Illuminating Keycap Dual Injection Layer Surface Flatness
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Solution Overview
Problem
The manufacturing method of illuminating keycaps for keyboards results in uneven surfaces due to gaps between injection members, leading to defective products and increased production defects.
Innovation Solution
The keycap is manufactured by forming a first injection layer and a second injection layer, where the second layer covers the first layer, ensuring a flat surface and improving production yield through injection molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the keycap is manufactured by injection molding with a first injection member and a second injection member, then the keycap can be formed with multiple layers, but the surface of the keycap becomes uneven due to gaps between the injection members
Solution Approach 1:
The patent applies preliminary action by designing the first injection member with a first surface that is preliminarily configured to match the second surface of the second injection member. This pre-matching of surfaces ensures that when the two injection members are combined, their surfaces align perfectly without creating gaps or unevenness, thus resolving the surface flatness issue while maintaining the multi-layer structure
Solution Approach 2:
The patent applies local quality by focusing on the specific interface between the first and second injection members. The first surface of the first injection member and the second surface of the second injection member are designed with matching local geometries at their contact interface, ensuring that this critical local region achieves perfect surface alignment while the rest of the injection members can maintain their functional structures
2Ease of manufacture
If the keycap surface is uneven due to gaps between injection members, then subsequent processing such as light shielding paint application is affected, but the production yield decreases due to defective products
Solution Approach 1:
The patent applies preliminary action by ensuring the surfaces of the injection members are pre-configured to match before subsequent processing steps. This preliminary surface matching prevents the formation of gaps that would otherwise interfere with light shielding paint application and other subsequent processing, thereby eliminating the need to discard defective products and maintaining high production yield
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach eliminates surface unevenness, reducing defective rates and enhancing the production yield of illuminating keyswitches by ensuring a smooth surface for subsequent processing.
Implementation Method 1
The keycap is manufactured by injection molding. The keycap usually has a first injection member and a second injection member, which are formed by first injection molding the first injection member, then injection molding the second injection member.
Data Source
AI summary
A keycap, an illuminating keyswitch and a method for manufacturing the same are provided. The illuminating keyswitch comprises a base plate, a printed circuit board, a light emitting element, a keycap and a lifting support structure. The printed circuit board is disposed on the base plate. The light emitting element electrically is connected to the printed circuit board. The keycap is disposed on the light emitting element. The lifting support structure is disposed between the base plate and the keycap. The keycap comprises a first injection layer and a second injection layer. The second injection layer covers the first injection layer. The light emitting element is configured to correspond to the first injection layer or the second injection layer. The keyswitch of the present invention covers the first injection layer through the second injection layer, so that the surface of the key cap is flat, thereby facilitating subsequent processing.