computer, and as such may be a structural component of the housing. Accordingly, key webs with improved mechanical properties (e.g., strength, stiffness, toughness, etc.) may improve the mechanical properties of the overall housing. More particularly, a stiffer, stronger key web may produce a stiffer, stronger laptop housing. 
     As one example, the disclosure provides a structural web for keyboards (or other input devices) that uses a continuous fiber material repeatedly layered to form the web. The single continuous fiber material may be layered with itself to form a layered fiber web. Stated another way, a single unbroken length of fiber is strung in a pattern that defines the keyboard web; the fiber is routed in a pattern multiple times such that the fiber is layered with or otherwise adjacent to earlier passes of the fiber. Typically, the continuous fiber material is a single length of unbroken carbon fiber, although in some embodiments multiple aligned carbon fibers may form the continuous fiber material. The layered fiber web may surround and define each of the multiple apertures of the layered fiber web, and may form layered walls. A matrix material, such as an adhesive or resin, may encapsulate the layers or passes of the fiber and bond them together. 
     A structural web formed from a single continuous fiber material, such as a carbon fiber, provides several features. Generally, a continuous fiber structural web may have reduced weight compared to a structural web made from conventional materials, such as aluminum, while maintaining equivalent or even increased strength. Also, a continuous fiber structural web may have increased strength compared to a structural web made by stamping a composite sheet, such as a carbon fiber sheet. A structural web made from a stamped composite sheet often has structural vulnerabilities caused by the indiscriminate severing of carbon fibers to form the apertures through which keys extend, and also may have few (if any) fibers running along a length of either a major or minor axis of a keyboard. Thus, a composite structural keyboard or other web manufactured by conventional stamping methods may have reduced strength relative to a similar structural web made of metal such as aluminum. 
     Further, because the structural web is formed using an additive process (e.g., arranging a carbon fiber into a particular shape), other structures and/or components may be formed into and/or incorporated with the carbon fibers and matrix material to form more complex components that provide functionality beyond that of a typical key web. For example, components such as antennas, wires, conductors, light sources, light pipes, and the like, may be built into the key web. Such components may be put in place during the process of positioning the carbon fiber, and then encapsulated (fully or partially) in the same matrix that encapsulates the carbon fiber. Such components may be used, for example, to route electrical signals between various components of the laptop computer, to send and/or receive wireless communications, illuminate the key web or other portions of the laptop computer, and so forth. 
     Additionally, the additive manufacturing process may be used to build more complex structures than a web that simply defines a group of key openings. For example, bottom surfaces may be formed within the key openings (using the same carbon fiber used to define the walls of the key openings) to support key mechanisms, hinges, switches, and the like. In some cases, keycap support structures may be built directly into the bottom surfaces to support the keycap and optionally provide tactile feedback to the key. Other types of structures, such as carbon filaments extending across key openings, venting structures, flexible cover members, and the like may also be incorporated with the carbon fiber key webs, as described in greater detail herein. 
     As used herein, a “carbon fiber” may refer to a fiber made of carbon atoms, which may typically be 5-10 μm in diameter or thickness. A carbon fiber is commonly combined with other materials, such as a matrix material (which may be a resin). When a carbon fiber is combined with a plastic resin or other matrix material, a carbon fiber reinforced polymer (CFRP) is formed. A carbon fiber may also be combined with other materials, such as graphite, forming a carbon-carbon composite material. Non-polymer materials may also be combined with carbon fibers. Any of the foregoing may be used as a carbon fiber in accordance with embodiments herein. 
     A “composite material” is a material made from two or more constituent materials that, when combined, produce a material having material properties different than either of the individual components. For example, a carbon fiber, when combined with a matrix material, produces a composite material. Constituent materials used in embodiments described herein typically include one matrix material and one reinforcement material, though other configurations are also contemplated. As noted above, a matrix material may be a binder that supports and holds the reinforcement material together, while the reinforcement material provides the bulk of the composite&#39;s strength (or another material property). In the carbon fiber reinforced polymer example, the matrix material is a resin and the carbon fiber is the reinforcement material. The degree to which the matrix material is combined with the reinforcement material will influence the material properties of the composite material. 
     A key web that includes continuous fibers, as described herein, may have an improved strength-to-weight ratio as compared to a conventional web (e.g., a web formed of metal or plastic). For example, because the apertures of the key web are integrally formed during the manufacturing process, rather than stamped or cut-out, no fibers within the web structure are split, chopped, sliced or the like. Also, the continuous fiber material may extend along the length of the major axis, and in some embodiments across the minor axis, of the key web, thereby providing increased strength, as the fibers may be aligned with the principle stress orientations of the key web. Furthermore, in some embodiments, an increase in density of stacked or layered fiber may be provided at structurally sensitive locations of the web, such as at aperture corners and at intersections of ribs. Further, the ribs (or other structures formed by the continuous fiber material) may have varying thicknesses and/or densities (or other dimensions) at different points in the web. Such variable density and/or thickness of the fibers of the structural web may further increase strength of the structural web in key areas. 
     A continuous fiber structural web may also have improved heat resistance, because a compact layer of stacked carbon fibers efficiently reflects heat. Such a characteristic may be beneficial if the structural web forms a keyboard structural web disposed above electronic components that generate significant heat, like a battery or processing unit. 
     In one example, a structural web is formed by repeatedly layering a single continuous fiber material in a keyboard web pattern that is defined by multiple retention channels of a mold. An end of the fiber is positioned in a first retention channel of the mold. The fiber is stretched under tension along the remaining portion of the retention channel and then routed throughout remaining retention channels. The single continuous fiber material is repeatedly routed though the retention channels, forming layered walls surrounding each of the multiple apertures of the mold and forming a layered fiber web. Adhesive is applied to the layered fiber web. The layered fiber web is then heated and compressed to form a structural web made of a carbon fiber reinforced polymer. 
     In one embodiment, the single continuous fiber material is pre-impregnated with an adhesive, thereby removing the step of adding adhesive to the mold retention channels and/or the layered fiber web prior to heating and/or compression. The application of heat and/or pressurization causes polymerization of the adhesive matrix with the fiber reinforcement material to form a composite material such as a carbon fiber reinforced polymer. 
     A “pre-impregnated” or “pre-preg” fiber is a fiber in which a thermoset polymer matrix material, such as a resin or epoxy, is coupled to the fiber to form a composite material. Stated another way, a pre-preg fiber includes an adjacent resin or epoxy and, when fully cured (such as by heating and/or pressure), forms a composite material, such as a carbon fiber reinforced polymer. 
     Multiple pre-preg fibers may be woven or weaved together prior to curing. The multiple pre-preg fibers are held together with the resin, yet may remain uncured until exposed to increased heat and/or pressure. Such bundles of pre-preg fibers may require temperature control prior to and during use to prevent premature curing. 
     In one embodiment, the mold includes one or more tow fixtures to secure an end or portion of the continuous fiber material. For example, a tow fixture may be positioned at one end of a first retention channel of a mold, such that an end of the continuous fiber material attached to the tow fixture. The tow fixture secures the end of the continuous fiber material such that the fiber may be stretched under tension and stretched across or along the remaining portion of the retention channel. A tow fixture may also be positioned at one or more locations of direction changes or turns of the fiber. For example, a tow fixture may be located at the intersection of a first retention channel positioned along a major axis of a mold and a second retention channel positioned along a minor axis of a mold. The tow fixture allows a change in direction of the fiber without the fiber pressing against an inside wall of the retention channel. 
     In one embodiment, the single continuous fiber material is of non-uniform diameter. For example, the fiber may have a first diameter for a first length, and a second diameter for a second length. A fiber with non-uniform diameter allows a different configuration of fibers to be positioned in different areas of a fiber web without the requirement to layer the fiber to increase fiber density. For example, a fiber may have a first (and larger) diameter along a first length, such as along a major axis of a structural web, and a second diameter for a second length, such as along a minor axis of a structural web. The second diameter may be smaller than that of the first length. Thus, the fiber positioned in the first retention channel will be provide a relatively increased fiber density as compared to that provided in the second retention channel. In one embodiment, the fiber is of two diameters, the fiber diameter alternating between a first diameter and a second diameter. Further, in some embodiments, a thickness, width, height or the like may vary between first and second lengths; this may enable fiber materials of varying dimensions that are not cylindrical or ovoid. As used herein, “fiber density” may refer to a number of fibers in a cross-sectional area of a key web. 
     In one embodiment, the laying or positioning of the continuous fiber material is performed with a positioning tool. The positioning tool may be used in any of several ways. For example, the positioning tool may position the fiber within a particular retention channel of the mold under a selectable tension. The positioning tool may secure an end of the fiber to a particular location within a retention channel, and/or may secure an end of the fiber to a tow fixture positioned on or in the mold, such as within a retention channel. In embodiments where other types of fibers or other components (e.g., wires, conductors, antennas, light pipes, flexible or fabric covers, etc.) are incorporated into the key web, they may be positioned in the mold during the process of positioning the fibers in a mold. For example, a first number of passes of a carbon fiber may be positioned in a mold, after which a different fiber or a component may be positioned in the mold. After positioning the different fiber or component, the positioning tool may resume positioning the carbon fiber in the mold. After all of the carbon fiber and the additional fiber(s) and/or component(s) are positioned, the web may be cured to form the final component. 
     In one embodiment, the laying or positioning of the continuous fiber material (as well as optional additional fiber(s) and/or component(s)) is performed with an automated positioning tool, such as a computer numeric control (CNC) machine. An automated positioning tool facilitates laying the material as a continuous process through computer control. Furthermore, an automated positioning tool facilitates precision application of tension to the fiber in addition to precision positioning. Stated another way, an automated positioning tool, such as a CNC machine, allows a uniform tension to be applied to a single continuous fiber material. Also, an automated positioning tool may be programmed to route the continuous fiber material through multiple channels of a mold, the multiple channels defining multiple apertures of a pattern that defines a keyboard structural web. 
     It will be appreciated that while the foregoing describes a structural web used for a keyboard, other structures are contemplated within the scope of the present disclosure. Further, the structural web may be used with any appropriate electronic device and is not limited to a laptop computer or keyboard. Sample devices include other key entry electronic devices, as described herein. As such, the discussion of any electronic devices meant as illustrative only. 
     These and other embodiments are discussed below with reference to  FIGS. 1-18 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1  depicts an example electronic device  100  having a housing  104  and a keyboard  102  incorporated therein. The keyboard may be positioned at least partially within the housing  104 . The keyboard  102  may include a stack-up of layered components that cooperate to initiate an input signal in response to a force input. The keyboard  102  may include a structural web, such as the structural web as discussed above and described in greater detail below. As described herein, the structural web (not shown in  FIG. 1 ) may be configured to provide structural integrity and strength internal components and assemblies of the keyboard  102  and an external environment. In some embodiments, the housing itself, or a portion of the housing such as the web between the keys and/or surrounding the keys, may be formed as a web in accordance with embodiments described herein. That is, the housing and/or a portion thereof may be formed as a layered structure from a single, continuous fiber material as discussed herein. 
     As shown, the electronic device  100  (or “device  100 ”) is a laptop computer, though it can be any suitable electronic device, including, for example, a desktop computer, a smart phone, an accessory, or a gaming device. Moreover, while the keyboard  102  in  FIG. 1  is incorporated with the electronic device  100 , the keyboard  102  may be separate from the electronic device  100 . For example, the keyboard  102  may be a standalone device that is connected (via a cable or wirelessly) to the electronic device  100  as a peripheral input device. The keyboard  102  may also be integrated into another product, component, or device, such as a cover or case for a tablet computer. In such cases, the housing  104  may refer to a housing of any product, component, or device in which the keyboard  102  is integrated or otherwise positioned. 
     The electronic device  100  may also include a display  103  within the housing  104 . In various embodiments, the housing  104  may be constructed from any suitable material, including metals (e.g., aluminum, steel, titanium), polymers, ceramics (e.g., zirconia, glass, sapphire), and the like. In one embodiment, the housing  104  is constructed from multiple materials. The housing  104  can form an outer surface or partial outer surface and protective case for the internal components of the electronic device  100 , and may at least partially surround the display  103 . The housing  104  can be formed of one or more components operably connected together, such as a front piece and a back piece. Alternatively, the housing  104  can be formed of a single piece operably connected to the display  103 . 
     The display  103  may be within or otherwise coupled to a display portion  108  of the housing  104  that is configured to pivot relative to a second portion  109  of the housing  104 . The display  103  can be implemented with any suitable technology, including, but not limited to liquid crystal display (LCD) technology, light emitting diode (LED) technology, organic light-emitting display (OLED) technology, organic electroluminescence (OEL) technology, or another type of display technology. The display  103  provides a graphical output, for example associated with an operating system, user interface, and/or applications of the electronic device  100 . In one embodiment, the display  103  includes one or more sensors and is configured as a touch-sensitive (e.g., single-touch, multi-touch) and/or force-sensitive display to receive inputs from a user. The display  103  is operably coupled to a processor of the electronic device  100   
     The keyboard  102  may be within or otherwise coupled to or incorporated with the second portion  109  (also referred to as a base portion) of the housing  104 . The keyboard  102  includes a set of key assemblies having a keycap or other input surface configured to receive a force input, including a representative key assembly  105 . While the instant application describes components of a representative keyboard  102 , the concepts and components described herein apply to other depressible input mechanisms as well, including key entry devices, card reader devices, standalone keys, switches, or the like. Moreover, such keys, buttons, or switches may be incorporated into other devices, including smart phones, tablet computers, or the like. Suitable input mechanisms may also include trackpads, mice, joysticks, buttons, and so on. 
     For purposes of illustration,  FIG. 1  depicts the electronic device  100  as including the keyboard  102 , the housing  104 , a display  103 , and one or more input/output members  107 . It should be noted that the electronic device  100  may also include various other components, such as one or more ports (e.g., a charging port, a data transfer port, or the like), communications elements, additional input/output members (including buttons), and so on. As such, the discussion of any computing device, such as the electronic device  100 , is meant as illustrative only. 
       FIG. 2  illustrates another example of an electronic device  200 , namely a keypad. The electronic device  200  includes a housing  204 , of which only a portion is shown; a structural web  210  defines an upper portion of the housing  204 . The keypad has multiple keys  205  extending through the structural web  210 . The keypad depicted may be used in any of several ways, such as a control input for a home heating and cooling unit, a security unit, and the like. 
     The structural web  210  includes multiple apertures  215  defined by multiple ribs  213 . A key  205  fits within each aperture  215  and extends from the aperture  215  to slightly above an upper surface of the structural web  210 . Some ribs  213  extend across an entire axis of the keypad. For example, the ribs defining the set of four keys  205  of the upper four rows of the keypad extend horizontally from the left to the right side of the keypad, across substantially a width of the keypad  200 . Similarly, the far right column of keys  205  (from the “F4” key to the “enter” key) includes a rib extending substantially the length of the keypad. 
       FIG. 3A  shows an exploded view of portions of a keyboard  102  of an electronic device with a structural web  310 . The keyboard  102  includes a flexible cover  311  (which may be omitted in many embodiments), structural web  310 , keycaps  314 , switch assemblies  316 , and a substrate  318 . As used herein, the structural web  310 , the keycaps  314 , the switch assemblies  316 , and/or other components or assemblies of the keyboard  102  may be discussed individually or collectively. 
     The structural web  310  may be part of, or affixed to, the housing  104  ( FIG. 1 ), and may define a group of openings  315  configured to receive keycaps  314  therein. The structural web  310  may also include other openings (not shown) for other buttons, input mechanisms, touchpads, microphones, speakers, and/or other components or assemblies. 
     The keycaps  314  may be coupled to switch assemblies  316  and may be manipulated (e.g., pressed or actuated) by a user to provide input to the electronic device  100 . For example, the keycaps  314  may be positioned over collapsible domes of the switch assemblies  316  such that when the keycaps  314  are pressed, the collapsible domes are collapsed to actuate the key and close a switch that allows the electronic device  100  to register an input. 
     The switch assemblies  316  may include components that facilitate mechanical and electrical operations of the keyboard  102 . For example, the switch assemblies  316  may include a switch housing, a dome or other switching element, and a support structure such as a scissor or hinge mechanism. The switch assemblies may be formed on or coupled to a substrate  318 . In some embodiments, the substrate  318  may also be formed from a continuous fiber material in a fashion similar to the structural web  310 , and may be co-cured with the structural web  310  to form a single, rigid component. The substrate  318  may be or may function as a circuit board, and may include conductors (e.g., conductive traces, wires, etc.) that carry electrical signals among various components of the device (e.g., from the switch assemblies  316  to a processor or other circuitry). 
     As described herein, some or all of the functions of the switch assemblies  316  may be integrated into a structural web. For example, conductive fibers may be integrated with the structural web  310  to form a capacitive sensor below a keycap. As another example the structural web  310  may be formed with bottom surfaces with integral spring members formed of carbon fiber, where the spring members movably support the keycaps  314  above the substrate  318 . 
     In some embodiments, the keyboard  102  may not include components depicted in  FIG. 3A . For example, the flexible cover  311  may be omitted from the keyboard  102 . In such an embodiment, the structural web  310  forms an externally facing upper surface of the keyboard  102 . 
       FIG. 3B  shows an exploded view of portions of another example keyboard  320  of an electronic device with a structural web. The keyboard  320  may be an embodiment of or otherwise similar to the keyboard  102  described above. The keyboard  320  may include keycaps  322 , a structural web  326  (e.g., a key web), and a substrate  328 . These components may be the same as or similar to the keycaps  314 , structural web  310 , the substrate  318 , respectively, of  FIG. 3A , and for brevity details of those components will not be repeated here. 
     The keyboard  320  also includes a structural web  326 . The structural web  326  may be part of, or affixed to, a housing (e.g., the housing  104 ,  FIG. 1 ), and may define a group of openings  327  configured to receive keycaps  322  therein. The structural web  326  may also include other openings (not shown) for other buttons, input mechanisms, touchpads, microphones, speakers, and/or other components or assemblies. 
     The keyboard  320  may also include a flexible cover  324 . The flexible cover  324  may be formed of or include any suitable material, such as a textile fabric, polymer sheet, composite material, or the like. The flexible cover  324  may define openings  325 , which may generally align with the openings  327  in the structural web  326 . The openings  325  may be smaller than the openings  327 , such that a portion of the flexible cover  324  extends into or partially encloses the top of the openings  327  in the structural web  326 . Keycaps  322  may be larger than the openings  325 , and may be positioned over the flexible cover  324  and optionally in contact with the flexible cover  324 . As described herein, the flexible cover  324 , and more particularly the portions of the flexible cover that extend over the openings  327 , may act as a spring member and/or supporting structure for the keycaps  322 . In some cases, the flexible cover  324  may provide sufficient support that no hinge mechanism (e.g., a scissor mechanism, a butterfly hinge) needs to be used to movably support a keycap. The flexible cover  324  may also form a seal that prevents ingress of liquid, debris, or other contaminants into the interior of a device. 
     In some cases, the flexible cover  324  is integrated with the structural web  326 . For example, as described in greater detail with respect to  FIGS. 11A-11D , the flexible cover  324  may be incorporated with the material of the structural web  326  during the manufacturing process of the structural web  326 . In such cases, the structural web  326  and the flexible cover  324  may be co-cured together or otherwise integrated to form a single integrated part. In such cases, the flexible cover  324  may not be removable from the structural web  326  without destroying the structural web  326  and/or the flexible cover  324 . 
     The keyboard  320  may also include switch assemblies, such as the switch assemblies  316  described above with respect to  FIG. 3A . In such cases, the switch assemblies may be positioned below the keycaps  322  and below the flexible cover  324 . 
       FIGS. 4A-4F  illustrate an example mold and operations for manufacturing a structural web for an electronic device, the structural web formed from a single continuous fiber material.  FIG. 4A  illustrates a sample mold  400  used to manufacture a structural web  480 .  FIGS. 4B-E  illustrate example operations used to manufacture a structural web  480  using the mold  400 .  FIG. 4F  illustrates a completed structural web  480  manufactured using the mold  400 . 
     A structural web  480  may be formed by repeatedly layering a single continuous fiber material  460  in a keyboard web pattern defined by multiple retention channels of a mold  400 . A first end  461  of the fiber is positioned in a first retention channel  401  of the mold  400 . The fiber  460  is then stretched, under tension, along the remaining portion of the first retention channel  401 , and subsequently routed throughout other retention channels to form the shape of the desired web. The single continuous fiber material  460  is repeatedly routed though the retention channels, forming layered walls surrounding each of the multiple apertures  423  of the mold  400 , thereby mapping a keyboard web pattern. Adhesive is applied to the layered fiber web or is an existing component of the fiber (e.g., if the fiber is a pre-preg fiber as discussed above). The layered fiber web is then heated and compressed to form a structural web made of a carbon fiber reinforced polymer. 
     With attention to  FIG. 4A , an example mold  400  is depicted with major axis  433 , minor axis  431 , and thickness  435 . The major axis is oriented in a longitudinal, horizontal, or first direction. The minor axis is oriented in a lateral, vertical, or second direction. The mold is substantially planar. 
     The mold  400  includes multiple retention channels which define multiple apertures  423 . The retention channels are configured to receive a portion of the fiber  460  unfurled from the fiber roll  440 . The fiber  460  is layered or stacked in the retention channels to form a layered fiber web. In the mold  400  of  FIGS. 4A-E , a set of four retention channels  401 ,  403 ,  405 ,  407  are oriented in a first or horizontal direction, each parallel with the major axis of the mold  400 . A first retention channel  401  is positioned along a first edge of the mold  400 . Second retention channel  403  and third retention channel  405  are positioned along an inner portion of the mold  400 . And fourth retention channel  407  is located at a second edge of the mold  400 . 
     A set of four retention channels  402 ,  404 ,  406 ,  408  are oriented in a second or vertical direction, each parallel with the minor axis of the mold  400 . A fifth retention channel  402  is positioned along a third edge of the mold  400 . Sixth retention channel  404  and seventh retention channel  406  are positioned along an inner portion of the mold  400 . And eighth retention channel  408  is located at a fourth edge of the mold  400 . Each of sixth retention channel  404  and seventh retention channel  406  do not follow or trace a straight line like the other retaining channels of the mold  400 , but rather each change direction with a set of two 90 degree turns. 
     The multiple retention channels define multiple apertures  423 . In the embodiment of the mold  400  of  FIGS. 4A-E , the set of eight retention channels define nine apertures  423 . The nine apertures  423  are not of uniform shape or size, some forming a square shape and other a rectangular shape. The varied aperture size is similar to portions of the structural web  310  of  FIG. 3A  (or the structural web  326  of  FIG. 3B ). The nine apertures  423  are configured to receive respective keycap, such that the keycap may actuate vertically within a particular aperture  423 . 
     Each of the multiple retention channels is of a cross-sectional shape to reflect the desired cross-sectional shape of the layered fiber web and, ultimately, the structural web. For example, the retention channels may be of a rectangular cross-section, to include a squared or flat bottom and vertical edges extending 90 degrees from the bottom of the retention channel, to provide a structured web with rectangular cross-section. For example, as depicted in  FIG. 4F , the finished structural web  480  includes nine apertures  483 , each with rectangular edges of thickness  490 . 
     As briefly discussed, a layered fiber web  470  is formed by repeatedly layering a single continuous fiber material  460  in a keyboard web pattern defined by multiple retention channels of a mold  400 . With attention to  FIG. 4B , a first end  461  of a fiber  460  is unfurled from a fiber roll  440 . The fiber roll  440  contains a sufficient length of fiber  460  to repeatedly lay fiber  460  within the multiple retention channels of the mold  400 . The length of fiber  460  depicted in fiber roll  440  is reduced in length for clarity purposes only. 
     The first end  461  of fiber  460  is attached to a first mold point  441  of a portion of the first retention channel  401  of the mold  400 . The attachment of the first end  461  of fiber  460  may be to a bottom portion or lower surface of the first retention channel  401 . The attachment of the first end  461  of fiber  460  may be to an end of the first retention channel  401 , meaning adjacent the intersection of the first retention channel  401  and the fifth retention channel  402 . 
     The first end  461  of fiber  460  may be attached to first mold point  441  of the first retention channel  401  of the mold  400  by any of several ways. For example, the first end  461  may be fitted with an adhesive such as a glue to attach to the first mold point  441  of the first retention channel  401 . In some embodiments, the first end  461  of the fiber  460  attaches to a tow element disposed at the first mold point  441 , as discussed with respect to  FIGS. 5A-B . In one embodiment, the first retention channel  401  includes an integrated hook feature disposed at the first mold point  441  which may receive the first end  461  of the fiber  460 . In some embodiments, the first end  461  is attached at any point within the first retention channel  401 , to include a lower surface and an edge surface of the first retention channel  401 . 
     After the first end  461  of the fiber  460  is attached to the first retention channel  401  of the mold  400  at the first mold point  441 , the fiber  460  is laid along the remaining portion of the first retention channel  401  in a first direction. Stated another way, the fiber  460 , from the attached first end  461 , is then laid along or within the first retention channel  401  in a first or longitudinal direction parallel with the major axis  433  of the mold  400 . The fiber  460  is laid from first mold point  441  to second mold point  442 . The laying of the fiber  460  within the first retention channel  401  may occur while the fiber  460  is under tension. When the laying of the fiber  460  within the first retention channel  401  occurs under a tension, the fiber  460  may stretch in length. 
     Fiber roll  440  is configured to unfurl the fiber  460  as the fiber  460  is positioned and routed through the multiple retention channels of the mold  400 . The fiber roll  440  may be a manually operated device or operated automatically, such as through an automated machine. The fiber roll  440  device may be any device that predictably and reliably unfurls the fiber  460 . In some embodiments, the fiber roll  440  is configured to impart a selectable tension to the fiber  460  as the fiber  460  is unfurled. It should be appreciated that dimension of the fiber roll and fiber are exaggerated for illustrative purposes. 
     With attention to  FIG. 4C , the fiber  460  is further unfurled from the fiber roll  440  and routed through additional retention channels of the mold  400 . Generally, the fiber  460  is routed, in this embodiment, in a back and forth manner along the major axis  433  of the mold  400 , working the fiber  460  from a lower edge area of the mold  400  to an upper edge area of the mold  400 . The fiber  460 , as depicted in  FIG. 4C , is routed from the following points of the mold: first mold point  441 , second mold point  442 , third mold point  443 , fourth mold point  444 , fifth mold point  445 , sixth mold point  446 , seventh mold point  447 , and eighth mold point  448 . Note that the fiber  460  makes substantially 90 degree turns at each of the mold points. The routing of the fiber  460  along the major axis  433  and minor axis  431  directions of the mold  400  results in definition of the apertures  423 . 
     After the laying of the fiber  460  in a first direction from the first mold point  441  along the first retention channel  401  to a second mold point  442 , the fiber  460  is turned to a second direction and laid within eighth retention channel  408 . The second direction is transverse to the first direction and parallel to the minor axis  431  of the mold  400 . The second direction may be substantially 90 degrees to the first direction. Note that the turning of the fiber  460  by 90 degrees at second mold point  442  may include the fiber  460  pressing against a cornered channel edge formed at the intersection of first retention channel  401  and eighth retention channel  408 . In some embodiments, a change in direction of the fiber  460 , such as the change occurring at mold point  442 , may be enabled or facilitated with a tow fixture, as described with respect to  FIGS. 5A-B . The fiber  460  is routed and laid within the eighth retention channel  408  until the fiber  460  reaches third mold point  443 . 
     The fiber  460  is then turned 90 degrees and routed and lay within the second retention channel  403  until the fiber  460  reaches fourth mold point  444 . Note that the fiber  460 , when laid in the second retention channel  403  from third mold point  443  to fourth mold point  444 , is laid in a direction opposite to the first direction. Stated another way, the laying of the fiber  460  from third mold point  443  to fourth mold point  444  within the second retention channel  403  is performed in a direction 180 degrees from the direction of laying of the fiber  460  from first mold point  441  to second mold point  442  within the first retention channel  401 . 
     After the laying of the fiber  460  in the second retention channel  403  to the fourth mold point  444 , the fiber  460  is routed and laid in fifth retention channel  402  from fourth mold point  444  to fifth mold point  445 . The direction of the fiber  460  in fifth retention channel  402  is parallel and in the same direction of the fiber  460  laying direction within eighth retention channel  408 . 
     After the laying of the fiber  460  in the fifth retention channel  402  to the fifth mold point  445 , the fiber  460  is routed and laid in third retention channel  405  from fifth mold point  445  to sixth mold point  446 . The direction of the fiber  460  in the third retention channel  405  is parallel and in the same direction of the fiber  460  laying direction within first retention channel  401 . 
     Upon reaching sixth mold point  446 , the fiber  460  turns 90 degrees and is laid within eighth retention channel  408  from sixth mold point  446  to seventh mold point  447 . The direction of the fiber  460  in the eighth retention channel  408  is parallel and in the same direction of the fiber  460  laying direction within both the eighth retention channel  408  and fifth retention channel  402 . 
     Lastly, upon the fiber  460  reaching seventh mold point  447 , the fiber  460  turns 90 degrees and is laid within the fourth retention channel  407  from seventh mold point  447  to eighth mold point  448 . Note that the direction of the fiber  460  in the fourth retention channel  407  is parallel and in the same direction as that of the fiber  460  within the second retention channel  403  between third mold point  443  and fourth mold point  444 . 
     It is noted that after the laying of the fiber  460  depicted in  FIG. 4C , the fiber  460  has begun to define the set of nine apertures  423  of the layered fiber web  470 . Also, a single continuous fiber material  460  runs across the major axis  433  length of the mold (and the layered fiber web  470 ) four times, one time each within the four major axis retention channels  401 ,  403 ,  405 ,  407 . A continuous fiber material running the length of the major axis  433  will, among other things, increase the relative longitudinal strength of the formed layered fiber web  470  and, once cured, the finished structural web  480 . 
     After completing a routing of the fiber  460  through each of the four major axis  433  lengths of the mold  400 , the fiber  460  is routed and laid within the minor axis  431  lengths of the mold  400 , as depicted in  FIG. 4D . 
     With attention to  FIG. 4D , the fiber  460  is depicted as routed within two of the lateral or minor axis  431  retention channels of the mold  400 . Specifically, the fiber  460  is depicted routed from eighth mold point  448  to ninth mold point  449 , then to tenth mold point  450 , and finally to eleventh mold point  451 . The fiber  460 , when routed between eighth mold point  448  and ninth mold point  449  within fifth retention channel  402 , defines an outer edge perimeter of the layered fiber web  470 . Note that a portion of the fiber  460  routed within fifth retention channel  402 , is adjacent to a portion of the fiber  460  already routed through a portion of fifth retention channel  402 . Thus, the portion of fiber  460  now routed from eighth mold point  448  to ninth mold point  449  overlaps or is layered with the previously laid portion of fiber  460 , thereby providing a portion of fiber  460  layered with itself. Such layering of the fiber  460  with itself will ultimately form the layered fiber web  470 . Note also that ninth mold point  449  is adjacent to first mold point  441 . In some embodiments, ninth mold point  449  is coincident with first mold point  441 . In some embodiments, the fiber  460 , at the ninth mold point  449 , is layered with the portion of fiber  460  lying at first mold point  441 , thereby beginning the layering of the fiber  460  upon itself. 
     The fiber  460 , from ninth mold point  449 , turns 90 degrees to lie within first retention channel  401 . However, the fiber  460 , unlike previous fiber routings within a given retention channel, does not run the length of the retention channel. Instead, the fiber  460 , from ninth mold point  449 , is laid within first retention channel  401  to tenth mold point  450  within first retention channel  401 . 
     The portion of fiber  460  routed and laid between mold point  449  and tenth mold point  450  within first retention channel  401  overlaps or is layered with a portion of fiber  460  already existing in first retention channel  401 . From tenth mold point  450 , the fiber  460  turns 90 degrees and is routed and laid within sixth retention channel  404 . Note that sixth retention channel  404 , unlike most retention channels (for example, all major axis  433  retention channels  401 ,  403 ,  405 ,  407 ), does not form a straight path. Instead, sixth retention channel  404  includes to paired 90 degree turns, in reflection of the non-uniform configuration of the apertures  423 . 
     After the laying of the fiber  460  depicted in  FIG. 4D , a single continuous fiber material  460  runs across the minor axis  431  length of the mold twice, one time within each of the minor axis retention channels  402 ,  404 . A continuous fiber material running the length of the minor axis  431  will, among other things, increase the relative lateral strength of the formed layered fiber web  470  and, once cured, the finished structural web  480 . 
     It should be appreciated that the continuous fiber material  460  may be laid multiple times within a single channel or within multiple channels, in order to fill the channels and/or impart additional strength to portions of a finished product. Thus, although the continuous fiber material  460  is shown as being laid only once in a single layer in each channel, in many embodiments the continuous fiber material may be laid multiple times in each channel, and/or in a particular pattern between mold points. The continuous fiber material  460  may be laid multiple times within a channel before entering (or being laid within) another channel, thus doubling back on itself one or more times. These multiple layers within a single channel are not illustrated solely for purposes of clarity. 
     For example, the continuous fiber material  460  may be laid or stretched along a particular retention channel or first set of retention channels a greater number of times than along a different retention channel or second set of retention channels. More specifically, the continuous fiber material  460  may be stretched along the first retention channel  401  a first number of times and stretched along the eighth retention channel  408  a second number of times, the first number of times greater than the second number of times. Thus, the resulting completed structural web will be relatively stronger along the portion associated with the first retention channel  401  than that associated with the eighth retention channel  408  because of the increased number of continuous fibers positioned in the portion associated with the first retention channel  401 . 
     As another example, the continuous fiber material  460  may be laid or stretched along a first set of retention channels a greater number of times than a second set of retention channels, so as to create increased strength along the direction associated with the first set of retention channels. More specifically, the continuous fiber material  460  may be stretched a first number of times along all retention channels positioned along the longitudinal or major axis  433  length of the mold  400 , and stretched a second number of times along all retention channels positioned along the lateral or minor axis  431  length of the mold  400 . Thus, the resulting completed structural web will be relatively stronger along the major axis  433  than the minor axis  431  because of the increased number of continuous fibers positioned along the major axis  433 . 
     The carbon layup process described with respect to  FIGS. 4A-4D  describe that the layers of fiber that extend completely along the major axis (e.g., along the horizontal direction, described with respect to  FIG. 4C ) are added first, and then the layers that extend completely along the minor axis (e.g., along the vertical axis, described with respect to  FIG. 4D ) are added subsequently. However, this is merely one example layup pattern, and other patterns are also possible. For example, the fiber layering process may alternate between horizontal segments and vertical segments. More particularly, a first pass of the fiber  460  may position the fiber  460  in the first retention channel  401  (extending horizontally through the entire retention channel  401 ), and the next pass of the fiber may position the fiber  460  in the fifth retention channel  402  (extending vertically through the entire retention channel  402 ). The process may continue in this manner, with continuous strands being alternately positioned in horizontal and vertical channels, thereby minimizing or reducing the number of fiber segments that do not extend along the full length of a retention slot. 
     A top view of a finished layered fiber web  470 , retained within mold  400 , is depicted in  FIG. 4E . The layered fiber web surrounds each of the multiple apertures of the layered fiber web, and forms layered walls. The layered walls encircle each aperture and form a perimeter of the layered fiber web. 
     The single continuous fiber material  460  is routed and layered within all eight retention channels of the mold  400 . The layered fiber web  470  includes eight apertures  423 , sized to receive keys, as described with respect to  FIG. 3A . The single continuous fiber material  460  is routed through the retention channels so as to repeatedly dispose a length of fiber along an entire length of a retention channels so as to increase strength along an axis parallel with the particular retention channel. For example, as briefly discussed above, the single continuous fiber material  460  is routed or laid across the entire length of each of the major axis  433  retention channels to increase strength along the major axis  433 . For example, multiple continuous fiber material strands along the major axis will increase the torsional or twisting strength of the completed structural web about the major axis. Also, multiple continuous fiber material strands along the major axis will increase the bending strength of the completed structural web about the major axis, and also increase the robustness of the structural web to fatigue loading (such as particularly prevalent in keyboard or keypad uses of the structural web). 
     A finished structural web  480  is depicted in  FIG. 4F . The structural web  480  is formed from the layered fiber web  470  after application of pressure and/or heat to the layered fiber web  470 . Prior to application of pressure and/or heat to the layered fiber web  470 , an adhesive or binding agent is activated. The adhesive may be incorporated with the fiber. For example, the fiber  460  may be a pre-preg fiber in which adhesive already exists adjacent to the fiber  460  or embedded with the fiber  460 . This configuration is discussed in more detail with respect to  FIG. 8 . 
     Alternatively, the adhesive may be applied at one or more steps of the laying of the fiber  460  discussed above. In one embodiment, the adhesive is applied after the layered fiber web  470  is completed, for example, the adhesive is applied to a top surface of the layered fiber web  470 . In one embodiment, the adhesive is applied to each of the multiple retention channels of the mold  400  prior to the laying of the fiber  460  within the retention channels. Embodiments or configurations of the structural web involving the application of adhesive (e.g., non pre-preg fiber embodiments) are discussed in more detail with respect to  FIG. 9 . 
     With attention to  FIG. 4F , a finished structural web  480  is depicted. The structural web  480  is formed after application of heat and or pressure to the layered fiber web  470  depicted in  FIG. 4E . After the application of heat and/or pressure, the continuous fiber material  460  of the layered fiber web  470 , as layered to form the walled apertures  483 , forms a composite, such as a carbon fiber reinforced polymer. Stated another way, the application of heat and/or pressurization causes polymerization of the adhesive matrix with the fiber reinforcement material to form a composite material such as a carbon fiber reinforced polymer. 
     The structural web  480  has thickness  490 . The walls surrounding each of the nine apertures  483  of the structural web  480  are of uniform thickness, and generally form a set of planar surface perpendicular to the upper and lower planar surfaces of the structural web  480 . The finished structural web  480  includes nine apertures  483 , sized to receive keys, as described with respect to  FIG. 3A . 
       FIGS. 5A-B  depict another embodiment of a mold  500  used to manufacture a structural web. The embodiment of the mold  500  is similar to the mold of  FIGS. 4A-E  except that multiple tow fixtures  530  are provided. The mold  500  includes a longitudinal or major axis  533  and a lateral or minor axis  531 . 
     Generally, a tow fixture  530  may provide any of several functions or the completed structural web and/or for the manufacture of the structural web. The tow fixture may secure the end of a continuous fiber material such that the fiber may be stretched under tension and stretched across or along a remaining portion of a retention channel. A tow fixture may also be positioned at one or more locations of direction changes or turns of the fiber. For example, in one embodiment, a tow fixture  530  is positioned within a retention channel of the mold  500 , the tow fixture  530  configured to receive a portion, to include an end portion, of the continuous fiber material  560 . A tow fixture  530  may be located at the intersection of an end of a first retention channel positioned along the major axis  533  of a mold  500  and a second retention channel positioned along a minor axis  531  of the mold  500 . The tow fixture may allow varied tension to be applied to the fiber. For example, a first tension between a first pair of tow fixtures, and a second tension between a second pair of tow fixtures. 
     The tow fixture  530  may be embedded to a wall of a retention channel of the mold  500 . The tow fixture  530  may be configured to allow a portion of the fiber  560  to wrap or encircle the tow fixture  530 . The tow fixture  530  may allow a change in direction of the fiber without the fiber pressing against an inside wall of the retention channel. In some embodiments, the fiber  560  may encircle the tow fixture  530  multiple times. Stated another way, the fiber  560  may wrap around a particular tow fixture  530  multiple times. 
     The tow fixture  530  may be formed or configured such that the tow fixture  530  remains with the mold  500  after completion of the structural web. Stated another way, after the layered fiber web is formed and after heat and/or pressure is applied to the layered fiber web, the tow fixture does not become a part of the resulting structural web, but instead remains with the mold  500 . 
     In one embodiment, the tow fixture  530  may be made of the same material as the mold  500 . In one embodiment, the tow fixture  530  may be made of a different material as the mold  500 , the material of the tow fixture  530  providing alternative material properties to portions of the finished structural web. For example, tow fixtures  530  positioned at corners of the structural web may be made of a softer (or less brittle) material than the structural web so as to withstand greater impact loading (due to, for example, dropping of a keyboard of which the structural web is a component; see  FIGS. 3A, 3B ). 
     In some embodiments, the tow fixture  530  is configured to attach to the layered fiber web such that, after heat and/or pressure is applied to the layered fiber web, the tow fixture  530  remains with the resulting structural web, and detaches from the mold  500 . In some embodiments, multiple tow fixtures  530  are used in the manufacture of the structural web, the multiple tow fixtures  530  having varied characteristics such as varied material properties, shapes, sizes, and the like. 
     In the embodiment of  FIG. 5A , a set of eight tow fixtures  530  are positioned at each of the four corners of the mold  500 , and also at each of four turn points along the minor axis  531  of the mold  500 . The configuration of the mold  500  and tow fixtures  530  facilitates routing or lying of multiple portions of a continuous fiber material along the major axis  533  of the mold  500 . 
       FIG. 5B  depicts a continuous fiber material  560  routed or laid through three retention channels of the mold  500 . A first end  561  of fiber  560  is attached to a tow fixture  530  disposed at an end of the first retention channel  501 . The fiber  560  is unfurled from fiber roll  540 . The fiber  560  extends from the attached position of first end  561  to the opposite end of the first retention channel  501  parallel with the major axis  533  of the mold  500 , wherein the fiber engages a second tow fixture  530 . The fiber  560  then turns 90 degrees in a direction parallel with the minor axis  531  of the mold  500 , wherein the fiber  560  engages a third tow fixture  530 . The fiber turns again 90 degrees in a direction parallel to the major axis  533  of the mold  500 , to engage a fourth tow fixture  530 . 
     The routing and laying of the fiber  560  then proceeds in a similar manner to that described above with respect to  FIGS. 4B-E  to form a layered fiber web. Upon completion of a layered fiber web, pressure and/or heat would be applied to the layered fiber web as discussed previously (and also below with respect to  FIGS. 8 and 9 ), to form a structured web. 
       FIG. 6  depicts another embodiment of a mold  600  used to manufacture a structural web. The embodiment of the mold  600  is similar to the mold of  FIGS. 4A-E  except that a continuous fiber material  660  with of non-uniform diameter is used to form a layered fiber web. The mold  600  includes a longitudinal or major axis  613  and a lateral or minor axis  611 . A fiber with non-uniform diameter allows a different density of fiber to be positioned in different areas of a fiber web without the requirement to layer the fiber to increase density. 
     The fiber  660  has a first diameter  681  and a second diameter  682 . The first diameter  681  is larger than the second diameter  682 . An end of the fiber  660  is attached to first mold point  641 . First mold point  641  is positioned within first channel  601 . The fiber  660  is then laid or routed along the remaining portion of first retainer channel  601  until reaching second mold point  642 . The fiber  660  is unfurled from fiber roll  640 . 
     The fiber  660  is configured such that the length or portion of fiber  660  that is disposed or laid within first retention channel  601  is of first diameter  681 . If the fiber  660  is placed in tension and thus stretched when extending through the first retention channel  601 , the length of fiber  660  when upstretched would be less than the length of the first retention channel  601 . 
     After reaching the second mold point  642 , the fiber  660  is turned 90 degrees to lie within second retention channel  608  from second mold point  642  to third mold point  643 . The fiber  660  is configured such that the length or portion of fiber  660  that is disposed or laid within second retention channel  608  is of second diameter  682 . Similar to the first portion of fiber  660  laying in first retention channel  601 , if the fiber  660  is positioned in second retention channel  608  under tension and thus the fiber  660  is stretched, the length of the unstretched fiber  660  would be less than the length of the second retention channel between second mold point  642  and third mold point  643 . 
     After reaching the third mold point  643 , the fiber  660  is again turned 90 degrees to lie within third retention channel  603  from third mold point  643  to fourth mold point  644 . The fiber  660  is configured such that the length or portion of fiber  660  that is disposed or laid within third retention channel  603  is of first diameter  681 . Similar to the first and second portions of fiber  660  laying in first retention channel  601  and second retention channel  608 , respectively, if the fiber  660  is positioned in third retention channel  603  under tension, the length of the unstretched fiber  660  would be less than the length of the third retention channel  603  between third mold point  643  and fourth mold point  644 . 
     Thus, the fiber  660  fiber may have a first (and larger) diameter for a first length that corresponds to the length of a first retention channel along a major axis of a structural web, and a second (and smaller or lesser diameter to the first length) diameter for a second length that corresponds to a length of a second channel along a minor axis of a structural web. The fiber positioned in the first retention channel will provide a relatively increased density of fiber to that provided in the second retention channel. The use of a fiber  660  with non-uniform diameter allows a different density of fiber to be positioned in different areas of a fiber web without the requirement to layer the fiber to increase density. 
     A processor may assist in determining the relative diameters of fiber as a function of routing or lying of the fiber through the multiple retention channels of a particular mold. The calculation of the lying or routing of a fiber through retention channels of a mold will be discussed in more detail with respect to  FIGS. 8-9  below. 
       FIG. 7  depicts another embodiment of a mold  700  used to manufacture a structural web. The embodiment of the mold  700  is similar to the mold of  FIGS. 4A-E  except that a tool  730  is used in cooperation with the fiber  760  to form a layered fiber web. The mold  700  includes a longitudinal or major axis  713  and a lateral or minor axis  711 . The tool  730  may be manually positioned and/or maneuvered, or may be automatically positioned and/or maneuvered. 
     The tool  730  may be used for any of several purposes. The tool  730  may be used to position the fiber  760  within the multiple retention channels of the mold. For example, the positioning tool may position the fiber  760  within a first retention channel  701  of a mold  700 , as depicted in  FIG. 7 . The tool  730  may be fitted between the fiber roll  740  and the working portion of the fiber  760 , meaning the portion of the fiber  760  being positioned in a retaining channel. 
     The tool  730  may also aid in securing or attaching a portion, to include an end portion, of the fiber  760  to one or more tow fixtures (not shown) that may be included in the mold  700 . (See  FIGS. 5A-B  for more discussion of tow fixtures.) 
     The tool  730  may also be configured to dispense an adhesive, such as a glue, to or on the fiber  760  before the fiber  760  is positioned in a retention channel. For example, the fiber  760  furled in fiber roll  740  may be fiber without any adhesive. However, as the fiber  760  passes through the tool  730 , an adhesive may be applied to the fiber  760 , such that, upon placement in a retention channel, the fiber  760  is coupled to an adhesive. The adhesive may simply ensure that the fiber  760  remains in the retention channel in the placed position, and/or may provide an adhesion so as to couple a placed portion of the fiber  760  to a later portion of fiber  760  positioned over or adjacent the placed fiber  760  portion. 
     The tool  730  may aid in providing a selectable tension to the fiber  760  as the fiber  760  is positioned within a retention channel. Also, as layers of fiber  760  are positioned within the retention channels of the mold  700 , the tool  730  may serve to compress previously placed fiber  760  portions to prepare for a next layer of fiber  760  portions. 
     In one embodiment the tool  730  is automatically positioned and/or maneuvered by an automated positioning tool, such as a computer numeric control (CNC) machine. An automated positioning tool allows lying of the continuous fiber  760  through computer control. Furthermore, an automated positioning tool  730  allows precision application of tension to the fiber in addition to precision positioning. Stated another way, an automated positioning tool  730  such as a CNC machine allows a uniform tension to be applied to a single continuous fiber  760 . Also, an automated positioning tool may be programmed to route the continuous fiber  760  through multiple channels of a mold  700 , the multiple channels defining multiple apertures  723  of a pattern that defines a keyboard structural web. 
       FIG. 8  is a flow chart that describes a method  800  of manufacturing a structural web. The method  800  is similar to the method described above with respect to  FIGS. 4-7 , and in particular to  FIGS. 4A-F  in which a fiber is routed repeatedly stretched through multiple retention channels of a mold to produce a layered fiber web, the layered fiber web subjected to pressure and/or heat to form a structured web, such as the structured web  480  of  FIG. 4F . The method  800  is described with respect to previous  FIGS. 4-7 . The method  800  assumes the fiber is a pre-preg fiber. 
     The method  800  begins at step  802  where a mold is positioned. The mold is positioned in a secure posture such that a continuous fiber material, such as a carbon fiber, may be precisely and repeatedly positioned within retention channels of the mold. The fiber may be positioned within the retention channels under one or more levels of tension. A fiber positioned under tension may stretch, meaning that the fiber will lengthen. 
     At step  806 , a first end of the fiber, as unfurled from a fiber roll, is attached or fixedly secured to a portion of a retention channel of the mold. The first end of the fiber roll may be attached to a tow fixture of the mold, as discussed, for example, with respect to  FIGS. 5A-B  above. 
     At step  810 , the fiber, as attached at a first fiber end to a portion of a retention channel of the mold, is positioned within the retention channels of the mold. For example, the fiber is stretched to route through the multiple retention channels, as described with respect to  FIGS. 4B-D . The routing of the fiber through the retention channels will determine the material properties of the finished structural web. Generally, for example, the strength of a given portion of a finished structural web will increase with additional layering of the continuous fiber material through the corresponding retention channel of the mold. 
     The routing, and thus the layering, of the continuous fiber material through the retention channels of the mold may be determined by a processor. The processor may consider any of several parameters, calculations, and/or analyses to determine the routing of the continuous fiber material. For example, a structural analysis (e.g., a finite element analysis) may determine that a particular aperture of a keyboard (e.g., the aperture receiving the space key of a keyboard), will undergo heightened fatigue loading, and thus suggest an increased strength around that particular aperture. The processor may then cause additional fibers to be routed to encircle the aperture designated to receive the space key so as to provided increased strength. Alternatively, as discussed with respect to  FIG. 6 , a thicker diameter fiber portion may be used to encircle the targeted aperture, so as to increase the relative strength of the targeted aperture. 
     The routing of the fiber through the retention channels of the mold may be performed with aid of a tool, as discussed with respect to  FIG. 7 . The tool may be automated, and may be driven at least partially by a processor. 
     After the fiber is routed through the retention channels of the mold in step  810 , a final or second end of the fiber is attached to the mold at step  814 , and the fiber cut from the fiber roll. The second end may be attached or secured to a tow fixture, as discussed, for example, with respect to  FIGS. 5A-B  above. At the completion of step  814 , a layered fiber web has been formed. 
     After the second or final end of the fiber is attached and the fiber cut from the fiber roll, at step  818  the layered fiber web is subjected to compression (e.g., pressure is applied to the layered fiber). As previously mentioned, method  800  is applicable when the fiber is a pre-preg fiber. Thus, upon application of pressure at step  818 , and/or the application of increased temperature at step  820 , the pre-preg fiber undergoes polymerization. As a result of the application of pressure at step  818  and/or heat at step  822 , the layered fiber web undergoes polymerization of the adhesive matrix (of the pre-preg) with the layered continuous fiber material to form a composite material such as a carbon fiber reinforced polymer. At the completion of step  826 , a structured web is formed. 
     At step  826  the structured web is cooled so as to form a rigid and stable material. At step  830  the completed structured web is removed from the mold. 
     The pressurization and/or heating steps of steps  818  and  822 , respectively, may be performed in any of several ways. For example, the pressurization and/heating may be performed using techniques involving an autoclave, vacuum bagging, and so on. Further, the heating and pressurization operations may occur at the same time or at separate times. As one example, the heating operation may occur prior to the pressurization operation 
       FIG. 9  is a flow chart that describes a method  900  of manufacturing a structural web. The method  900  is similar to the method  800  described above, but the method assumes that the fiber is solely fiber and specifically is not a pre-preg fiber. Stated another way, the method  900  assumes that the fiber is not provided with any adhesive or binding matrix as dispensed from a fiber roll. 
     The method  900  begins at step  902  where a mold is positioned. The mold is positioned in a secure posture such that a continuous fiber material, such as a carbon fiber, may be precisely and repeatedly positioned within retention channels of the mold. Adhesive may be applied to a portion of the retention channels of the mold, such as along the edges of the retention channels and/or along a bottom surface of the retention channels. 
     At step  906 , a first end of the fiber, as unfurled from a fiber roll, is attached or fixedly secured to a portion of a retention channel of the mold. The first end of the fiber roll may be attached to a tow fixture of the mold, as discussed, for example, with respect to  FIGS. 5A-B  above. 
     At step  910 , the fiber, as attached at a first fiber end to a portion of a retention channel of the mold, is positioned within the retention channels of the mold. For example, the fiber is stretched to route through the multiple retention channels, as described with respect to  FIGS. 4B-D . The routing, and thus the layering, of the continuous fiber material through the retention channels of the mold may be determined by a processor. 
     The routing of the fiber through the retention channels of the mold may be performed with aid of a tool, as discussed with respect to  FIG. 7 . The tool may be automated, and may be driven at least partially by a processor. In one embodiment, the tool may provide an adhesive to the fiber as the fiber is unfurled from the fiber roll. 
     After the fiber is routed through the retention channels of the mold in step  910 , a final or second end of the fiber is attached to the mold at step  914 , and the fiber cut from the fiber roll. The second end may be attached or secured to a tow fixture, as discussed, for example, with respect to  FIGS. 5A-B  above. Adhesive may be applied to an upper portion of the layer of fiber disposed in the retention channels at step  916 . At the completion of step  910 , a layered fiber web has been formed. 
     At step  918  the layered fiber web is subjected to compression. Upon application of pressure at step  918 , and/or the application of increased temperature at step  920 , the adhesive, as applied in any or all of the above steps to the fiber and/or the layers of fiber, undergoes polymerization. As a result of the application of pressure at step  918  and/or heat at step  922 , the layered fiber web undergoes polymerization of the adhesive matrix (of the pre-preg) with the layered continuous fiber material (of the layered fiber web) to form a composite material such as a carbon fiber reinforced polymer. At the completion of step  922 , a structured web is formed. 
     At step  926  the structured web is cooled so as to form a rigid and stable material. At step  930  the completed structured web is removed from the mold. 
     A structural web formed in accordance with the foregoing techniques may be secured to other components within an electronic device housing (and/or the housing itself) in order to increase the strength, stiffness, or other structural property of the device. Due to the material of the structural web and the manner in which the structural web is formed, various techniques may be used to secure the structural web to another component of a device.  FIGS. 10A-10D  illustrate various example techniques for securing a structural web to a substrate. The structural webs and substrates in  FIGS. 10A-10D  may be embodiments of any of the structural webs and substrates described herein, and while details of those components may not be repeated here for brevity, it will be understood that properties, characteristics, materials, functions, and the like of those components apply equally to the embodiments shown in  FIGS. 10A-10D . 
       FIG. 10A  illustrates a partial cross-sectional view of an example electronic device  1001 , which may be an embodiment of the device  100 ,  FIG. 1 . The cross-sectional view shown in  FIG. 10A  may correspond generally to a view along line A-A in  FIG. 1  (or a similarly positioned line through a different device), though some components shown in  FIG. 1  may be omitted for clarity. As shown in  FIG. 10A , a structural web  1000  may be secured to a substrate  1002  (which may correspond to a substrate  318 ,  328 ). The portions of the structural web  1000  shown may correspond to the ribs that define an opening  1003  in which a keycap and/or other components of a switch assembly may be positioned. The substrate  1002  and the structural web  1000  may be positioned above and coupled to a housing component  1004 , which may define an exterior wall of the housing (e.g., the bottom wall of a base portion of a laptop computer). 
     As shown in  FIG. 10A , the structural web  1000  and the substrate  1002  are co-cured to define a single integrated component. For example, the structural web  1000  and the substrate  1002  may be formed separately, optionally partially cured, and then, prior to fully curing, placed in contact with one another. After being placed in contact, they may be cured together such that the matrix materials of the structural web  1000  and the substrate  1002  may adhere, fuse, intermingle, or otherwise bond together to form a unitary matrix structure. As another example, the structural web  1000  and the substrate  1002  may be formed as a single component. For example, a continuous carbon fiber may be used to form both the substrate  1002  and the structural web  1000  (using the same or similar forming techniques described above), and the matrix material may encapsulate both the web portion and the substrate portion. 
     In some cases, the substrate  1002  and the structural web  1000  may be formed from different materials. For example, the structural web  1000  may be formed of a carbon fiber composite, and the substrate  1002  may be formed from or include a metal (e.g., aluminum, stainless steel, titanium, etc.). In order to establish a secure coupling between the structural web  1000  and a metal substrate  1002 , the metal substrate  1002  may have engagement features such as clips, posts, pins, holes, or the like, and the carbon fiber of the structural web  1000  may be intertwined or otherwise engaged with the engagement features of the substrate  1002 . The matrix material may then be applied and cured such that the rigid structural web  1000  is interlocked with the metal substrate  1002 . A mold may be positioned on the metal substrate  1002  before or after the carbon fiber is engaged with the engagement features to help position the carbon fiber and the matrix material in the appropriate locations to define the shape of the structural web  1000 . 
       FIG. 10B  illustrates a partial cross-sectional view of an example electronic device  1011 , which may be an embodiment of the device  100 ,  FIG. 1 . The cross-sectional view shown in  FIG. 10B  may correspond generally to a view along line A-A in  FIG. 1  (or a similarly positioned line through a different device). 
     As shown in  FIG. 10B , a structural web  1010  may be secured to a substrate  1012  using an adhesive  1013 . The structural web  1010  and the substrate  1012  may be positioned above and coupled to a housing component  1014 , which may define an exterior wall of the housing (e.g., the bottom wall of a base portion of a laptop computer). The adhesive  1013  may be any suitable adhesive, such as a pressure sensitive adhesive, heat sensitive adhesive, epoxy, cyanoacrylate, or the like. The adhesive  1013  may be positioned between the structural web  1010  and the substrate  1012  after the structural web  1010  and the substrate  1012  are formed and cured, or it may be positioned between the structural web  1010  and the substrate  1012  before they are cured, and it may be co-cured with the structural web  1010  and the substrate  1012 . 
       FIG. 10C  illustrates a partial cross-sectional view of an example electronic device  1021 , which may be an embodiment of the device  100 ,  FIG. 1 . The cross-sectional view shown in  FIG. 10C  may correspond generally to a view along line A-A in  FIG. 1  (or a similarly positioned line through a different device). 
     As shown in  FIG. 10C , a structural web  1020  may be secured to a substrate  1022  using fasteners  1023 . The structural web  1020  and the substrate  1022  may be positioned above and coupled to a housing component  1024 , which may define an exterior wall of the housing (e.g., the bottom wall of a base portion of a laptop computer). The fasteners  1023  may be threaded fasteners such as screws or bolts, or other types of fasteners such as rivets. The structural web  1020  may define openings  1025  that receive the fasteners  1023  and optionally include threads that engage with the threads of the fasteners  1023 . The openings  1025  may be formed in the structural web  1020  during the molding and/or layup process described above. For example, a mold in which a structural web  1020  is formed may include protruding features that extend into a mold cavity to define the openings  1025 . When a carbon fiber is layered in the mold cavity, the fiber and matrix material may surround or otherwise accommodate the protrusions such that when the matrix material is cured the openings  1025  are defined in the structural web  1020  without the carbon fiber being broken or severed due to a drilling, tapping, and/or machining operation. 
       FIG. 10D  illustrates a partial cross-sectional view of an example electronic device  1031 , which may be an embodiment of the device  100 ,  FIG. 1 . The cross-sectional view shown in  FIG. 10D  may correspond generally to a view along line A-A in  FIG. 1  (or a similarly positioned line through a different device). 
     As shown in  FIG. 10D , a structural web  1030  may be secured to a substrate  1032  via an interlock between in the structural web  1030  and/or the substrate  1032 . The structural web  1030  and the substrate  1032  may be positioned above and coupled to a housing component  1034 , which may define an exterior wall of the housing (e.g., the bottom wall of a base portion of a laptop computer). The structural web  1030  may define support segments  1033  that extend below the substrate  1032  and contact (and are optionally secured to) the housing component  1034 . The contact between the housing component  1034  and the support segments  1033  of the structural web  1030  may improve the structural rigidity, stiffness, strength, or the like of the device  1031 . For example, the additional structural integration of the structural web  1030 , the substrate  1032 , and the housing component  1034  may reduce the likelihood of these components shearing or sliding relative to one another, which may in turn increase the bending stiffness or other structural property of the device  1031 . 
     As shown, the structural web  1030  defines recesses  1035  that receive portions of the substrate  1032 . The structural web  1030  and the substrate  1032  may be assembled together during the process of forming the structural web  1030 . For example, the carbon fiber for the support segments  1033  may be positioned in a mold, after which the substrate  1032  may be positioned on top of the support segments  1033 , after which web portions  1037  of the structural web  1030  may be formed (e.g., using the same continuous fiber that was used to form the support segments  1033 ). The support segments  1033  and the web portions  1037  may together define the recesses  1035  in the structural web  1030 . The matrix material of the structural web  1030  may then be cured to form a rigid assembly. In some cases, the substrate  1032  is at least partially cured during the curing of the matrix material of the structural web  1030 , thus resulting in an at least partially unitary matrix between the structural web  1030  and the substrate  1032 . 
       FIGS. 11A-11C  depict partial cross-sectional views of various example devices that include flexible covers positioned over and/or integrated with a structural web. These devices may generally correspond to the keyboard configuration shown in  FIG. 3B  in which a flexible cover defines openings that correspond to and/or are aligned with the keycap openings in a structural web. Flexible covers may be flexible sheets, layers, or membranes, and may be formed of or include plastic, fabric, or the like. Where the flexible cover is a fabric cover, the fabric may be organic materials, synthetic materials, woven materials, knit materials, composite materials, coated fabrics, sealed fabrics, watertight fabrics, multi-layer fabrics, or the like. 
       FIG. 11A  illustrates a partial cross-sectional view of an example electronic device  1100 , which may be an embodiment of the device  100 ,  FIG. 1 . The cross-sectional view shown in  FIG. 11A  may correspond generally to a view along line A-A in  FIG. 1  (or a similarly positioned line through a different device). 
     The device  1100  includes a substrate  1102  (which may be an embodiment of the substrate  328 ,  FIG. 3B , or any other substrate or keyboard feature plate described herein), a structural web  1104  (which may be an embodiment of the structural web  310 ,  FIG. 3B ), a flexible cover  1106  (which may be an embodiment of the flexible cover  324 ,  FIG. 3B ), and a keycap  1108 . The device  1100  may define a space  1109  below the keycap  1108  in which a switch assembly may be positioned. The switch assembly may include components that facilitate mechanical and electrical operations of the keyboard. 
       FIG. 11A  illustrates a device  1100  in which the flexible cover  1106  is overlaid on the structural web  1104 . The flexible cover  1106  may be adhered to the structural web  1104  with an adhesive or other bonding agent. In some cases, the flexible cover  1106  is co-cured with the structural web  1104  such that a matrix or resin material of the flexible cover  1106  and a matrix material of the structural web  1104  form a unitary structure, thus securing the flexible cover  1106  and the structural web  1104  together. 
     The keycap  1108  may be attached to the flexible cover  1106  (e.g., with adhesive), or it may simply be positioned on or above the flexible cover  1106 . The flexible cover  1106  may be sufficiently flexible to allow the keycap  1108  to move downward when a user presses on the keycap  1108  to provide an input to the keyboard. The flexible cover  1106  may function as a seal or guard to prevent or inhibit the ingress of dust, dirt, liquid, or other debris or contaminants into the space  1109 . The areas of the flexible cover  1106  between adjacent keycaps may also be exposed and thus define an exterior surface of the keyboard. 
       FIG. 11B  illustrates a partial cross-sectional view of an example electronic device  1110 , which may be an embodiment of the device  100 ,  FIG. 1 . The cross-sectional view shown in  FIG. 11B  may correspond generally to a view along line A-A in  FIG. 1  (or a similarly positioned line through a different device). 
     The device  1110  includes a substrate  1112  (which may be an embodiment of the substrate  328 ,  FIG. 3B , or any other substrate or keyboard feature plate described herein), a structural web  1114  (which may be an embodiment of the structural web  310 ,  FIG. 3B ), a flexible cover  1116  (which may be an embodiment of the flexible cover  324 ,  FIG. 3B ), and a keycap  1118 . The device  1110  may define a space  1119  below the keycap  1118  in which a switch assembly may be positioned. The switch assembly may include components that facilitate mechanical and electrical operations of the keyboard. 
       FIG. 11B  illustrates a device  1110  in which portions of the flexible cover  1116  are positioned in recesses  1117  in the structural web  1114 . The flexible cover  1116  may be assembled with the structural web  1114  in a manner similar to the process described with respect to  FIG. 10D , where the structural web  1114  and the flexible cover  1116  are assembled together during the process of forming the structural web  1114 . For example, the carbon fiber for the lower portions  1113  of the structural web  1114  may be positioned in a mold, after which the flexible cover  1116  may be positioned on top of the lower portions  1113 . Web portions of the structural web  1114  (e.g., the portions above the flexible cover  1116 ) may then be formed (e.g., using the same continuous fiber that was used to form the lower portions  1113 ). The matrix material of the structural web  1114  may then be cured to form a rigid assembly. In some cases, the flexible cover  1116  is at least partially cured during the curing of the matrix material of the structural web  1114 , thus resulting in an at least partially unitary and/or integrated matrix between the structural web  1114  and the flexible cover  1116 . In other cases, the flexible cover  1116  is not integral with the matrix of the structural web  1114 . The structural web  1114  may pass through openings in the flexible cover  1116 , as shown. More particularly, the flexible cover  1116  may define openings that are adjacent to and at least partially surround the keycap openings, and the narrowed portion of the structural web  1114  (corresponding to the recesses  1117 ) may extend through those openings. In some cases, the openings that into which the structural web  1114  extend do not completely sever or separate the flexible cover  1116  into multiple different segments, but instead the flexible cover  1116  may be a single segment with multiple discontinuous openings. 
       FIG. 11C  illustrates a partial cross-sectional view of an example electronic device  1120 , which may be an embodiment of the device  100 ,  FIG. 1 . The cross-sectional view shown in  FIG. 11C  may correspond generally to a view along line A-A in  FIG. 1  (or a similarly positioned line through a different device). 
     The device  1120  includes a substrate  1122  (which may be an embodiment of the substrate  328 ,  FIG. 3B , or any other substrate or keyboard feature plate described herein), a structural web  1124  (which may be an embodiment of the structural web  310 ,  FIG. 3B ), a flexible cover  1126  (which may be an embodiment of the flexible cover  324 ,  FIG. 3B ), and a keycap  1128 . The device  1120  may define a space  1129  below the keycap  1128  in which a switch assembly may be positioned. The switch assembly may include components that facilitate mechanical and electrical operations of the keyboard. 
       FIG. 11C  illustrates a device  1120  in which the flexible cover  1126  is sandwiched between an upper portion  1121  and a lower portion  1125  of the structural web  1124 .  FIG. 11C  also shows an example fiber orientation within the structural web  1124 . For example, fibers  127  may be aligned so that the long axis of the fiber is substantially parallel to the length of the walls of the structural web  1124  (as illustrated by the ends of the fibers  1127  being visible in the cross-sectional view). 
     The structural web  1124  and the flexible cover  1126  may be assembled together in a manner similar to the process described with respect to  FIGS. 10D and 11B , where the structural web  1124  and the flexible cover  1126  are assembled together during the process of forming the structural web  1124 . For example, the carbon fiber for the lower portion  1125  of the structural web  1124  may be positioned in a mold, after which the flexible cover  1126  may be positioned on top of the lower portion  1125 . The upper portion  1123  of the structural web  1124  may then be formed on top of the flexible cover  1126 . In this example, the upper portion  1123  may be formed of or include a single, continuous carbon fiber, and the lower portion  1125  may be formed of or include a single, continuous carbon fiber, though the fibers for the upper and lower portions may not be the same fiber (e.g., they may be discontinuous fibers). After the carbon fibers for the upper and lower portions  1123 ,  1125  are positioned above and below the flexible cover  1126 , respectively, the matrix material may be cured. In some cases, the flexible cover  1126  is at least partially cured during the curing of the matrix material of the upper and lower portions  1123 ,  1125 , thus resulting in an at least partially unitary and/or integrated matrix between the structural web  1124  and the flexible cover  1126 . In other cases, the matrix material of the upper and lower portions  1123 ,  1125  may adhere or bond to the flexible cover  1126  to form an integrated component. In other cases, the upper and lower portions  1123 ,  1125  may be formed (and at least partially cured) separately from one another, and the flexible cover  1126  may be secured between them using adhesives or other bonding agents. 
       FIG. 11C  shows an example configuration in which the flexible cover  1126  is substantially flat or planar in the region between the upper and lower portions  1123 ,  1125 .  FIG. 11D  shows an example configuration in which a flexible cover  1136  has a folded or otherwise non-planar shape. More particularly,  FIG. 11D  illustrates a partial cross-sectional view of a device  1130 , which may be similar to the device  1120  except in the shape of the portion of the flexible cover  1136  that is between the upper and lower portions  1133 ,  1135  of the structural web. This configuration may allow the carbon fibers  1137  to reside in the loops and contours defined by the folded portion of the flexible cover  1136 , which may increase the strength of the bond between the flexible cover  1136  and the structural web, or otherwise improve a mechanical property of the assembly that includes the upper and lower portions  1133 ,  1135  and the flexible cover  1136 . 
       FIGS. 11A-11C  illustrate example devices in which a flexible cover is attached to or integrated with a structural web. In each case, a switch assembly may be positioned under the keycap and the flexible cover to provide input detection functionality and mechanical support and tactile feedback for the keycaps. For example, the switch assemblies may include scissor or butterfly hinges to support the keycap, and a dome switch to detect key makes. In some cases, the mechanical support and/or tactile feedback functionalities may be provided by the flexible cover instead of (or in addition to) other mechanical support mechanisms such as scissor or butterfly hinges.  FIGS. 12A-12B  illustrate one such embodiment. 
       FIGS. 12A-12B  illustrate partial cross-sectional views of an example electronic device  1200 , which may be an embodiment of the device  100 ,  FIG. 1 . The cross-sectional view shown in  FIGS. 12A-12B  may correspond generally to a view along line A-A in  FIG. 1  (or a similarly positioned line through a different device).  FIG. 12A  illustrates a key in an unactuated (e.g., undepressed) state, and  FIG. 12B  illustrates the key in an actuated (e.g., depressed) state. 
     The device  1200  may include a keycap  1208  that is attached to a flexible cover  1206 . The flexible cover  1206  may be integrated with a structural web  1204 , which may be attached to a substrate  1202 . As shown, the flexible cover  1206 , structural web  1204 , and substrate  1202  are similar to the configuration shown in  FIG. 11B , though other configurations are also contemplated. 
     The keycap  1208  may be attached to the flexible cover  1206  such that the flexible cover  1206  mechanically supports the keycap  1208  above a switching element  1209  (which may be a dome switch or any other component that detects actuation of the keycap  1208 ). When the keycap  1208  is depressed or actuated, the flexible cover  1206  may deform to allow the keycap  1208  to move and engage the switching element  1209 .  FIG. 12B  shows the device  1200  in an actuated state in which the flexible cover  1206  is deformed and/or deflected in response to an application of force on the keycap  1208 . The switching element  1209 , shown as a dome switch, is collapsed, resulting in the detection of a key press. Once the actuation force is removed from the keycap  1208 , the flexible cover  1206  may return the keycap  1208  to the position shown in  FIG. 12A . 
     The deformation of the flexible cover  1206  may provide a resistance force, and optionally a “click” feel, when the keycap  1208  is actuated. Further, the flexible cover  1206  may movably support the keycap  1208  between an actuated position ( FIG. 12B ) and an unactuated position ( FIG. 12A ). Accordingly, the flexible cover  1206  may provide several functionalities to the key, and may thus allow the omission of other components, such as hinges, mechanical supports, and the like. Further, because these functions are provided at least in part by the flexible cover  1206 , the switching element  1209  may not need to provide such functions. This may allow a wider range of switching elements to be used, as it may not be necessary for the switching element to provide a force to return the keycap to an unactuated state, for example. 
       FIGS. 12A-12B  illustrate devices in which a flexible cover provides mechanical and/or tactile functionality to a key of a keyboard. Forming a structural web from carbon fiber as described herein may allow for the integration of other types of structures and mechanisms that provide similar functionality.  FIGS. 13A-13C  illustrate an example device  1300  in which fibers extend over a key opening in a structural web and provide various mechanical and/or electrical functions to the key. 
       FIG. 13A  is a partial view of a device  1300 , showing a portion of a structural web  1302 . The portion of the structural web  1302  shown in  FIG. 13A  may correspond to an area similar to the area B-B in  FIG. 4F  (or a similar area of any other structural web described herein). The structural web  1302  may be formed of a carbon fiber material as described herein, and may define a key opening  1304 . Fibers  1306  may be integrated with the structural web  1302  and may extend across the key opening  1304 . The fibers  1306  may be any suitable material. For example, the fibers  1306  may be carbon fibers. In such cases, the fibers  1306  may be a portion of a continuous carbon fiber that also forms the structural web  1302 . In such cases, the fiber may be positioned over the opening  1304  as part of the carbon lay-up process for the structural web  1302 . In other cases, the fibers  1306  may be separate or discontinuous fibers that are integrated with the other carbon fibers of the structural web  1302 . The fibers  1306  may be encapsulated in a matrix material (e.g., the same matrix material as the other portions of the structural web  1302  or a different matrix material), or they may remain uncoated. In some cases, the fibers  1306  remain uncoated or treated with a matrix material that allows the fibers  1306  to elastically deform, as described with respect to  FIGS. 13B-13C . The fibers  1306  may be formed from or include any suitable material. For example, they may be carbon fiber (e.g., the same or a different carbon fiber than that used for the bulk of the structural web  1302 ), a polymer material, an elastic polymer material, metal, amorphous metal, an alloy, aramid, or the like. 
       FIG. 13A  illustrates various ways that the fibers  1306  may be integrated with the structural web  1302 . For example, a single fiber segment  1307  may define a serpentine path that is anchored in the matrix of the structural web  1302  and makes several passes across the key opening  1304 . As another example, a single fiber segment  1309  that also forms walls of the structural web  1302  may have a segment that passes across the key opening  1304  between segments that define the walls of the structural web  1302 . The fiber segments  1307 ,  1309  may be a portion of a single fiber that forms the structural web  1302 , as described above. As yet another example, multiple discrete fibers  1308  may extend across the opening  1304 , with their respective ends anchored in the matrix of the structural web  1302 . While  FIG. 13A  shows three different configurations of fiber segments in one key opening, this is merely for illustrative purposes, and a given implementation of a structural web may include only one configuration of the fiber segments (e.g., either a serpentine fiber segment such as the segment  1307 , a group of individual discrete fiber segments such as the segments  1308 , or segments of fibers where the portion extending across the opening is between portions defining sidewalls such the segment  1309 ). Alternatively, the segments extending across the opening may include combinations of these or configurations of fiber segments. 
     The fibers  1306  may provide various functions to a key of a keyboard. For example, the fibers  1306  may movably support a keycap  1310  above a switching element, in a manner similar to the flexible cover  1206  in  FIGS. 12A-12B .  FIGS. 13B-13C  illustrate partial cross-sectional views of the example electronic device  1300 . The cross-sectional view shown in  FIGS. 13B-13C  may correspond generally to a view along line C-C in  FIG. 13A  (or a similarly positioned line through a different device), and may include components not shown in  FIG. 13A  (e.g., a substrate, a keycap, and a switching element).  FIG. 13B  illustrates a key in an unactuated or undepressed state, and  FIG. 13C  illustrates the key in an actuated or depressed state. 
     The device  1300  may include a keycap  1310  that is attached to the fibers  1306 . The keycap  1310  may be attached to the fibers  1306  such that the fibers  1306  mechanically support the keycap  1310  above a switching element  1312  (which may be a dome switch or any other component that detects actuation of the keycap  1310 ). For example, the keycap  1310  may be attached to the fibers  1306  using an adhesive, or the keycap  1310  may be molded around the fibers  1306  such that the material of the keycap  1310  encapsulates at least a portion of the fibers  1306 . 
     When the keycap  1310  is depressed or actuated, the fibers  1306  may deform to allow the keycap  1310  to move and engage the switching element  1312 .  FIG. 13C  shows the keycap  1310  in an actuated state in which the fibers  1306  are deformed and/or deflected in response to an application of force on the keycap  1310 . The switching element  1312 , shown as a dome switch, is collapsed, resulting in the detection of a key press. Once the actuation force is removed from the keycap  1310 , the fibers  1306  may return the keycap  1310  to the position shown in  FIG. 13B . 
     The deformation of the fibers  1306  may provide a resistance force when the keycap  1320  is actuated. Further, the fibers  1306  may movably support the keycap  1310  between an actuated position ( FIG. 13C ) and an unactuated position ( FIG. 13B ). Accordingly, the fibers  1306  may provide several functionalities to the key, and may thus allow the omission of other components, such as hinges, mechanical supports, and the like. Further, because these functions are provided at least in part by the fibers  1306 , the switching element  1312  may not need to provide such functions. This may allow a wider range of switching elements to be used, as it may not be necessary for the switching element to provide a force to return the keycap to an unactuated state, for example. 
     In some cases, the fibers  1306  may provide other functionalities instead of or in addition to the mechanical support functions described above. For example, the fibers  1306  may be formed from a light-transmissive material such as a fiber optic material. In such cases, light from a light source (e.g., an LED) may be carried by the fibers  1306  and emitted from the fibers  1306  along the portions that span the opening  1304 . In such cases, light receiving portions of the fibers  1306  may be exposed along a surface of the structural web  1302 , and light may enter the fibers  1306  through the light receiving portions. The fibers  1306  may also include light extracting features (e.g., lens features, surface textures, grooves, etc.) along the portions that span the opening  1304 , which may extract the light. The extracted light may be used to illuminate a glyph on the keycap  1310 , or surrounding areas of the keyboard (e.g., the structural web, etc.). 
     As another example, the fibers  1306  may be conductive and may be configured to carry electrical signals or even act as electrodes for sensing functions. For example, the fibers  1306  may be formed of or include a conductive material such as a metal. The conductive fibers  1306  may be connected to various types of electrical circuitry. In some cases, the conductive fibers  1306  are connected to sensing circuitry and act as electrodes for a touch and/or a force sensor that detects touch- and/or force-based inputs to the keycap  1310 . The sensing circuitry may use any suitable sensing technology or techniques, such as a capacitive sensor, inductive sensor, resistive sensor, piezoelectric sensor, strain-gauge-based sensor, or the like. In the case of capacitive sensors, sensing circuitry may detect electrical changes caused by the proximity of a finger to the fibers  1306 . When a detection threshold is reached (e.g., indicating that a finger is sufficiently close to or in contact with the keycap  1310  or the fibers themselves), the sensing circuitry may register that the key has been actuated. 
     Where the fibers  1306  are conductive and are used to carry electrical signals (e.g., for touch and/or force sensing, or simply for electrical signal routing), the fibers  1306  may have or be connected to exposed conductive terminals on the structural web  1302 , thus allowing access to the conductors. The conductors may be electrically isolated from other conductors within the structural web, for example, by jacketing or insulating the conductors so that they do not short against adjacent carbon fibers or other conductive materials. Further, where the fibers  1306  are conductive and/or are used to carry electrical signals, they may not be configured to deform or provide the mechanical support functions described above with respect to  FIGS. 13B-13C . And while the fibers  1306  are shown as being positioned generally towards the top of the opening  1304  and in contact with the keycap  1310 , other configurations are also contemplated. For example, the fibers  1306  may be positioned nearer the bottom of the opening  1304 , and the keycap  1310  may be positioned above and not in contact with the fibers  1306 . 
       FIGS. 14A-14C  depict an example device  1400  in which mechanical functionality of a key is provided by features of a substrate that may be integrally formed with or attached to a structural web as described herein.  FIG. 14A  is a partial view of a device  1400 , showing a portion of a structural web  1402  and a substrate  1404 . The portion of the structural web  1402  shown in  FIG. 14A  may correspond to an area similar to the area B-B in  FIG. 4F  (or a similar area of any other structural web described herein). The structural web  1402  may be formed of a carbon fiber material as described herein, and may define a key opening  1406 . The substrate  1404  may be formed of a carbon fiber material, and may be co-cured with or attached to the structural web  1402 . In some cases, the structural web  1402  and the substrate  1404  may be formed together (e.g., using a single carbon fiber or a common reinforcement structure) such that they define a single structural component. 
     The substrate  1404  may define a spring member  1407 . The spring member  1407  may be integrally formed with the substrate  1404 . For example, the substrate  1404  may be formed of carbon fiber, allowing detailed shapes, such as the spring member  1407 , to be formed or molded directly into the substrate  1404  as part of the manufacturing process. Accordingly, the spring member  1407  may be part of a monolithic substrate  1404 . 
     The spring member  1407  may provide various functions to a key of a keyboard. For example, the spring member  1407  may movably support a keycap  1410  and optionally provide tactile feedback such as a “click” or detent sensation when the keycap  1410  is actuated.  FIG. 14B  illustrates a partial cross-sectional view of the electronic device  1400 . The cross-sectional view shown in  FIG. 14B  may correspond generally to a view along line D-D in  FIG. 14A  (or a similarly positioned line through a different device), and may include components not shown in  FIG. 14A  (e.g., a keycap). 
     As shown in  FIG. 14B , the spring member  1407  is cantilevered from the substrate  1404 , such that the spring member  1407  defines a free end  1411 . This configuration may produce a particular tactile sensation when the keycap  1410  is depressed. For example, the spring member  1407  may provide a substantially continuous or continuously increasing force response as the keycap  1410  is depressed. 
       FIG. 14C  illustrates a partial cross-section of another example electronic device  1420 , which is similar to the device  1400  except that the spring member  1427  may not be cantilevered, and instead joins the substrate  1424  at two ends (or more) of the spring member  1437 . As shown, the spring member  1427  joins the substrate  1424  at opposite ends, though other configurations are also contemplated. 
     The physical constraints on the spring member  1427  from being joined to the substrate  1424  at two ends may cause the spring member  1427  to produce a tactile (and optionally audible) click or detent when pressed. The click or detent may be produced by an inflection in a force response of the spring member  1427 . For example, as the spring member  1427  is deflected downwards, the force response may increase until it reaches a certain amount of deflection, at which point the force response may briefly decrease, resulting in a feeling of a click or detent. After that point, the force response may increase again. 
     The spring members  1407 ,  1427  may be used to produce the tactile output, and may also provide a biasing force that returns the keycaps  1410 ,  1430  to unactuated positioned. The spring members  1407 ,  1427  may also provide electrical switching functionality, such as by closing an electrical circuit when the spring members are deflected. In some cases, other switching and/or key-make sensing components are used to detect key actuations. Further, other mechanical components such as supports, hinges (e.g., butterfly hinges, scissor hinges), guides, and the like may be used in conjunction with the spring members  1407 ,  1427  to provide other functionality and to support the keycaps. 
     While the features described with respect to  FIGS. 13A-14C  are shown in one key opening, it will be understood that a keyboard may include these features in some or all of the key openings of the keyboard. 
     As noted above, the additive process by which structural webs are formed may allow the integration of other components, materials, fibers, or the like, in addition to the structural carbon fibers and the matrix material.  FIGS. 15A-15B  illustrate an example in which optical fibers are incorporated into a structural web to produce illumination effects. 
       FIG. 15A  is a partial view of a device  1500 , showing a portion of a structural web  1502 . The portion of the structural web  1502  shown in  FIG. 15A  may correspond to an area similar to the area B-B in  FIG. 4F  (or a similar area of any other structural web described herein). The structural web  1502  may be formed of a carbon fiber material as described herein, and may define a key opening with a keycap  1504  positioned at least partially in the opening. 
     The structural web  1502  may include light-transmissive fibers (or light sources) that can emit light  1506  to illuminate portions of the structural web  1502 . In cases where the structural web  1502  is under another component, such as flexible cover, light emitted by the integrated light-transmissive fibers may illuminate the overlying component. Illumination may be used for aesthetic and/or functional purposes, such as to illuminate glyphs or other input regions. 
       FIG. 15B  is a detail view of the area E-E in  FIG. 15A , illustrating an example fiber configuration of the structural web  1502 . The structural web  1502  may include carbon fibers  1508  (or other structural fibers), which form the bulk of the structural web  1502  as described above. The structural web  1502  may also include light-transmissive fibers  1510  that are embedded in the structural web  1502  and at least partially encapsulated and/or secured by the matrix material. The light-transmissive fibers  1510  may be positioned so that they are at or near the top of the structural web  1502  so that light emitted from the fibers  1510  is visible to a user. The light-transmissive fibers  1510  may be incorporated into the structure of the structural web  1502  using the techniques described above for other fibers and/or components. 
     The light-transmissive fibers  1510  may be formed from or include any suitable materials, such as glass, acrylic, polymer, or the like. The light-transmissive fibers  1510  may have exposed light receiving portions into which light may be directed. The light-transmissive fibers  1510  may also include light extraction features such as lens features, surface textures, grooves, etc., at locations where the light is to be emitted from the light-transmissive fibers  1510  (e.g., rather than being transmitted further along the fiber without being emitted through a side wall of the fiber). These features may allow light to escape the light-transmissive fibers  1510  through the sides of the fibers where desired, while capturing and propagating the light where light emission is undesirable or unnecessary. 
       FIG. 16  illustrates an example structural web  1602  in which conductive conduits  1608  are integrated with the structural web  1602  to route signals between various locations and/or components of a device. The structural web  1602  has a shape and configuration similar to that shown in  FIG. 4F , though this is merely one example, and the same features described with respect to the structural web shown in  FIG. 16  may equally apply to other structural webs shown or described herein. As described herein, the structural web  1602 , which may be used as a key web and may define external surfaces of a device such as a laptop computer, may also include conductive conduits that form electrical interconnects between internal components of the laptop. 
     The structural web  1602  may include conductive conduits  1608  that are incorporated into the matrix material of the structural web  1602  using the techniques described above (e.g., placing them in a mold along with the structural carbon fibers and encapsulating the conduits and carbon fibers in a matrix material). The conductive conduits  1608  may be conductive wires, traces, fibers, or any other suitable conductive material. The conductive conduits  1608  may terminate at connectors  1604  that include terminals  1606  to couple to other components. The connectors  1604  may be integrated with the structural web  1602  in the same or similar manner as other components, fibers, and the like, as described above. 
     The conductive conduits  1608  and associated connectors may allow the structural web  1602  to act as an electrical interconnecting structure for multiple components. For example, the conductive conduits  1608  may carry power from a battery to multiple different components. As another example, a conductive conduit  1608  may carry a signal from an input device (e.g., a button, key, switch, etc.) to a processor or other circuitry. As yet another example, a conductive conduit  1608  may carry signals from an antenna to communication circuitry, or even itself act as a radiating and/or receiving structure of an antenna. 
     While the description of  FIG. 16  relates to conductive conduits, the same or similar configuration may be used for other types of conduits as well. For example, the conductive conduits  1608  may instead be optical conduits (e.g., fiber optic strands), and the connectors  1604  may include optical connectors. 
       FIG. 17  illustrates an exploded view of a portion of a device  1700 . The device  1700  may correspond to laptop computer, and more particularly to a base portion of a laptop computer. The device  1700  includes an internal interconnect web  1704  that is used to interconnect various components within the laptop. The interconnect web  1704  may be formed using the same or similar process as described above for other structural webs. The device  1700  may also include a housing component  1708  that may define one or more exterior walls of the device  1700  and may at least partially define an interior volume of the housing in which the circuit board  1702  and the interconnect web  1704  are positioned. In some cases, the interconnect web  1704  is attached to the housing component  1708  using fasteners, adhesives, mechanical interlocks, or the like. 
     The device  1700  includes a circuit board  1702 . The circuit board  1702  may include processors, memory, and/or other circuitry that provide computing functions of a laptop. The device  1700  also includes an interconnect web  1704 . The interconnect web  1704  may be formed of a continuous carbon fiber in a matrix material. The interconnect web  1704  may define openings  1711  in which other components may be positioned. For example,  FIG. 17  illustrates batteries  1706  that may fit into the openings  1711 . 
     The interconnect web  1704  may include conductive conduits  1710 ,  1712  formed into the matrix material of the interconnect web  1704 , as described above, as well as connectors  1716 ,  1718  for connecting other components to the conductive conduits  1710 ,  1712 . For example, the interconnect web  1704  may include battery connectors  1716  that conductively couple to corresponding connectors  1720  on the batteries  1706 . The conductive conduits  1712  carry electrical power from the batteries  1706  through the interconnect web  1704  and to a circuit board connector  1718  (which may conductively couple to or otherwise interface with the circuit board  1702  to provide electrical power to the components on the circuit board  1702 ). The conductive conduit  1710  may conductively couple an embedded component  1714  to the circuit board connector  1718 . The embedded component may be any suitable component, such as an antenna, light source, speaker, microphone, connector, sensor, or the like. The connectors  1716 ,  1718  and the embedded component  1714  may be embedded in the interconnect web  1704  using techniques described above, for example, by including them in a mold and at least partially surrounding them with the matrix material of the interconnect web  1704 . Thus,  FIG. 17  illustrates how various different types of interconnects may be formed in a single structural web formed of carbon fiber using the manufacturing process(es) described above. Further, because of the strength and/or stiffness of a carbon fiber web such as the interconnect web  1704 , the interconnect web  1704  may provide the interconnect functionality described above while also producing a device that is stronger, stiffer, tougher, or otherwise improved relative to configurations without the interconnect web  1704 . 
     Various structural webs described herein define key openings in which switch assemblies and keycaps may be positioned. As the keycaps are pressed downwards into the key openings, air pressure within the openings may increase due to the change in volume under the keycap. In order to prevent the increased air pressure from negatively affecting the function and/or tactile feel of the key mechanism, venting structures may be formed in a structural web to allow air to escape from under the keycap during key actuation (and to re-enter the volume under the keycap as the keycap is returning to an unactuated state). 
       FIG. 18  illustrates an example structural web  1802  that includes venting structures for allowing air to flow into and out of key openings  1804 . In some cases, the structural web  1802  may define a channel  1812  that defines a vent path from the key opening  1804  to another volume or area. The channel  1812  may be formed during the molding process of the structural web  1802 , as opposed to being machined after the web is cured, to ensure that no fibers in the structural web  1802  are severed and to maintain the structural integrity of the structural web  1802 . 
       FIG. 18  also illustrates an air conduit  1810  that may be embedded in the structural web  1802 . The air conduit  1810  may be a tube, hose, or other hollow structure. The air conduit  1810  may be positioned in the structural web  1802  so that a first opening  1808  communicates with the key opening  1804  and a second opening  1806  communicates with another volume (e.g., outside of the structural web  1802 ). The air conduit  1810  may be incorporated in the structural web  1802  in a manner similar to other components described herein, such as by placing the air conduit  1810  in a mold during a carbon layup process, encapsulating the air conduit  1810  and the carbon fiber in the matrix material, and then curing the matrix material. 
     Either or both of the air conduit  1810  and the channel  1812  may be used in any given implementation. Further, while  FIG. 18  illustrates one air conduit  1810  and one channel  1812 , other implementations may use multiple conduits or channels. For example, a structural web  1802  may include at least two channels  1812  for each key opening. The particular number and dimension of the air conduits  1810  and the channels  1812  may be selected to achieve a particular venting performance. In some cases all of the key openings in a structural web may be interconnected via air conduits  1810  and/or channels  1812 , essentially forming an interconnected network so that air can move between various key openings and optionally an external space. 
     The foregoing structures may all be manufactured using a single carbon fiber layup process as described above with respect to  FIGS. 4A-9 . In some cases, other techniques are used in combination with the techniques in  FIGS. 4A-9  for shaping, positioning, molding, curing, or otherwise producing the structures described herein. For example, in cases where a structural web is integrally formed or co-cured with another component (e.g., a substrate, a circuit board, etc.), the other component may include a woven carbon material that includes multiple discontinuous fibers. The web and the other component may be co-cured together so that they bond and forma unitary structure, despite not having a common carbon fiber reinforcing structure. In some cases, in addition to continuous carbon fibers, shorter, discontinuous fibers may be included as reinforcing material within the matrix. These fibers may intermingle with the fibers of various different components that are joined together. For example, chopped carbon fibers may be added to a mold in which a structural web (that includes a single continuous carbon fiber) and a substrate (that includes woven carbon fiber fabric) are being cured with a matrix material. The chopped or smaller fibers may thus form part of the reinforcing material of the final structure (e.g., the single carbon fiber web, the woven carbon fiber substrate, and the chopped carbon fiber may all form the carbon structure of the final, unitary component). Other combinations of carbon fiber reinforcement materials are also contemplated and may be used to produce the components described herein. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20180921
Publication Date: 20201215
Grant Date: 20201215
Priority Date: 20170925
Inventors: LANCASTER-LAROCQUE, SIMON R.
MILLER, ARI P.
Owen-Elia, Christopher I.
WANG, PAUL X.
CAO, ROBERT Y.
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/1637", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/345", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C70/24", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C70/345", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C70/48", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/541", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2229/028", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2307/04", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/70", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1662", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/56", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1662", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/56", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/543", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2105/0872", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2229/034", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2233/07", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/34", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/705", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/24", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29K2063/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2105/0872", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C70/24", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C70/56", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1662", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/541", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/543", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/345", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1637", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/34", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/70", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2233/07", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2063/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C70/48", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2307/04", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 65808701