Thin keypad assemblies and components for electronics devices and methods.

(54) Title: THIN KEYBOARD ASSEMBLIES AND COMPONENTS FOR ELECTRONIC DEVICES AND METHODS.

(54) Title: THIN KEYPAD ASSEMBLIES AND COMPONENTS FOR ELECTRONICS DEVICES AND METHODS.

(57) Summary

The present invention relates to a keyboard assembly, the keyboard assembly comprises: a plurality of keys flexibly coupled to a carrier portion, the plurality of keys have a user interface side and a rear side, the plurality of keys and the carrier portion constitute a substantially flat unitary member, the plurality of keys is defined by grooves through the unitary member, the grooves are devoid of a material from which the plurality of keys and the carrier portion are formed, no part of the carrier portion extends into the grooves between adjacent keys; a resilient material that bridges the grooves between the plurality of keys; A luminescent layer positioned towards the rear side of the plurality of keys, the luminescent layer carries a plurality of contact caps, the plurality of contact caps are each aligned with a corresponding key of the plurality of keys.

(57) Abstract

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

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Mexican Institute of Industrial Property

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PATENT TITLE NO. 340245

Owner (s): MOTOROLA MOBILITY, INC.

Address: 600 North US Highway45, Libertyville, Illinois, 60048, USA

Name: THIN KEYBOARD ASSEMBLIES AND COMPONENTS FOR

ELECTRONIC DEVICES AND METHODS.

Classification: int.CI.8: G06F3 / 023; H01H13 / 702

Inventor (s): RICHARD J. DOMBROWSKI; RYSZARD J. GORDECKI; DANIEL P. RODGERS;

PATRICK J. CAUWELS; STEVE C. EMMERT

REQUEST

Number: International filing date:

MX / a / 2009/010227 May 26, 2005

Divisional Patent Number: 270707

PRIORITY

Country: Date: Number:

US June 18, 2004 10 / 871,664

Validity: Twenty years

Expiration Date: May 26, 2025

The reference patent is granted based on articles 1, 2 fraction V, 6 fraction III, and 59 of the Law (Industrial Property fabric.

In accordance with article 23 of the Industrial Property Law, this patent has a non-renewable term of twenty years, counted from the date of filing of the international application and will be subject to the payment of the term to maintain the rights in force. .

Who subscribes to this title does so based on the provisions of article * 0^to tcaoelonaa Iti and 7 ° bis ¿of the Industrial Property Law (Official Decree of the Federacteft (DOF) 06/27/1981, to reform the OJ'OS / lbM 25 I^-* 1396, 12/26 / l4 | 7, 05/17/1999, &lt;¿1/6/2004, 06/16/200 &lt;01/25/2 (316, 06/05 / 2009,06 / M8¿LQ , 06/18/2818, 06/28 / gftlO, 01/27 / 2M? And 400 (, 2012) articles f&gt;, 3rd fraction V subsection a), sub subsection ii¡) 4th and 12th tractions I and III of the Joteutu raoteregoto tttenJfnno de M Pm. Industrial age (D.Ci.F. 14/12/1999, reformed on 07/01/2004 07/15/2) 4, 07/28/2004 and 09/07/2007 '«βα« Μ I^to 9^to freffljlír V 'lo a), sub clause ii), 16 factions I and III and .30 of the Organic Statute of the Mexican Literature of IndusM Property PCLf 27712/1999, amended on 10/10/2 (^ 2, 29/07 / 2004, 08/08/2004 and 09/13/20 # #); 1st, 3rd and 5th subsection a) and the third to last paragraph of the Agreement that delegates powers to the General Directors

Direct * MMte Wtete * · * • * Bte «l'W | *« tee * e **** tetea * lr? Departmental Coordinators and other subordinates of the Mexican Institute of Industrial Property. (DOF 12/15/1999, amended on 02/04/2000, 07/29/2004, 08/04/2004 and 09/13/2007).

Issue Date: July 1, 2016

DIVISIONAL DEPUTY DIRECTOR OF EXAMINATION OF PATENT FUND, MECHANICAL, ELECTRICAL AREAS AND DEJZEfiWBIMe9HnEÑOS INDUSTRIALES Y

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Arenal No 550, Floor 1.

Col. Pueblo Santa María Tepecan. Xochimico. CP 1tt0z0

Mexico City 551 53 34 07 OI vw ι _ ln

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IMPI

MEXICAN INSTITUTE Dt THE INDUSTRIAL PROPERTY

THIN KEYBOARD ASSEMBLIES AND COMPONENTS FOR

ELECTRONIC DEVICES AND METHODS

FIELD OF THE INVENTION ♦

The present description refers generally to input devices, and very specifically to keyboard assemblies and keyboard components, for example, keyboard assemblies and components for use in super-thin applications, for example, in wireless communication devices, and corresponding methods.

BACKGROUND OF THE INVENTION

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In the past, keyboards in cellular radiotelephone devices have comprised a multi-layer structure that has a large part of a piece that is relatively thick, thereby limiting the thinness of the devices in which the keyboard is integrated. Typical keyboards include a user interface that forms the keys accessible to the user, which are often interconnected via a network. The keys are aligned on a corresponding contact dust cap mounted on a carrier made of Mylar or some other carrier material. The carrier and dust cover assembly are placed in a layer of switch contact circuitry.

IMPI

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To provide keyboard illumination, a luminescent layer is placed between the dust cover and the keys. However, the luminescent layer includes cutouts through which the piston portions of the * keys can contact the dust covers to actuate switches in the circuit layer. This setting lacks luminescence directly below or behind the keys where it is most desired. Instead, the keys are indirectly illuminated by scattered light, part of which emanates from circumferential areas surrounding the keys.

The various aspects, features, and advantages of the description will become more apparent to those skilled in the art upon careful consideration of the following Detailed Description with the accompanying figures described below.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 is an exemplary keyboard assembly.

Figure 2 is an exemplary key layer.

Figure 3 is another exemplary key layer.

Figure 4 is a tab holding the exemplary key layer.

Figure 5 is a part view of an exemplary key layer assembly.

IMPI

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FIG. 6 is a part diagram of an exemplary luminescent / contact dust layer.

Figure 7 is an exemplary luminescent layer that "

It has lots of color.

*

Figure 8 is a sectional view of a portion of an exemplary keyboard assembly.

Figure 9 is a sectional view of a portion of another exemplary keyboard assembly.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a part view of an exemplary keyboard assembly 100 generally comprising a user interface key layer assembly 110, a contact / luminescent overlay layer assembly 120 and a keyboard circuitry layer 130. The exemplary 100 keypad assembly and variations thereof, which will be more apparent from the following discussion, have applications in portable electronic devices, for example, in calculators, personal organizers, personal digital assistants, wireless and connected communication devices including telephones. cell phones, and portable computing machines, among other devices.

Exemplary key assembly layer 110 generally comprises a key layer having a

IMPI ^

MEXICAN INSTITUTE

OF THE PROPERTY tV. J plurality of user interface keys f le $ í33Teme? Rre coupled to a carrier or carrier portions. The igiguia ^ illustrates an exemplary 510 key layer. In one embodiment, each key is flexibly coupled to the carrier along at least one side of the key, and other remaining sides of the key are separated from other keys and / or carrier portions through a gap, thus allowing the keys are flexible in response to the user's tactile pressing action. In another embodiment, each of a plurality of user interface keys are coupled to the carrier by means of a flexible carrier portion positioned along not more than one side of the corresponding user interface key, on which other sides Each user interface key is separated from neighboring keys and / or carrier portions by a space.

Figure 2 illustrates an exemplary key assembly layer 200 viewed from the user interface side thereof. Exemplary keyboard assembly layer 200 includes a plurality of keys, for example, key 7 210, key 0 212, and key 9 214 flexibly coupled by intermediate carrier portions 211 and 213. Figure 2 also illustrates the space between adjacent keys and between keys and carrier potions. For example, there is a space 220 between the 210 key and the * 216 key. The same

IMPI

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space 220 separates key 216 from the carrier portion

211. In Figure 2, at least some of the plurality of keys and some of the carrier portions form a unitary element, for example, * keys 210, 212, 214 and carrier portions 211 and 213.

FIG. 3 illustrates another exemplary key assembly layer 300 viewed from the user interface side thereof. Exemplary key assembly layer 300 includes a plurality of keys, eg, the 7 310 key, the 0 312 key, and the 9 314 key, are flexibly coupled to the intermediate carrier portions 311 and 313.

The key assembly layer of Figure 3 is distinguished from Figure 2 by means of a carrier portion or portions 316 and 318 along the lateral sides of the plurality of user interface keys. Exemplary side carrier portions 316 and 318 interconnect all rows of keys, for example, the row containing keys 1, 5, and 3 and the row containing keys 4, 8, and 6, thereby forming a unitary element comprising the plurality of keys and carrier portions. Figure 3 also illustrates spaces between adjacent keys and between keys and carrier portions. For example, there is a 320 space between the 310 key and the 4 322 number key. Space 320 also extends between key 310 and carrier portion 316.

* IMPI

MEXICAN INSTITUTE I heard THE PROPERTY

INDUSTRIAL

FIG. 5 illustrates a part view of an exemplary key assembly layer 500 comprising a key layer 510, and a flexible web 520 applied to the rear of the key layer. In one embodiment, the key layer including the plurality of user interface keys flexibly coupled to the wearer is formed from a single sheet material, eg, stainless steel, or aluminum, or phosphor bronze, alloy copper or some other suitable metallic material. In an exemplary embodiment, the keycap is of SS304 stainless steel grade. In other embodiments, the key layer is formed of a synthetic or composite material with appropriate stiffness and flexibility characteristics. In some embodiments, the plurality of keys is defined by the formation of gaps in a stamping process or some other material removal process, for example, by chemical or laser engraving, high-speed fluid cutting, etc. In other embodiments, the keys are formed in a casting or casting process or some other manufacturing process. In one embodiment, the key layer is no more than 1.5mm thick, and in an exemplary super-thin keyboard application, the key layer is between about 0.2 and about 0.3mm thick. However, these exemplary ranges are not intended to be limited.

IMPI

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Other exemplary ranges are discussed below:

In Figure 1, the exemplary key assembly layer 110 comprises a plurality of fastening tabs protruding from the side portions of the keyboard layer. FIG. 4 is a more detailed view of an exemplary clamping tab 400. Clamping tab 400 includes a first tab 410 extending from a side carrier portion 404 of the key, and a second tab 420 extending from the first eyelash. The fastening tab is preferably unitarily formed with the keys and the carrier of a single sheet material, although in other embodiments, the fastening tabs can be added via some fastening means. Figure 4 illustrates a curved corner portion 412 between the first flange and the second flange.

In some embodiments, the corner portion 412 is formed along a thin portion 414 of the sheet material from which the fastening tab is manufactured. The thin portion 414 facilitates the formation of the corner portion and can be formed by engraving or some other process. Fig. 4 also illustrates a corner portion 416 between the side carrier portion and the first flange 410. In one embodiment, the corner portion 416 is thin to facilitate folding.

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and providing continuity of an edge portion 402 along the side carrier portion 404. Unlike conventional keyboard assemblies that must be installed from within electronic device housings, keyboard assemblies comprising exemplary key layers Described herein, they can be installed from outside the device housing, and can be attached to the housing by means of locking tabs.

In some embodiments, the flexible portion of the carrier that flexibly couples the plurality of user interface keys to the carrier portion is relatively thin compared to other portions of the carrier and / or keys. In Figure 3, for example, the carrier portion 330, between the keys 1 and 5, has a reduced thickness to provide increased flexibility. The amount of thinness of any carrier depends on many factors, including but not limited to the thickness and stiffness of the sheet material from which the carrier and keys are formed, desired tactile performance, etc. In one embodiment, the thin carrier portion is formed by engraving or by some other material removal process applied to the surface of the sheet material of which the key layer is formed.

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In one embodiment, a flexible network interconnects at least some of the plurality of user interface keys. The flexible network generally bridges the gap between the plurality of user interface keys and the gap between the keys and any carrier portions, eg, the side carrier portions 316 and 318 in Figure 3. The flexible network generally prevents debris from entering the space between the keys, and in some embodiments the flexible network is part of the exterior of the key layer.

In one embodiment, the flexible network that interconnects the plurality of user interface keys comprises of a different material than the material of the user interface keys. In an exemplary embodiment, the flexible web is a resilient material, for example silicone. More generally, in other embodiments, the flexible web may be some other elastomeric material. In one embodiment, the flexible network is formed of a translucent material that allows the backlight to emanate from the luminescent layer, which is discussed below. The flexible network can be transparent or colored to provide contrast relative to the keys. In some embodiments, the flexible material is doped with other materials to provide special effects, and / or may be covered with ink or other coloration.

IMPI

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Figure 5 illustrates the exemplary key assembly layer 500 comprising the above described key layer 510, and a flexible web 520 applied to a rear part of the key layer. Exemplary flexible network 520 may be molded, for example, injection molded or insert molded, or otherwise deposited at the back of the key layer. In one embodiment, the flexible netting material protrudes into the space between the keys and any carrier portions, and in some embodiments, the flexible netting forms part of the visible exterior of the key layer. In Figure 5, exemplary flexible netting 520 is fairly applied to the wearer and partially to the keys, leaving portions of keys exposed for the application of another reinforcing material discussed below.

In other embodiments, the flexible network may be a flexible network film placed on or applied to an outer surface of the key layer. In another alternative embodiment, the flexible network and the plurality of user interface keys comprise a common material that forms the unitary element. According to this alternative embodiment, the flexible network is formed from sheet material of which the key layer is formed. In one embodiment, the portions of the flexible network, between the keys and any carrier portions, are formed

IMPI

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reducing the thickness of the portions of the sheet material, for example, by engraving. In this mode,

The removed portion of the sheet material forms the space between the individual keys, and the reduced thickness portion of the material. Reed also forms the flexible net that saves space.

In an exemplary key layer assembly, a reinforcing material is placed at the rear of the corresponding keys. In some embodiments, the reinforcing material provides stiffness for the keys, particularly in applications where the keys are relatively thin and also in embodiments where the key material is not rigid enough to provide the desired tactile performance. In the exemplary embodiment of FIG. 5, the portions of reinforcing material 530 are placed on the corresponding keys of the key layer 510, for example the rear portion

502 it is applied to the 512 keys.

In some embodiments, the reinforcing material is different from the material that constitutes the flexible web. For example, the flexible net can be an elastic or relatively resilient material, and the reinforcing material can be a relatively rigid or hard material. In an exemplary embodiment, the reinforcing material is a TOYOLAC 900 Series material. In some embodiments, the material

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'MPI' • ^ 'UTO MEXICANO ^η INDUSTRIAL PROPERTY reinforcement is doped with materials to provide special effects, and / or may be covered with ink or other coloration.

In an exemplary application process, the reinforcing material is applied to a rear side of a plurality of keys, eg, flexible keys interconnected by means of a carrier portion. In embodiments where multiple user interface keys are flexibly coupled to one or more carrier portions, a flexible net is applied to the back of the key layer. In one embodiment, the flexible mesh is applied to the back of the key layer. The flexible network can be applied by any application process, for example, by an insert molding process. In an alternative embodiment, the resilient material is first applied to the key, such that the resilient material forms a wall portion surrounding the portion of the key where the reinforcing material is desired. The reinforcing material is then applied to the key portion surrounded by the resilient material wall portion, where the resilient material wall portion attracts the reinforcing material applied to the key. In another alternative embodiment, the reinforcing material is part of the flexible network placed on the back of the keys.

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IMPI

MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY

In some modes, some or all of the keys have graphics placed on them to indicate functionality and / or provide other information associated with the corresponding key. The graphic can be printed or marked on the keys. In other embodiments, the embossed or gravure graphic is applied to the keys, for example, to a key such as the 5 key, or to all keys to provide a touch interface.

Exemplary key layers 200 and 300 of Figures 2 and 3 comprise keys including graph slits. Exemplary graph slits include alphanumeric characters and other functional symbols appropriate for use in a communication device application. In some embodiments, the key reinforcement material covers or fills the graph slit.

In one embodiment, the reinforcing material is a clear or colored translucent material that allows light to emanate from a luminescent layer, placed below the keys, as will be discussed later. Pursuant to a related aspect of the description, the reinforcing material placed in the graph slit can be used to capture portions of the graph that would otherwise require support structure or be susceptible to displacement. These reproduced graphic portions include, for example, the central portions of the

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“IMPI '' STÍTUTO MEXICANO r&gt; E the« remaining numbers 0, 4, 6, 8, etc. An interface '£ ac £' i^Ll be formed on some or all of the keys as discussed above, or by allowing some of the reinforcing material to protrude through the graphic slit beyond the surface. of the key. The touch interface can also be produced through the process of embossing or gravure.

In accordance with another process for manufacturing the key layer assembly, the function of the key or identification graphic is engraved on a relatively thin sheet of metal, for example, a thickness of between

0.2mm and 0.3mm. Next, a hard translucent plastic material is molded to the back of the metal sheet where the keys will be defined. The perimeters of the keys are then engraved on the thin sheet.

And then the flexible network is formed around the perimeter of the keys, as discussed above. The flexible network allows the keys to move independently, and also prevents the keys from being lifted. As a final step, the keys may be subject to finishing operations to polish the cosmetic surface and / or to remove excessive molding of material from the layer of the keys.

In FIG. 1, the contact / luminescent overlay layer 120 comprises a luminescent layer,

IMPI

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for example, an electro-luminescent coating. In the exemplary embodiment, the luminescent layer functions as a carrier for a formation of switch caps aligned with the corresponding keys on the key layer. FIG. 6 is a part diagram of an exemplary luminescent / contact cap layer assembly 600. The exemplary assembly comprises a luminescent layer 610. In one embodiment, the 610 luminescent layer is an electro-luminescent layer, for example, the Durel DFLX-665 flexible electroluminescent lamp manufactured by Rogers

Corporation, Durel Division, Chandler, Arizona. In other embodiments, the luminescent layer may comprise other luminescent materials.

In one embodiment, the luminescent layer is colored or painted to provide colored backlighting. In FIG. 7, the exemplary luminescent layer includes a green color or tint portion 7 02 and a red color or tint portion 7 04. The exemplary green and red color portions may be located behind the ON or

SEND, and OFF or FINISH respectively. In other modes, other colors can be used on these and other keys.

Figure 6 also illustrates an adhesive layer 620, eg, a printed adhesive, which is adhered to one side of the luminescent layer 610. Also shown is ¹⁶ ΪΜΡΙ '' MEXICAN TITUTE ^Γ'Ε INDUSTRIAL rtOFIEDAD includes with the contact / luminescent layer a contact dust arrangement 630 adhered to the luminescent layer 610 by means of the adhesive layer 62 0 in alignment with the corresponding keys. Alternatively, the overalls 630 can be adhered to the luminescent layer 610 by discrete amounts of adhesive, without the requirement of the exemplary adhesive layer. In other embodiments, the contact caps may be attached to the luminescent layer through other fastening means. Wearing the overalls in the luminescent layer eliminates the need for a dedicated carrier, for example the Mylar layer, used in conventional designs.

In the exemplary embodiment, the contact cap arrangement 63 0 is adhered to a back of the luminescent layer 610 by means of the intermediate adhesive layer. In one embodiment, the luminescent layer is a malleable material that fits around the dome surface of the contact dust cover, thereby ensuring sufficient adhesion with the adhesive layer. In an alternative embodiment, the overalls may be placed between the luminescent layer and some other layer. Placing the contact caps on the back of the luminescent layer ensures that light emanates from the luminescent layer directly behind the keys.

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IMPI

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In an alternative embodiment, the contact overalls are positioned in front of, or on top of, the luminescent layer. The use of a clear or translucent contact dust cap will reduce any obstruction, by the dust cap, to light emanating directly from the back of the keys. In the exemplary embodiment, the contact overalls include a 632 connector bracket, which provides good tactile performance by ensuring that the overhang point of the overall is actuated. In other embodiments, the protrusion may be located within or in the reinforcing material placed on the keys.

In alternative embodiments, the luminescent layer includes cut portions that house contact caps or portions thereof, thus reducing the thickness of the assembly resulting from layer stacking.

In other embodiments, a conventional carrier layer, eg, a Mylar layer, carries the contact overalls. The contact dust carrier layer is positioned such that the bonded or otherwise attached dust caps are aligned with corresponding switches on a layer of keyboard circuitry. In FIG. 1, the exemplary luminescent layer dust jacket carrier 120 is positioned such that the plurality of contact dust caps, eg, dust caps 122 and 124, positioned thereon, are

IMPI

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positioned on the corresponding switches, for example, switch 132 and 134, on circuitry layer 130. The resulting assembly of keyboard layer assembly 110, the 'contact / luminescent dust cover layer 120 and the circuitry layer provide an assembly A relatively compact keyboard that has an overall thickness between approximately 1.0mm and 5.0mm.

In Figure 8, a sectional portion of an exemplary keyboard assembly 800 comprises an exemplary keyboard assembly incorporating the features described above. The sectional portion of the figure corresponds, for example, to a section through the directional cursor controller 230 and the selection key 232 in Figure 2. A key layer 802 includes a selection key 803 and a directional cursor controller input 805 corresponding to the selection key 232 and cursor controller 230 of Figure 2. The exemplary key layer is approximately 0.15mm and includes a liner. surface 806, for example, a Urethane. The select key includes a graph slit filled with a translucent 805 material to allow light to pass through from a subsequent light source, discussed later. A base film 810, which is preferably transparent, is co-molded between the upper silicone films and

IMPI

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lower 812 and 814, respectively. The top layer of the key is adhered to the base film by a glue layer 816. A luminescent layer 82 0 functions as a dust carrier. An exemplary dust cap 822 is located below the 803 key. A piston 824 is positioned between the 803 key and the 822 dust cap. The piston may be part of, or be attached to, the dust cap or to the structure opposite the dust cap. The overall thickness of the exemplary keyboard layer is less than about

1.2mm.

In Figure 9, another exemplary keyboard assembly

0 it comprises a key layer including a first key 902 and a second key 904. A flexible network portion 906 is positioned between adjacent keys 902 and 904 and other neighboring keys. A reinforcing material 908 is placed at a rear of the key 902 and protrudes through a graphic slit in the key, as illustrated. A piston 912 is integrally formed with the reinforcing material along with a contact dust cap below key 902. A 920 luminescent layer is placed below the key layer assembly. Exemplary luminescent layer 920 functions as a carrier for 922 contact caps, which are adhered thereto by means of an intermediate adhesive layer 924. As discussed above. The

IMPI

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Luminescent layer and dust covers are placed on a 93 0 circuit board, which is mounted in a 940 housing.

Although the present invention and the best modes thereof have been described in a manner that establishes possession by the inventors and enables those skilled in the art to manufacture and use the same, it will be understood and appreciated that there are many equivalents to the exemplary embodiments herein described and that modifications and variations can be made to it without departing from the scope and spirit of the inventions, they will be limited not by the exemplary modalities, but by the appended claims.

IMPI

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