Bonded keyboard and method for making the same

Abstract

A bonded keyboard and method for making the same are disclosed. The bonded keyboard uses adhesive as the primary agent, and in some embodiments, as the sole agent for coupling various components of the keyboard stackup together. The keyboard stackup uses a skeletal adhesive to couple a top case to a backcase assembly. In one embodiment, the skeletal adhesive is an interconnected matrix of ribs dimensioned to fit within the spacing existing between adjacent keys, which are mounted on the backcase assembly. The skeletal adhesive is fixed to the backcase assembly, occupies a portion of the spacing that exists between keys, and the top case is fixed to the top of the skeletal adhesive.

What is claimed is: 
     
         1 . A bonded keyboard, comprising:
 a backcase assembly including a feature plate, an adhesive layer and a membrane, the membrane bonded to the feature plate with the adhesive layer;   a plurality of keys mounted on the backcase assembly and arranged in a predetermined configuration such that spacing exists between adjacent keys, the keys including outer keys that a define a periphery;   a skeletal double sided adhesive layer secured to the backcase assembly and constructed to occupy a portion of the spacing and a portion of the periphery; and   a top case secured to the skeletal double sided adhesive.   
     
     
         2 . The keyboard of  claim 1 , wherein the skeletal adhesive layer comprises a plurality of interconnected skeletal ribs. 
     
     
         3 . The keyboard of  claim 2 , wherein a first portion of the skeletal ribs has a first predetermined thickness and a second portion of the skeletal ribs has a second predetermined thickness. 
     
     
         4 . The keyboard of  claim 1 , wherein the skeletal adhesive layer surrounds each one of the keys. 
     
     
         5 . The keyboard of  claim 1 , wherein the skeletal adhesive layer surrounds select groups of the keys. 
     
     
         6 . The keyboard of  claim 1 , wherein the skeletal double sided adhesive comprises a one-piece carrier. 
     
     
         7 . The keyboard of  claim 1 , wherein skeletal double sided adhesive has a thickness ranging between about 0.005 to 0.1 mm. 
     
     
         8 . The keyboard of  claim 1 , wherein the skeletal double sided adhesive does not interface with any of the keys. 
     
     
         9 . The keyboard of  claim 10 , wherein the top case mimics the shape of the skeletal double sided adhesive. 
     
     
         10 . The keyboard of  claim 1 , further comprising at least one fastener that couples the backcase assembly to the top case. 
     
     
         11 . The keyboard of  claim 2 , wherein the top case comprises top case skeletal ribs, wherein a thickness of the top case skeletal ribs is at least as thick as a thickness of the skeletal ribs of the skeletal adhesive. 
     
     
         12 . A computing device, comprising:
 a bonded keyboard comprising:
 a backcase assembly having top and bottom surfaces; 
 a plurality of keys mounted to the top surface of the backcase assembly, the keys arranged such that spacing exists between adjacent keys; 
 a skeletal double sided adhesive layer mounted to the top surface of the backcase assembly, the adhesive constructed to surround each key by occupying a portion of the spacing existing between adjacent keys; and 
 a top case including a skeletal structure secured to the adhesive layer. 
   
     
     
         13 . The keyboard of  claim 12 , wherein the keys include outer keys, and wherein the adhesive layer occupies a portion of a periphery surrounding the outer keys. 
     
     
         14 . The keyboard of  claim 12 , wherein each key has first and second edges, wherein a minimum gap distance exist between edges and an edge of the skeletal adhesive. 
     
     
         15 . The keyboard of  claim 12 , wherein the backcase assembly is operative to detect key strokes. 
     
     
         16 . The keyboard of  claim 12 , further comprising fasteners to couple the backcase assembly to the top case. 
     
     
         17 . A method for assembling a keyboard, the method comprising:
 mounting a plurality of keys to a backcase assembly;   applying a skeletal double sided adhesive layer to the backcase assembly, the skeletal adhesive layer surrounding at least one of the keys; and   securing a top plate to the backcase assembly via the skeletal adhesive, the top plate constructed to mimic construction of the skeletal adhesive layer.   
     
     
         18 . The method of  claim 17 , wherein the backcase assembly comprises a feature plate, adhesive layer, and a membrane, the method further comprising:
 securing the membrane to the feature plate with the adhesive layer.   
     
     
         19 . The method of  claim 17 , further comprising:
 using at least one fastener to secure the top case to the back case assembly.   
     
     
         20 . The method of  claim 17 , wherein the keys are arranged in a predetermined configuration having a periphery defined by outer keys and spacing exists between the outer keys and adjacent inner keys and between adjacent inner keys, and the skeletal double adhesive occupies a portion of the spacing and a portion of the periphery.