PATENT DOCUMENT

Publication Number: US-9997308-B2
Application Number: US-201615154706-A
Country: US
Kind Code: B2

Title: Low-travel key mechanism for an input device

Abstract:
A key mechanism for an electronic device includes a switch housing and a hinged structure. As one example, the hinged structure can be a butterfly hinge. The switch housing includes switch pin retaining mechanisms on opposing sides of the switch housing. The hinged structure includes two separate wings that are positioned adjacent to each other such that a cavity is formed between the two wings. The two wings are coupled together by coupling elements. The wings of the hinged structure can include switch housing pins on each arm of the wing that extend into the cavity and couple to the switch pin retaining mechanisms in the switch housing. Various configurations of switch pin retaining mechanisms and switch housing pins can be used to attach the hinged structure to the switch housing.

Claims:
What is claimed is: 
     
       1. A key mechanism, comprising:
 a switch housing defining a set of switch pin retaining mechanisms on opposing sides of the switch housing; and 
 a single hinged structure comprising:
 two symmetric wings constrained to one another by a flexible hinge; and 
 a switch housing pin located on each of the two symmetric wings and extending into a respective switch pin retaining mechanism of the set of switch pin retaining mechanisms. 
 
 
     
     
       2. A hinged structure, comprising:
 two separate wings positioned adjacent to each other such that a cavity is formed between the two wings; 
 coupling elements that couple the two wings together; 
 multiple switch housing pins on each arm of the wings that extend into the cavity; and 
 keycap pins on each arm of the wings that extend out from an exterior surface of the wing. 
 
     
     
       3. The hinged structure of  claim 2 , wherein the wings are formed from a first material and the coupling elements are formed from a second, different material. 
     
     
       4. The hinged structure of  claim 3 , wherein the coupling elements are formed with a fabric. 
     
     
       5. The hinged structure of  claim 3 , wherein at least a portion of each coupling element is formed with a fabric. 
     
     
       6. An electronic device comprising:
 an enclosure; and 
 a keyboard assembly positioned at least partially within the enclosure, the keyboard assembly comprising:
 a substrate positioned within the enclosure; 
 a switch housing positioned over the substrate and defining switch pin retaining mechanisms on opposing sides of the switch housing; and 
 a hinged structure positioned adjacent to the switch housing and comprising:
 wings positioned adjacent to each other such that a cavity is formed between the wings; 
 coupling elements operative to couple the wings together; and 
 multiple switch housing pins on each arm of the wings that extend into the cavity and couple to the switch pin retaining mechanisms in the switch housing. 
 
 
 
     
     
       7. The electronic device of  claim 6 , wherein:
 the switch pin retaining mechanisms comprise multiple U-shaped switch pin retaining mechanisms on each of two opposing sides of the switch housing; and 
 the U-shaped switch pin retaining mechanism have opening that faces one another. 
 
     
     
       8. The electronic device of  claim 6 , wherein:
 the switch pin retaining mechanisms comprise multiple switch pin retaining mechanisms on each of two opposing sides of the switch housing; and 
 at least one switch pin retaining mechanism on each side of the switch housing comprises a U-shaped pin retaining mechanism having an opening that faces another switch pin retaining mechanism on a same side of the switch housing. 
 
     
     
       9. The electronic device of  claim 6 , wherein:
 the switch pin retaining mechanisms comprise multiple switch pin retaining mechanisms on each of two opposing sides of the switch housing; 
 a first switch pin retaining mechanism on each side of the switch housing comprises a U-shaped switch pin retaining mechanism having an opening that faces a keycap; and 
 a second switch pin retaining mechanism on a same side of the switch housing comprises a U-shaped switch pin retaining mechanism having an opening that faces away from the first switch pin retaining mechanism. 
 
     
     
       10. The electronic device of  claim 6 , wherein the coupling elements are formed with a fabric. 
     
     
       11. The electronic device of  claim 6 , wherein:
 the switch pin retaining mechanisms comprise multiple switch pin retaining mechanisms on each of two opposing sides of the switch housing; and 
 each switch pin retaining mechanism defines a cutout in a respective side of the switch housing. 
 
     
     
       12. The electronic device of  claim 6 , wherein:
 the switch pin retaining mechanisms comprise multiple switch pin retaining mechanisms on each of two opposing sides of the switch housing; and 
 at least one switch pin retaining mechanism on each side of the switch housing comprises a cutout in a respective side of the switch housing. 
 
     
     
       13. The electronic device of  claim 11  or  claim 12 , wherein:
 the cutout is a first cutout; and 
 each cutout includes a lead-in cutout adjacent the first cutout. 
 
     
     
       14. The electronic device of  claim 6 , wherein the wings of the hinged structure each comprise keycap pins extending outward from exterior surfaces of the wings. 
     
     
       15. The electronic device of  claim 14 , further comprising:
 a keycap comprising keycap pin retaining mechanisms that are configured to couple to the keycap pins; 
 a membrane layer attached to the substrate; and 
 a dome switch coupled to the membrane layer and positioned in the cavity of the hinged structure. 
 
     
     
       16. The electronic device of  claim 15 , wherein the switch housing substantially surrounds the dome switch and is positioned between the dome switch and the hinged structure. 
     
     
       17. The electronic device of  claim 15 , wherein:
 the switch pin retaining mechanisms comprise multiple U-shaped switch pin retaining mechanisms on each of two opposing sides of the switch housing; and 
 the U-shaped switch pin retaining mechanisms include openings that face the keycap. 
 
     
     
       18. A method of assembling a key mechanism, comprising:
 bending a flexible switch housing that includes a set of blind recesses; 
 positioning the bended switch housing within a cavity of a hinged structure that includes a set of switch housing pins; 
 and 
 unbending the flexible switch housing such that each switch housing pin of the set of switch housing pins is inserted into a blind recess of the set of blind recesses. 
 
     
     
       19. The method of  claim 18 , further comprising attaching the switch housing to a membrane in the key mechanism. 
     
     
       20. The method of  claim 18 , further comprising attaching the switch housing to a substrate in the key mechanism.

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. 62/161,103, filed on May 13, 2015, and entitled “Low-Travel Key Mechanism For An Input Device,” which is hereby incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The present invention relates generally to electronic devices, and more particularly to input devices for electronic devices. 
     BACKGROUND 
     Many electronic devices typically include one or more input devices such as keyboards, touchpads, mice, or touchscreens that enable a user to interact with the device. These devices can be integrated into an electronic device or can stand alone as discrete devices that transmit signals to another device either via a wired or wireless connection. For example, a keyboard can be integrated into the housing of a laptop computer or it can exist as a separate device that is operably connected to a computer. 
     It is often desirable to reduce the size of an electronic device and to minimize the machining costs and manufacturing time of the device. However, as the overall size of an electronic device is reduced, the available space for the keyboard and its various components is also reduced. Consequently, the internal components of the keyboard may be reduced in size or eliminated to decrease the overall size, dimension, and/or thickness of the keyboard assembly. But the reduction or elimination of components or layer(s) in the stack-up of the keyboard may negatively affect the functionality of the keyboard or may require significant re-working of the stack-up, which can increase the time, complexity, and/or cost to manufacture the keyboard assembly. 
     Additionally or alternatively, the reduction or elimination of components or layer(s) in the stack-up may negatively affect the tactile response or “feel” of the key mechanisms in the keyboard. For example, a key mechanism may not provide a user with a desirable amount of tactile response (a “click”) when the user depresses a key mechanism. Alternatively, the downward movement of the key mechanism can be non-uniform depending on where the user presses down on the key mechanism. For example, the downward movement of the key mechanism can differ depending on whether the user presses down at the center of a key mechanism, at a corner of the key mechanism, or at the edge of the key mechanism. 
     SUMMARY 
     A keycap mechanism for an electronic device can include a switch housing and a hinged structure. The switch housing may include switch pin retaining mechanisms that may be positioned on at least two sides of the switch housing (e.g., on opposing sides of the switch housing). The hinged structure includes two separate wings that are positioned adjacent to each other such that a cavity is formed between the two wings. The two wings are coupled together by coupling elements. Each wing of the hinged structure can include switch housing pins that extend into the cavity and are configured to couple with the switch pin retaining mechanisms in the switch housing. Various configurations of switch pin retaining mechanisms and switch housing pins can be used to attach the hinged structure to the switch housing. 
     For example, in one embodiment the switch pin retaining mechanisms include a pair of U-shaped switch pin retaining mechanisms on two opposing sides of the switch housing. The U-shaped switch pin retaining mechanisms in each pair may include openings that face the keycap and are configured to receive switch housing pins. Alternatively, at least one U-shaped switch pin retaining mechanism in a pair has an opening that faces the keycap and is configured to receive a switch housing pin. 
     In another embodiment, the switch pin retaining mechanisms include a pair of L-shaped or U-shaped switch pin retaining mechanisms on two opposing sides of the switch housing. The L-shaped or U-shaped switch pin retaining mechanisms in each pair may include openings that face each other and are configured to receive switch housing pins. Alternatively, at least one L-shaped or U-shaped switch pin retaining mechanism in a pair has an opening that faces towards or away from the other switch pin retaining mechanism in the pair. 
     In another embodiment, the switch pin retaining mechanisms include a pair of U-shaped switch pin retaining mechanisms on two opposing sides of the switch housing. The U-shaped switch pin retaining mechanisms in each pair may include openings that face downward (e.g., toward a substrate). The U-shaped switch pin retaining mechanisms are configured to receive switch housing pins. Alternatively, at least one U-shaped switch pin retaining mechanism in a pair has an opening that faces the substrate and is configured to receive a switch housing pin. 
     In yet another embodiment, the switch pin retaining mechanisms include a pair of switch pin retaining mechanisms on two opposing sides of the switch housing. One switch pin retaining mechanism in the pair can be a U-shaped switch pin retaining mechanism and the other switch pin retaining mechanism in the pair can be a U-shaped or L-shaped switch pin retaining mechanism. The openings in the U-shaped and L-shaped retaining mechanism can face any direction. 
     The keycap mechanism can be included in an electronic device. For example, the keycap mechanism can be part of a keyboard assembly. The electronic device can include an enclosure with the keyboard assembly positioned at least partially within the enclosure. The keyboard assembly may include a substrate positioned within the enclosure, with the switch housing and the hinged structure positioned over the substrate. Each wing in the hinged structure can include keycap pins on each arm that extend out from an exterior surface of the wing. The electronic device may also include a keycap that includes keycap pin retaining mechanisms that are configured to couple to the keycap pins on the hinged structure, a membrane layer attached to the substrate, and a dome switch coupled to the membrane layer and positioned in the cavity of the hinged structure. 
     In some embodiments, a hinged structure can include two separate wings positioned adjacent to each other such that a cavity is formed between the two wings. The two wings are coupled together by coupling elements. Each wing includes a pair of switch housing pins on each arm of the wing that extend into the cavity and keycap pins that extend out from an exterior surface of the wing. At least a portion of each coupling element may be formed with a fabric. 
     In another aspect, a method of assembling a key mechanism can include bending a flexible switch housing and positioning the bended switch housing within a cavity of a hinged structure. The switch housing includes switch pin retaining mechanisms and the hinged structure includes corresponding switch housing pins. The switch housing pins are then placed into respective switch pin retaining mechanisms and the flexible switch housing is unbended such that the switch housing pins are retained within the switch pin retaining mechanisms. 
    
    
     
       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  depicts an example electronic device that includes a keyboard assembly; 
         FIG. 2  illustrates an exploded view of one example of a key mechanism shown in  FIG. 1 ; 
         FIG. 3  depicts a top view of the key mechanism shown in  FIG. 2  with the keycap removed; 
         FIG. 4  illustrates a side view of the key mechanism shown in  FIG. 2  depicting the attachment of the hinged structure to the switch housing when the key mechanism in a rest position; 
         FIG. 5  depicts a side view of the key mechanism shown in  FIG. 2  illustrating the attachment of the hinged structure to the switch housing when the key mechanism is in a depressed position; 
         FIG. 6  illustrates a top view of a second switch housing that is suitable for use in a key mechanism; 
         FIG. 7  depicts a bottom view of the second switch housing; 
         FIG. 8  illustrates a side view of a key mechanism depicting the attachment of the hinged structure to the switch housing shown in  FIG. 6 ; 
         FIG. 9  depicts a side view of a flexible switch housing; 
         FIG. 10  shows a flowchart of a method of coupling the switch housing to the hinged structure; 
         FIG. 11  illustrates a bottom view of a third key mechanism; 
         FIG. 12  depicts a top view of the switch pin retaining mechanism in  FIG. 11 ; 
         FIG. 13  illustrates a side view of the switch pin retaining mechanism in  FIG. 11 ; 
         FIG. 14  depicts a side view illustrating the attachment of the hinged structure to the switch housing shown in  FIG. 11 ; 
         FIG. 15  illustrates a top view of a fourth key mechanism with the keycap removed; 
         FIG. 16  depicts a side view illustrating the attachment of the hinged structure to the switch housing shown in  FIG. 15 ; 
         FIG. 17  illustrates a fifth embodiment of a switch housing; 
         FIG. 18  depicts a top view of a key mechanism with the keycap removed to show a second example of a hinged structure; 
         FIG. 19  depicts a third example of a hinged structure that is suitable for use in a key mechanism; and 
         FIG. 20  depicts a fourth example of a hinged structure that is suitable for use in a key mechanism. 
     
    
    
     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. 
     Embodiments described herein provide a key mechanism for an input device (e.g., a keyboard) that includes a hinged structure, such as a butterfly hinge. The hinged key mechanism can enable substantially low travel distances with good tactile response. The hinged structure includes a double wing design operative to move between a depressed position and non-depressed or rest position. Corresponding arms of the hinged structure are coupled together with coupling elements. The coupling elements can be, for example, a flexible hinge, a gear hinge, an over-molded hinge, and/or a fabric hinge. Various techniques are disclosed for coupling the hinged structure to a switch housing. 
     The techniques disclosed herein for attaching the hinged structure to the switch housing can produce a key mechanism that is easier to assemble and manufacture compared to conventional key mechanisms. Additionally or alternatively, one or more of the techniques can increase the retention force of the attachment between the hinged structure and the switch housing so that it is more difficult to accidentally separate the hinged structure from the switch housing. In some embodiments, one or more of the techniques can simplify the structure of the key mechanism, the switch housing, and/or the hinged structure. 
     These and other embodiments are discussed below with reference to  FIGS. 1-20 . 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  shows an illustrative electronic device that includes a keyboard assembly. The key mechanisms in the keyboard assembly include a switch housing that is attached to a support element or hinged structure by coupling multiple switch housing pins on the hinged structure to corresponding switch pin retaining mechanisms formed in the sides of the switch housing (e.g., on two opposing sides of the switch housing). The hinged structure includes two separate wings that are positioned adjacent to each other and coupled together with coupling elements. Each coupling element (or a portion of a coupling element) can be formed with a fabric, which may increase the strength of the coupling elements. For example, the weave in the fabric can allow a coupling element to bend or flex in one direction but not in another. Additionally, in some embodiments at least a portion of the switch housing is flexible to simplify the attachment process and to reduce the amount of time needed to attach the hinged structure to the switch housing. 
     In the illustrated embodiment, the electronic device  100  is shown as a laptop computer. However, the electronic device  100  may be any suitable electronic device that may utilize a keyboard assembly, a key mechanism, or a similar input device or structure. For example, the electronic device  100  may be a desktop computer, a tablet computing device, a smartphone, a gaming device, a display, a digital music player, a wearable computing device or display, a health monitoring device, and so on. Likewise, the key mechanism  104 , and the components of the key mechanism  104  discussed herein, may be utilized or implemented in a variety of input mechanisms including, but not limited to, buttons, switches, toggles, and wheels. 
     The electronic device  100  may include an enclosure  106 . The enclosure  106  may take the form of an exterior housing or shell for the electronic device  100  and the various internal components in the electronic device  100 . The enclosure  106  may be formed as a single, integral component or as two or more components that operably connect together, such as a front piece and a back piece. Additionally, the enclosure  106  may be formed from any suitable material. In non-limiting examples, the enclosure  106  may be made from a metal, a ceramic, a rigid plastic or another polymer, a fiber-matrix composite, and so on. 
     The keyboard assembly  102  allows a user to interact with the electronic device  100 . Each key mechanism  104  may include a keycap  108  that is positioned within the enclosure  106  of the electronic device  100 . The keycaps  108  may partially protrude from the enclosure  106  and each may be substantially surrounded by the enclosure  106 . That is, the keycaps  108  may extend beyond a surface of the enclosure  106  and may be divided or separated by a portion of the enclosure  106 . In the non-limiting example shown in  FIG. 1 , the keyboard assembly  102  may be positioned within and/or may be received by the electronic device  100 . In another embodiment, the keyboard assembly  102  may be a distinct, standalone component that is operably connected to the electronic device  100  via a wired or wireless connection. 
       FIG. 2  illustrates an exploded view of one example of a key mechanism shown in  FIG. 1 . The key mechanism  104  may be formed from various layers of components, or a stack-up of layered components. Each layer and/or component of the stack-up may provide different functionality and/or operations for the electronic device  100 . Although a single key mechanism  104  is shown in  FIG. 2 , in some embodiments multiple key mechanisms in the keyboard assembly  102  may be formed from similar components and/or layers in a similar configuration and/or may function in a substantially similar manner. Other embodiments can include different or additional layers in a key mechanism than the layers shown in  FIG. 2 . 
     The keyboard assembly  102  may include a substrate  200  positioned within the enclosure  106 . In one embodiment, the substrate  200  can be a printed circuit board (PCB). The substrate  200  may provide a rigid support structure for the various components forming the keyboard assembly  102 . The substrate  200  may include a plurality of electrical traces (not shown) formed therein that may be in electrical communication with distinct components or layers of the keyboard assembly  102 . The traces may subsequently provide an electrical signal (e.g., input) to the electronic device  100  when a keycap and/or dome switch is compressed, as discussed herein. The substrate  200  may cover and/or may include a geometry that is substantially equal to the area of keyboard assembly  102 . 
     As shown in  FIG. 2 , a light source  202  may be positioned on the substrate  200 . The light source  202  may be formed from any suitable light source configured to illuminate the key mechanism  104  and/or the keycap  108 . In a non-limiting example, the light source  202  may be a light emitting diode (LED) coupled and/or affixed to the substrate  200 . 
     The key mechanism  104  may also include a membrane layer  204 . In some embodiments, the membrane layer  204  may be a sensing membrane that includes at least one trace or sensor positioned in or on the membrane layer  204 . As discussed herein, traces or sensors positioned in or on the membrane layer  204  may be configured to detect or determine when the keycap  108  is actuated or depressed by a user, and subsequently provide an electrical signal (e.g., input) to the electronic device  100 . 
     As shown in  FIG. 2 , a dome switch  208  may be coupled directly to the membrane layer  204 . The dome switch  208  may be formed from any suitable material that is substantially flexible, durable, and/or elastic. In a non-limiting example, the dome switch  208  may be formed from an elastomeric material such as rubber. As discussed herein, when the keycap  108  is depressed by a user, the dome switch  208  collapses such that a portion of the dome switch  208  contacts the membrane layer  204  to form an electrical connection and/or input within the electronic device  100 . 
     An adhesive layer  210  may be positioned between the membrane layer  204  and the substrate  200  to attach or directly couple the membrane layer  204  to the substrate  200 . For example, an anisotropic conductive film can be used to adhere and/or bond the membrane layer  204  to the substrate  200 . In another non-limiting example, a pressure sensitive adhesive may be used to attach the membrane layer  204  to the substrate  200 . 
     The key mechanism  104  may also include a switch housing  212 . The switch housing  212  may be formed with any suitable material, including, but not limited to, metal, plastic, and ceramic. As shown in  FIG. 2 , the switch housing  212  may be positioned above the substrate  200  and may substantially surround the dome switch  208 . In a non-limiting example, the dome switch  208 , coupled directly to the membrane layer  204 , may be positioned within an opening  214  of the switch housing  212 . In one embodiment, the switch housing  212  may be attached to the membrane layer  204  using an adhesive layer  216 . The switch housing  212  may be formed from a substantially rigid material for providing support to the various components of the key mechanism  104  and/or for protecting and/or sealing the dome switch  208  within the key mechanism  104 . Additionally, the material forming the switch housing  212  may include optically transparent properties for distributing and/or dispersing the light emitted by the light source  202 . 
     A hinged structure  218  may be positioned outside of and adjacent to the sides of the switch housing  212 . In one embodiment, the hinged structure  218  is a butterfly hinge. The hinged structure  218  may be formed with any suitable material, such as a plastic. As shown in  FIGS. 2 and 3 , the switch housing  212  may be positioned between (e.g., around) and/or may separate the dome switch  208  and the hinged structure  218 . The hinged structure  218  may be affixed within the key mechanism  104  by being coupled to the switch housing  212  and to the keycap  108 . 
     The support element or hinged structure  218  supports the keycap  108  and functions as a movable hinge that enables the keycap  108  to move relative to the substrate  200 . The hinged structure  218  includes wings  220  and  222 , which are separate components coupled together by coupling elements  224 . The wings  220 ,  222  may each include a cutout that defines a cavity  226  when the wings  220 ,  222  are coupled together. The cavity  226  can have any suitable shape such as, for example, a square, a rectangle, circle, or ellipse. The switch housing  212  resides within the cavity  226  and the dome switch  208  extends into the cavity  226  when the key mechanism  104  is assembled. 
     As will be described in more detail later, each wing  220 ,  222  of the hinged structure  218  may include switch housing pins  304 ,  306 ,  308 ,  310  on each arm  221 ,  223  (see  FIG. 3 ) of the wings  220 ,  222  that extend into the cavity  226  and are configured to couple with the switch pin retaining mechanisms  404 ,  406 ,  408  in the switch housing  212  (see  FIG. 4 ). Each wing  220 ,  222  can also include keycap pins  300 ,  302  on each arm  221 ,  223  that extend out from an exterior surfaces of the wings  220 ,  222  (see  FIG. 3 ). 
     The coupling elements  224  can be formed with any suitable material. In some embodiments, the coupling elements  224  are formed with a flexible elastic material, such as rubber. In other embodiments, at least a portion of each coupling element  224  can be formed with a fabric. The fabric can increase the strength of the coupling element  224 . For example, the weave in the fabric can allow the coupling element  224  to bend or flex in one direction but not in another. Additionally or alternatively, in some embodiments the fabric can be formed to be thinner than other materials, which may reduce the size (e.g., length and/or height) of the hinged structure  218 . 
     As shown in  FIGS. 1 and 2 , the keycap  108  may protrude or extend, at least partially, through opening  228  formed in the enclosure  106 . Additionally, the various keycaps  108  of the keyboard assembly  102  may be substantially surrounded and/or separated by web  230  of the enclosure  106 . 
       FIG. 3  is a top view of the key mechanism shown in  FIG. 2  with the keycap removed.  FIG. 4  illustrates a side view of the key mechanism shown in  FIG. 2  depicting the attachment of the hinged structure to the switch housing when the key mechanism is in a rest position.  FIG. 5  illustrates a side view of the key mechanism shown in  FIG. 2  depicting the attachment of the hinged structure to the switch housing when the key mechanism is in a depressed position. In  FIGS. 4 and 5 , other components and layers that may be included in the key mechanism, such as, for example, the adhesive layer  210 , the dome switch  208 , and the adhesive layer  216 , are not shown for clarity. 
     With respect to  FIGS. 3-5 , the wings  220 ,  222  each include keycap pins  300 ,  302  and switch housing pins  304 ,  306 ,  308 ,  310 . The keycap pins  300  each attach to respective keycap pin retaining mechanisms  400  disposed on the bottom surface of the keycap  108 . The keycap pin retaining mechanisms  400  can be integrally formed with the keycap  108  or attached to the keycap  108 . The keycap pin retaining mechanisms  400  secure the keycap pins  300  in place and enable the keycap pins  300  to rotate freely when the key mechanism  104  moves between the rest and depressed positions. 
     Similarly, the keycap pins  302  are held in place by respective keycap pin retaining mechanisms  402  disposed on the bottom surface of the keycap  108 . The keycap pin retaining mechanisms  402  can be integrally formed with the keycap  108  or attached to the keycap  108 . The keycap pin retaining mechanisms  402  secure the keycap pins  302  in place and enable the keycap pins  302  to slide freely when the key mechanism  104  moves between the rest and depressed positions. As shown in  FIGS. 4 and 5 , the keycap pin retaining mechanisms  400  are configured as u-clip or c-clip retaining members while the keycap pin retaining mechanisms  402  have an L or C shape. Other embodiments can use a different structure for a keycap pin retaining mechanism  400 ,  402  and/or may orient a keycap pin retaining mechanism differently. 
     The coupling elements  224  enable the wings  220 ,  222  to move independent of each other. Thus, if one wing is locked in a position, the other wing is free to move, and vice versa. Both wings  220 ,  222  are secured to the switch housing  212  (via switch housing pins  304 ,  306 ,  308 ,  310 ) and the keycap  108  (via keycap pins  300 ,  302 ) and are operative to move (or flap) in concert with each other, with the coupling elements  224  changing the positions of the wings  220 ,  222  between a v-shaped position (the rest position) and a substantially flat-shaped position (the depressed position). In other embodiments, the coupling elements  224  can be omitted from the hinged structure  218 . 
     The manner in which the switch housing pins  304 ,  306 ,  308 ,  310  couple to the switch housing  212  varies depending on specific embodiments, which are discussed below. In the embodiment of  FIGS. 4 and 5 , the switch housing pins  304 ,  306 ,  308 ,  310  couple to respective switch pin retaining mechanisms  404 ,  406 ,  408  of the switch housing  212 . The switch pin retaining mechanisms  404  and  406  secure the switch housing pins  306  and  310 , respectively, in place and enable the switch housing pins  306 ,  310  to rotate freely within a respective switch pin retaining mechanism  404 ,  406  when the hinged structure  218  is attached to the switch housing  212 . The switch pin retaining mechanisms  404  and  406  permit the switch housing pins  306  and  310  to rotate when the keycap  108  is depressed. In a non-limiting example, the switch pin retaining mechanisms  404 ,  406  are each formed as a cutout or a cavity in a side of the switch housing  212  at a location that corresponds to a respective switch housing pin  306 ,  310 . 
     The switch pin retaining mechanism  408  is configured to permit the switch housing pins  304  and  308  to move (e.g., slide and/or raise and lower) when the key mechanism  104  transitions between the rest and the depressed positions. The switch pin retaining mechanism  408  secures the switch housing pins  304  and  308  in place and enables the switch housing pins  304 ,  308  to move freely within the switch pin retaining mechanism  408  when the hinged structure  218  is attached to the switch housing  212 . In a non-limiting example, each switch pin retaining mechanism  408  is formed as a cutout in a side of the switch housing  212  at a location that corresponds to the switch housing pins  304 ,  308 . In one embodiment, the switch pin retaining mechanisms  404 ,  406 ,  408  are formed in opposing sides of the switch housing  212 . 
     In the embodiments shown in  FIGS. 2-5 , the hinged structure  218  can be pre-installed in the switch housing  212  (from the top side of the switch housing) prior to fabrication of the keyboard assembly  102 . This is described in more detail in conjunction with  FIG. 10 . The combined hinged structure  218  and switch housing  212  can then be attached to the membrane layer  204  or to the substrate  200 . 
     Referring now to  FIGS. 6 and 7 , a second switch housing that is suitable for use in a key mechanism is shown.  FIG. 6  depicts a top view of the second switch housing and  FIG. 7  illustrates a bottom view of the second switch housing. The switch pin retaining mechanisms  602 ,  604  secure the switch housing pins  306  and  310 , respectively, in place and enable the switch housing pins  306 ,  310  to rotate freely within a respective switch pin retaining mechanism  602 ,  604  when the hinged structure  218  is attached to the switch housing  600 . Similarly, the switch pin retaining mechanism  408  secures the switch housing pins  304  and  308  in place and enables the switch housing pins  304 ,  308  to move (e.g., slide and/or raise and lower) freely within the switch pin retaining mechanism  408  when the hinged structure  218  is attached to the switch housing  600 . 
     In the illustrated embodiments, the switch pin retaining mechanisms  408 ,  602 ,  604  are configured as cutouts within the switch housing  600  at locations that correspond to respective switch housing pins  304 ,  306 ,  308 ,  310 . In one embodiment, the switch pin retaining mechanisms  408 ,  602 ,  604  are formed in opposing sides of the switch housing  600 . 
     In some embodiments, the lead-in cutouts  606  and  608  adjacent the switch pin retaining mechanism  602  and  604 , respectively, can make it easier to insert the switch housing pins  306  and  310  into the switch pin retaining mechanisms  602  and  604 . The lead-in cutouts  606 ,  608  are configured as cutouts within the switch housing  600  at locations that correspond to respective switch housing pins  306 ,  310 . The lead-in cutouts  606 ,  608  position the switch housing pins  306 ,  310  at locations that correspond to the switch pin retaining mechanisms  602 ,  604 . Additionally, the lead-in cutouts  606 ,  608  reduce the thickness of the switch housing  600  below the switch pin retaining mechanisms  602 ,  604 , which can make it easier to insert the switch housing pins  306 ,  310  into the switch pin retaining mechanisms  602 ,  604 . 
     Additionally, in some embodiments the switch housing  600  (and the switch housing  212  in  FIG. 2 ) can include legs  700  and a cutout  702 . In one embodiment, the legs  700  may attach to the membrane layer  204  (see  FIG. 2 ). In another embodiment, the legs  700  can extend into openings (not shown) in the membrane layer  204  and the adhesive  210  to attach to the substrate  200  (see  FIG. 2 ). The cutout  702  may be included in the switch housing  600  and/or  212  to distribute and/or disperse light emitted by the light source  202  (see  FIG. 2 ). 
     In the embodiments shown in  FIGS. 6 and 7 , the hinged structure  218  can be pre-installed in the switch housing  600  (from the bottom side of the switch housing) prior to fabrication of the keyboard assembly  102 . This is described in more detail in conjunction with  FIG. 10 . As discussed earlier, the lead-in cutouts  606  and  608  can make it easier to insert the switch housing pins  306  and  310  into the switch pin retaining mechanisms  602  and  604  when the hinged structure  218  is installed from the bottom side of the switch housing  600 . The combined hinged structure  218  and switch housing  600  can then be attached to the membrane layer  204  or to the substrate  200 . 
       FIG. 8  illustrates a side view of a key mechanism depicting the attachment of the hinged structure to the switch housing shown in  FIG. 6 . For clarity, other components and layers that may be included in the key mechanism, such as, for example, the adhesive layer  210 , the dome switch  208 , and the adhesive layer  216 , are not shown in  FIG. 8 . 
     The switch pin retaining mechanisms  602  and  604  secure the switch housing pins  306  and  310 , respectively, and permit the switch housing pins  306 ,  310  to rotate freely within the switch pin retaining mechanisms  602 ,  604  when the keycap  108  is depressed. The switch pin retaining mechanism  408  secures the switch housing pins  304  and  308  and enables the switch housing pins  304 ,  308  to move freely (e.g., slide and/or raise and lower) within the switch pin retaining mechanism  408  when the key mechanism  104  moves between the rest and the depressed positions. In a non-limiting example, the switch pin retaining mechanisms  602 ,  604  and the lead-in cutouts  606 ,  608  are each formed as a cutout in a side of the switch housing  600  at locations that correspond to the switch housing pins  306 ,  310 . In one embodiment, the switch pin retaining mechanisms  408 ,  602 ,  604  are formed in two opposing sides of the switch housing  600 . 
       FIG. 9  depicts a side view of a flexible switch housing that is suitable for use as the switch housing  212  or the switch housing  600 . A region  902  of the switch housing  900  can be narrowed or thinned to permit the switch housing  900  to bend around the center of the switch housing  900  (e.g., bend around line  904 ). In some embodiments, it may be easier to insert the switch housing pins  306  and  310  into the switch pin retaining mechanisms  602  and  606  with the switch housing  900  in a bended position. 
     In some embodiments, a method of assembling a key mechanism can include bending a flexible switch housing and positioning the bended switch housing within a cavity of a hinged structure.  FIG. 10  shows a flowchart of a method of coupling the switch housing to the hinged structure. The switch housing includes switch pin retaining mechanisms and the hinged structure includes corresponding switch housing pins. As shown in blocks  1000  and  1002 , the flexible switch housing is bent and the bent hinged structure is positioned in the cavity of the hinged structure. Bending the switch housing can make it easier to position the switch housing within the cavity of the hinged structure. 
     In the embodiment shown in  FIGS. 2-5 , the hinged structure can be positioned over and around the bent switch housing from the top side of the switch housing. Alternatively, in the embodiment depicted in  FIGS. 6-8 , the hinged structure can be positioned over and around the bent switch housing from the bottom side of the switch housing. This configuration allows the lead-in cutouts  606 ,  608  to assist in positioning the switch housing pins  306  and  310  into the switch pin retaining mechanisms  602 ,  604 . 
     Next, as shown in block  1004 , the switch housing pins on the hinged structure are coupled to the switch pin retaining mechanisms in the switch housing. The bent switch housing may make it easier to couple the switch housing pins to the switch pin retaining mechanisms while the switch housing is positioned within the cavity. Finally, at block  1006 , the bent switch housing is un-bent such that the switch housing pins on the hinged structure are retained within the switch pin retaining mechanisms in the housing. Thereafter, the switch housing can be attached to a membrane layer and/or a substrate in the key mechanism. 
     In some embodiments, the switch housings can be connected together when manufactured. The hinged structures may then be attached to the switch housings while the switch housings are connected. Thereafter, the switch housings can be singulated or separated from one another. Keeping the switch housings connected when attaching the hinged structures can improve the alignment of the key mechanisms in the X-Y plane. 
       FIGS. 11-14  depict a third embodiment of a switch housing.  FIG. 11  illustrates a bottom view of a third key mechanism showing the hinged structure. The key mechanism  1100  is similar to the key mechanism shown in  FIG. 3  except for the switch housing  1102 . The switch housing  1102  includes two U-shaped switch pin retaining mechanisms  1104 ,  1106  that retain the switch housing pins  306  and  310 , respectively. A cutout  1108  in the switch housing  1102  retains the switch housing pins  304  and  308 . 
       FIGS. 12 and 13  depict top views of the switch pin retaining mechanisms  1104  and  1106 , respectively.  FIG. 14  depicts a side view illustrating the attachment of the hinged structure to the switch housing shown in  FIG. 11 . For clarity, other components and layers that may be included in the key mechanism, such as, for example, the adhesive layer  210 , the dome switch  208 , and the adhesive layer  216 , are not shown in  FIG. 14 . 
     Referring to  FIGS. 11-14 , the U-shaped switch pin retaining mechanism  1104  may be wider than the U-shaped switch pin retaining mechanism  1106  to permit the switch housing pin  306  to slide when the key mechanism  1100  moves between the rest and the depressed positions. The switch housing pin  310  is secured in and rotates within the U-shaped switch pin retaining mechanism  1106  when the key mechanism  1100  moves between the rest and the depressed positions. And the switch housing pins  304  and  308  are secured in and slide within the cutout  1108  when the key mechanism  1000  moves between the rest and the depressed positions. 
     In the illustrated embodiments, the switch pin retaining mechanisms  1104 ,  1106 ,  1108  are formed as cutouts in at least one side of the switch housing  1102  at a location that corresponds to a respective switch pin  304 ,  306 ,  308 ,  310 . For example, in the illustrated embodiment the switch pin retaining mechanisms  1104 ,  1106 ,  1108  are formed as a cutout in two opposing sides of the switch housing  1102 . 
       FIGS. 15 and 16  depict a fourth embodiment of a switch housing.  FIG. 15  illustrates a top view of a fourth key mechanism with the keycap removed.  FIG. 16  depicts a side view illustrating the attachment of the hinged structure to the switch housing shown in  FIG. 15 . Other components and layers that may be included in the key mechanism, such as, for example, the adhesive layer  210 , the dome switch  208 , and the adhesive layer  216 , are not shown in  FIG. 16  for clarity. 
     Referring to  FIGS. 15 and 16 , the switch housing  1502  includes a U-shaped switch pin retaining mechanism  1504  that secures the switch housing pin  306  in place and enables the switch housing pins  306  to rotate freely in the U-shaped switch pin retaining mechanisms  1504  when the key mechanism  1500  moves between the rest and the depressed positions. The switch housing pin  310  is secured in a switch pin retaining mechanism  1600  that enables the switch housing pins  310  to slide freely within the switch pin retaining mechanism  1600  when the key mechanism  1500  moves between the rest and the depressed positions. 
     The switch housing  1502  can also include a cutout  1508  that permits the switch housing pins  304  and  308  to slide within the cutout  1508  when the key mechanism  1500  moves between the rest and the depressed positions. In a non-limiting example, each switch pin retaining mechanism  1504 ,  1508 ,  1600  is formed as a cutout in at least one side of the switch housing  1502  at a location that corresponds to a respective switch pin  304 ,  306 ,  308 ,  310 . In one embodiment, the switch pin retaining mechanisms  1504 ,  1508 ,  1600  are formed in opposing sides of the switch housing  1502 . 
       FIG. 17  illustrates a fifth embodiment of a switch housing. The key mechanism  1700  and the switch housing  1702  shown in  FIG. 17  can be similar to the embodiment shown in  FIG. 14  except for the switch pin retaining mechanisms  1704 ,  1706 . The U-shaped switch pin retaining mechanisms  1704 ,  1706  are positioned such that the openings in the switch pin retaining mechanisms  1704 ,  1706  face each other. In one embodiment, a switch housing pin (e.g.,  310 ) is secured in place by and rotates freely within one U-shaped switch pin retaining mechanism (e.g.,  1706 ) and the other switch housing pin (e.g.,  306 ) is secured in place by and slides freely within the other switch pin retaining mechanism (e.g.,  1704 ). In other embodiments, both switch housing pins  306 ,  310  can slide within the switch pin retaining mechanisms  1704 ,  1706  when the key mechanism  1700  moves between the rest and the depressed positions. 
     The switch housing  1702  can also include a cutout  1708  that secures the switch housing pins  304 ,  308  and enables the switch housing pins  304  and  308  to move freely (e.g., slide and/or raise and lower) within the cutout  1708  when the key mechanism  1700  moves between the rest and the depressed positions. In a non-limiting example, each switch pin retaining mechanism  1704 ,  1706 ,  1708  is formed as a cutout in at least one side of the switch housing  1702  at a location that corresponds to a respective switch pin  304 ,  306 ,  308 ,  310 . In one embodiment, the switch pin retaining mechanisms  1704 ,  1706 ,  1708  are formed in opposing sides of the switch housing  1702 . 
     When the hinged structure  218  is attached to the switch housing  1702  in the embodiment of  FIG. 17 , the hinged structure  218  can be held in a folded position such that the outer ends of the two wings  220 ,  222  are near each other. The hinged end of the folded hinged structure  218  may then be inserted into the cutout  1708  between the switch pin retaining mechanisms  1704 ,  1706  and the switch housing pins  306 ,  310  aligned with the openings in the switch pin retaining mechanisms  1704 ,  1706 . This also positions the switch housing pins  304 ,  308  in the cutout  1708  of the switch housing  1702 . The hinged structure  218  can then be released from the folded position, allowing the hinged structure  218  to unfold and the switch housing pins  306 ,  310  to slide into the openings in the switch pin retaining mechanisms  1704 ,  1706 . 
     In some embodiments, fasteners such as screws are used to attach the substrate (e.g., PCB) to the enclosure of an electronic device. For example, the fasteners can be inserted or screwed into openings in the bottom surface of the enclosure and extend into the interior of the enclosure and attach to the substrate. In another embodiment, the fasteners may be inserted or screwed into openings in the substrate and extend into and attach to the bottom surface of the enclosure. In such an embodiment, the fasteners can be positioned below the key mechanisms in the keyboard assembly. The key mechanism  1800  shown in  FIG. 18  can be used in embodiments that position fasteners below the key mechanisms. 
     The hinged structure  1802  includes two wings  220  and  1804 . Wing  1804  includes a cutout  1806  that can extend around a fastener  1808 . The fastener  1808  is shown as a screw, but other types of fasteners can be used. The cutout  1806  can accommodate the fastener  1808  and allow the fastener  1808  to be inserted and removed without removing or damaging the wing  1804  and/or the hinged structure  1802 . 
     In some embodiments, a hinged structure  1900  can include a stiffener or support plate  1902  (see  FIG. 19 ). The support plate is attached to the top surface of the portion of the wing  1804  adjacent the cutout  1806  (see  FIG. 19 ). The support plate  1902  can provide support and strengthen the portion of the wing  1804  adjacent the cutout  1806 . The support plate  1902  may be attached to the wing  1804  using any suitable attachment mechanism. For example, in one embodiment an adhesive can be used to attach the support plate  1902  to the wing  1804 . 
     Additionally or alternatively, as shown in  FIG. 20 , a hinged structure  2000  that includes a cutout  1806  in a wing  2002  can extend the wing portion (see  2004 ) around or adjacent to the cutout  1806 . The projection  2004  of the wing  2002  may extend into the cavity of the hinged structure  2000 . The projection  2004  can increase the strength of the wing  2002 . 
     In embodiments that include the cutout  1806 , a shield can be positioned over or adjacent the cutout. For example, a pattern of apertures or cuts can be positioned in structures over, within, and/or around the cutout  1806 . In some embodiments, the pattern of cuts can prevent contaminants, such as a liquid, from entering into the key mechanism and/or the keyboard assembly. For example, in some embodiments the tension in the cuts or apertures can be sufficiently high to prevent a liquid from entering the cutout  1806 . 
     In some embodiments, the substrate  200  may act as a mechanism that retains the switch housing (e.g.,  212 ) and the hinged structure  218  within the key mechanism (e.g.,  104 ) and the keyboard assembly  102 . 
     In some embodiments, a switch pin retaining mechanism that permits the switch housing pin to rotate is directly below a keycap retaining mechanism that allows the keycap pin to slide. This can increase the retention force of the attachment between the switch housing and the hinged structure. 
     Although the switch pin retaining mechanisms have been described as cutouts formed in a side of the switch housing, other embodiments can form the switch pin retaining mechanisms differently. For example, other embodiments can form the switch pin retaining mechanisms differently. For example, a loop or a hook that is formed in or on the switch housing, or attached to the switch housing, may be used as a switch pin retaining mechanism. 
     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 targeted 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: 20160513
Publication Date: 20180612
Grant Date: 20180612
Priority Date: 20150513
Inventors: LEONG, Craig C.
CAO, ROBERT Y.
ZERCOE, BRADFORD J.
MATHEW, DINESH C.
BERG, BRUCE E.
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H3/125", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1666", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/88", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/705", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H3/125", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/85", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/88", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1666", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/86", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/705", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H13/705", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1666", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H3/125", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/88", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/86", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/85", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 56027264