Keyboard and method for producing

• US 5,610,602 A
• Filed: 06/07/1995
• Issued: 03/11/1997
• Est. Priority Date: 08/18/1992
• Status: Expired due to Term

• Current Assignee: Kinesis Corporation
• Original Assignee: Kinesis Corporation
• Inventors: Hargreaves, William R.
• Primary Examiner(s): Hofsass, Jeffery
• Assistant Examiner(s): HILL, ANDREW M
• Application Number:
  US08/548,512
• Time in Patent Office: 643 Days
• Field of Search: 341/20, 341/21, 341/22, 341/34, 345/168, 400/472, 400/488, 400/489, 400/473, 400/477, 400/479, 400/486, 400/490, 400/492, 400/495, 235/145 R, D14/100, D14/114, D14/115, D18/12, 200/5 A, 361/680, 361/749
• US Class Current: 341/22
• CPC Class Codes: B41J 5/10 Arrangements of keyboards , e.g. key button disposition
• CPC Class Codes: G06F 3/0202 Constructional details or processes of manufacture of the input device
• CPC Class Codes: G06F 3/0219 Special purpose keyboards
• CPC Class Codes: H01H 13/807 characterised by the spatial arrangement of the contact sites, e.g. superimposed sites
• CPC Class Codes: H01H 13/84 characterised by ergonomic functions, e.g. for miniature keyboards; characterised by operational sensory functions, e.g. sound feedback legends H01H13/83
• CPC Class Codes: H01H 2217/028 on planes with different or alterable inclination, e.g. convex plane
• CPC Class Codes: H01H 2223/054 Mounting of key housings on same printed circuit
• CPC Class Codes: H01H 2223/056 Mounting of key housings on same frame
• CPC Class Codes: H01H 2225/022 other then row-column disposition

Abstract

A keyboard having an array of non-planar keys and a method for manufacturing such a keyboard is provided. In one embodiment, the non-planar array is a double-convex array. Electrical connection along the keys and/or from the keys to associated electronics is provided by way of a circuit board. The circuit board has a geometry and flexibility which permits the circuit board to conform to a shape which is non-planar along two non-parallel axes. In one embodiment, the circuit board can be configured in a double-concave shape. The circuit board includes one or more slots defining two or more projections. These projections can be placed in a configured non-coplanar configuration along a first axis and the circuit board can be flexed to a non-planar configuration along a second non-parallel axis.

Claims

1. A keyboard comprising:

a key-switch support having a first region defining a plurality of holes for engaging and supporting key-switches, said first region being bowl-shaped;

a plurality of key-switches disposed in said holes, each switch having electrical contacts on a bottom surface thereof, to provide a substantially bowl-shaped array of said electrical contacts; and

a circuit board coupled to said contacts, said circuit board being flexible to permit the board to be bent, in a first region of the board, along a first axis and said circuit board having a plurality of slots defining two or more fingers to permit said first region of the board to be shaped in a non-planar configuration along a second, substantially perpendicular axis, substantially in the absence of overlapping of said fingers, wherein at least said first region of the circuit board is substantially bowl-shaped and substantially conformed to the shape of said bowl-shaped array of electrical contacts.

2. A keyboard comprising:

a plate having at least a first plurality of key-switches mounted thereon, each of said first plurality of key switches having a user-activatable surface and an opposite surface, said opposite surfaces of said key switches having electrical contacts, said contacts forming an array which is non-planar along at least two non-parallel axes;

a circuit board having a plurality of substantially non-contacting finger regions and having a plurality of substantially conductive traces, said circuit board positioned adjacent said array of electrical contacts, to form electrical paths from said contacts to said traces.

3. A keyboard, as claimed in claim 2, further comprising:

electronics for converting a keypress into an electrical signal; and

a bus connecting said circuit board to said electronics.

4. A keyboard, comprising:

an upper and lower shell, having at least first and second openings in said upper shell;

first and second bowl-shaped plates positioned in said first and second openings, said first and second plates each having a plurality of holes configured to accommodate key switches;

a plurality of key switches positioned in said holes of said first and second plates, each key switch having an user-activatable upper surface and an opposite lower surface, with at least one electrical contact on said lower surface;

said holes of each of said first and second plates arranged to position said key switches in at least five groups, each group configured to place the upper surface of said key switches in said group in a concave configuration;

a flexible circuit board having a plurality of conductive traces printed thereon and having a first integral region and at least five finger-like projections extending outward from said first region said flexible circuit board mounted in a bowl-like configuration;

each of said five projections positioned in substantially non-overlapping fashion to couple the electrical contacts of the key switches of one of said five groups of key switches to at least one of said plurality of traces.

5. A keyboard, as claimed in claim 4, wherein said circuit board is curved along two orthogonal axes.

6. A keyboard comprising:

a chassis having means for positioning a plurality of user-activatable keys in a predetermined configuration, at least some keys having electrical contacts, said contacts being non-planar over at least two non-parallel axes;

a bowl-shaped circuit board, having predetermined electrical traces, and having substantially non-overlapping means for coupling said electrical contracts of said keys to said predetermined electrical traces.

7. A keyboard, as claimed in claim 6, wherein said circuit board includes a flexible substrate means for substantially conforming at least a portion of said circuit board means to a configuration adjacent at least some of said electrical contacts.

8. A keyboard, as claimed in claim 6, wherein said circuit board includes slot means separating a first region of said circuit board means from a second region of said circuit board, permitting said first region to be positioned in a configuration non-coplanar with said second region.

9. A keyboard, as claimed in claim 6, wherein said user-activatable keys comprise mechanical key switches.

10. A keyboard, as claimed in claim 6, wherein said user-activatable keys comprise membrane switches.

11. A keyboard, as claimed in claim 6, wherein said means for coupling comprises means for providing a solder connection to said key switches.

12. A keyboard, as claimed in claim 6, wherein said means for coupling comprises means for solderless connection to said key switches.

13. A method for providing electrical connection to a plurality of keys in a chassis, comprising:

providing a plurality of user-activatable keys, at least some keys having electrical contacts;

providing a circuit board having a plurality of electrical traces;

coupling said electrical contacts with at least some of said plurality of electrical traces;

placing said circuit board in a configuration which is non-linear over a first axis in a first region of said circuit board;

placing said circuit board in a configuration which, in said first region, is non-linear over a second axis, non-parallel with said first axis to provide a substantially bowl-shaped configuration.

14. A method, as claimed in claim 13, wherein:

said step of providing a circuit board comprises providing a circuit board which is flexible in at least a first region; and

wherein said step of placing said circuit board in a configuration which is non-linear over a first axis comprises bending at least said first region into a configuration which is curved along said first axis.

15. A method, as claimed in claim 13, wherein:

said step of providing a circuit board comprises providing a circuit board which includes at least a first slot separating a first portion from a second portion; and

wherein said step of placing said circuit board in a configuration which is non-linear over a second axis comprises positioning said first and second portions in non-coplanar, substantially non-contacting configurations.

16. A method, as claimed in claim 15, wherein said step of positioning said first and second portions comprises bending said first portion to a curved configuration substantially along a first arc and bending said second portion to a curved configuration substantially along a second arc, different from said first arc.

17. A method, as claimed in claim 16, wherein said first arc has an approximate radius of curvature greater than the approximate radius of curvature of said second arc.

18. A method, as claimed in claim 16, wherein:

said step of providing a circuit board comprises providing a circuit board which is flexible in at least a first region; and

wherein said step of placing said circuit board in a configuration which is non-linear over a first axis comprises bending at least said first region into a configuration which is curved along said first axis.

19. A method, as claimed in claim 16, wherein at least said first portion has a substantially linear cross-section along a third axis, substantially parallel with said first axis.

20. A method, as claimed in claim 16, wherein at least said first portion has a curved cross-section along a third axis, substantially parallel with said first axis.

21. A method, as claimed in claim 13, further comprising:

providing a region of said chassis with a plurality of holes configured to accommodate said keys and positioning said keys in said holes.

22. A method, as claimed in claim 21, wherein said step of providing a region of said chassis with a plurality of holes comprises coupling a non-integrally formed plate, having said holes formed therein, to said chassis.

23. A method, as claimed in claim 21, wherein said step of providing a region of said chassis with a plurality of holes comprises forming said holes in said chassis.

24. A method, as claimed in claim 21, wherein said chassis has an interior surface and an exterior surface and further comprising positioning said keys in said holes by pushing said keys partially through said holes in a direction from said interior toward said exterior surface.

25. A method, as claimed in claim 21, wherein said chassis has an interior surface and an exterior surface and further comprising positioning said keys in said holes by pushing said keys partially through said holes in a direction from said exterior toward said interior surface.

26. A method, as claimed in claim 22, wherein said plate has an upper and a lower surface, further comprising:

pushing the keys partially through said holes in a direction form said lower surface toward said upper surface; and

wherein

said step of positioning said circuit board comprises positioning said circuit board substantially adjacent said lower surface of said plate.

27. A method, as claimed in claim 22, wherein said plate has an upper and a lower surface, further comprising:

pushing the keys partially through said holes in a direction from said upper surface toward said lower surface; and

wherein

said step of positioning said circuit board comprises positioning said circuit board substantially adjacent said lower surface of said plate.

28. A method as claimed in claim 15, wherein said step of providing a circuit board which includes at least a first slot is performed before said step of coupling said electrical contacts.

29. A method as claimed in claim 13, wherein said step of coupling said electrical contacts is performed before either said steps of placing said circuit board in a configuration.

30. A method as claimed in claim 13, wherein said step of coupling said electrical contacts includes coupling said electrical contacts while said circuit boards is in a substantially flat configuration.

31. A method as claimed in claim 13, wherein said plurality of user activatable keys are held in a substantially stable position by the mutual coupling of both the circuit board and said region of said chassis to said plurality of user-activatable keys.

32. A method as claimed in claim 24, further comprising positioning said keys using a snap action mechanism.

33. A method as claimed in claim 25, further comprising positioning said keys via a snap action mechanism.