Singulated keyboard assemblies and methods for assembling a keyboard

• US 10,115,544 B2
• Filed: 08/08/2016
• Issued: 10/30/2018
• Est. Priority Date: 08/08/2016
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Wu, Chia Chi, Gao, Ming, Gao, Zheng, Li, Zhengyu
• Primary Examiner(s): Jimenez, Anthony R.
• Application Number:
  US15/230,724
• Publication Number:
  US 20180040441A1
• Time in Patent Office: 813 Days
• Field of Search: 200 5 A, 200200, 200402, 200468
• CPC Class Codes: H01H 13/023 Light-emitting indicators for multi-layer switches H01H13/83
• CPC Class Codes: H01H 13/14 Operating parts, e.g. push-button
• CPC Class Codes: H01H 13/70 having a plurality of operating members associated with different sets of contacts, e.g. keyboard mounting together a plurality of independent switches H02B
• CPC Class Codes: H01H 13/83 characterised by legends, e.g. Braille, liquid crystal displays, light emitting or optical elements
• CPC Class Codes: H01H 13/88 Processes specially adapted for manufacture of rectilinearly movable switches having a plurality of operating members associated with different sets of contacts, e.g. keyboards
• CPC Class Codes: H01H 2205/016 Separate bridge contact
• CPC Class Codes: H01H 2219/062 Light conductor
• CPC Class Codes: H01H 2219/066 Lens
• CPC Class Codes: H01H 3/122 with enlarged actuating area, e.g. of the elongated bar-type; Stabilising means therefor

Abstract

Methods for assembling low-profile, singulated keyboards by prefabricating key assemblies onto a chassis strip that is divided into individual key assemblies only after the substrate is affixed to a feature plate of keyboard. For example, a row of key assemblies is fabricated onto a chassis strip. The row corresponds to a partial or complete row of keys of the keyboard. The chassis strip is thereafter affixed to a feature plate in a specific location, thereby aligning each prefabricated key assembly to a precise location on the feature plate. While connected, each prefabricated key assembly is independently affixed to the feature plate. Thereafter, interconnecting portions of the chassis strip between the prefabricated key assemblies are removed, thereby singulating each key assembly.

Claims

1. A row of interconnected key assemblies comprising:

an array of key assemblies, each key assembly comprising;

a chassis having a first retaining feature and a second retaining feature;

a switch housing formed on the chassis;

a key mechanism surrounding the switch housing and engaged with the first retaining feature; and

a buckling dome positioned within an opening defined through the switch housing and engaged with the second retaining feature.

2. The row of interconnected key assemblies of claim 1, wherein for at least one key assembly of the array of key assemblies the buckling dome is electrically connected to the chassis via the second retaining feature.

3. The row of interconnected key assemblies of claim 1, wherein for at least one key assembly of the array of key assemblies the second retaining feature is configured to flex in response to an actuation of the buckling dome.

4. The row of interconnected key assemblies of claim 1, wherein for at least one key assembly of the array of key assemblies the switch housing comprises an upstop that accommodates a portion of the buckling dome.

5. The row of interconnected key assemblies of claim 1, wherein each chassis associated with each key assembly of the array of key assemblies is coupled to at least one other chassis via a removable interconnecting portion.

6. The row of interconnected key assemblies of claim 5, wherein at least one removable interconnecting portion defines a breakaway feature that facilitates removal of the at least one removable interconnecting portion from the array of key assemblies.

7. The row of interconnected key assemblies of claim 6, wherein the breakaway feature comprises one or more of:

a perforation;

a score;

or

a channel.

8. A keyboard comprising:

a feature plate; and

a row of key assemblies comprising;

a first key assembly comprising a first chassis affixed to the feature plate;

a second key assembly comprising a second chassis affixed to the feature plate; and

a removable interconnecting portion attached to the first chassis and to the second chassis, thereby coupling the first chassis to the second chassis.

9. The keyboard of claim 8, wherein the first chassis is configured to complete an electrical path between at least two electrical contacts accommodated on the feature plate.

10. The keyboard of claim 8, wherein:

the first key assembly comprises a buckling dome; and

the first chassis electrically connects the buckling dome to an electrical circuit accommodated on the feature plate.

11. The keyboard of claim 8, wherein:

the first key assembly comprises a switch housing molded onto the first chassis; and

the first chassis aligns an optical feature of the switch housing with a light emitting diode disposed on the feature plate.

12. The keyboard of claim 8, wherein the removable interconnecting portion is disconnected from the feature plate.

13. A method of manufacturing a keyboard comprising:

forming an array of key assemblies, comprising;

forming a first key assembly on a first chassis of a chassis strip;

forming a second key assembly on a second chassis of the chassis strip, the second chassis separated from the first chassis by an interconnecting portion;

positioning the chassis strip on a feature plate;

affixing the first chassis to the feature plate;

affixing the second chassis to the feature plate; and

removing the interconnecting portion, wherein

the first key assembly includes a switch housing on the first chassis;

the first chassis includes a first retaining feature and a second retaining feature; and

forming the first key assembly includes;

engaging a key mechanism with the first retaining feature; and

engaging a buckling dome with the second retaining feature.

14. The method of claim 13, wherein the operation of forming the first key assembly comprises

molding the switch housing onto the first chassis.

15. The method of claim 13, wherein:

forming the first key assembly further comprises placing an optical film over the switch housing;

positioning the chassis strip on the feature plate comprises aligning the first key assembly with a light emitting diode coupled to the feature plate; and

the light emitting diode is optically coupled to the switch housing.

16. The method of claim 13, wherein removing the interconnecting portion occurs substantially simultaneously with the operation of affixing the first chassis to the feature plate.

17. The method of claim 13, further comprising positioning the feature plate within a housing that defines a group of apertures arranged in a grid.

18. The method of claim 17, wherein positioning the feature plate within the housing comprises:

aligning the first key assembly within a first aperture of the group of apertures; and

aligning the second key assembly within a second aperture of the group of apertures.

19. The method of claim 13, wherein forming the first key assembly further comprises forming the first retaining feature by bending one or more portions of the first chassis.

20. The method of claim 19, wherein engaging the key mechanism with the first retaining feature includes inserting a pin of the key mechanism into a hole defined in the first retaining feature.