I already thought about magnets clipping the modules together, however, it might not hold up when you pick the whole assembly up. Like when you have guests and somebody decides to move your 'board around resulting in a part falling to the floor. So, something like a docking station (with F1-F12 and cursor block) might provide more stability.
falling apart when moved may actually be okay -- the logitech dinovo was exactly like that and it sold like a blockbuster. I owned one of those and I didnt really find it inconvenient since 99 percent of the time it just sat on the desktop. The spacesaver keyboard part of the dinovo wasnt physically attached to the numpad/calculator that it came with, they just sat side by side on the desktop (and *looked* as if they were connected), but you could move each one separately. It might be something to consider at least for v1. They were each connected wirelessly (and independently) to the usb wireless receiver. That would be one way to solve the problem of "joining" them I guess. Even if the board/modules were wired instead of wireless, you could still do the same thing. True that that wouldnt be the same as a rigid board, but people would know that up front.
Also true that some kind of docking station may work, but what are you envisioning for that? Wouldnt that add height to the board?
Wellington, do you think about F-keys as a module and cursor as another? That would leave a hole where F-keys and cursor block meet.
if you have connectors for the modules (instead of independent wired or wireless connections) then yes there will have to be some kind of hole for the connector -- But even here I think there may be ways to minimize the aesthetics of it so it remains sleek. For instance: a ribbon connector could connect from
underneath and minimize the need to put a hole on the side of the modules and board. If you wanted more rigidity it would be threaded thru a spacer that clips to the underside of board/module.
This could work for F keys too (tho for F keys I still think that 2 versions of the board would be best, one hhkb version that uses Fn key, and a normal version that just has them built in normally). So the modules would really be more of a left-side and right-side issue.
There are a few millimeters space left and right. Should be enough for magnets, maybe even clips.
what do you think of ribbon cables from underneath, connecting left/right modules to the board? Is that a possible connector that could be used here? If I remember from pics of the g80 3000 (or one of those cherry boards that someone on geekhack took apart), the numpad was connected just by a ribbon cable. The clip that its threaded thru could posible hold the module/board together relatively rigidly - or just leave them magnetic and take-apart able (you could even dispense with the magnets like the dinovo and have them put-next-to-each-other-able.)
Lots of possibilities; I think whatever you do for the prototype though, the OEM manufacturer will likely have other ideas too.