Keycap Light-Guiding Microstructure Layer for Uniform Illumination
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Solution Overview
Problem
Existing key structures suffer from uneven brightness on the top surface of keycaps due to shading from elements beneath and the emission angle of light sources, leading to localized illumination and uneven character illumination.
Innovation Solution
A keycap design incorporating a light-guiding microstructure layer and a light-transmitting layer made of different materials, with the light-transmitting layer having a diffusing agent and a specific structural arrangement to ensure uniform illumination, along with a manufacturing method involving sequential injection molding processes to form these layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a conventional keycap structure with a single layer is used, then the manufacturing process is simple, but the illumination uniformity is poor due to shading and emission angle limitations
Solution Approach 1:
The keycap is divided into multiple functional layers: a light-guiding microstructure layer with microlens arrays that directs light uniformly, and a light-transmitting layer that diffuses light. This segmentation allows each layer to perform its specific function optimally, resolving the contradiction between illumination uniformity and structural simplicity.
Solution Approach 2:
The patent uses composite material structure combining a light-guiding material with microstructures and a light-transmitting material with diffusing properties. This composite approach enables both layers to work together to achieve uniform full-surface illumination while maintaining manufacturing feasibility through injection molding.
2Illumination intensity
If a single-layer keycap structure is used, then the manufacturing process is simple, but the light distribution is uneven due to shading from elements beneath and emission angle limitations
Solution Approach 1:
The light-guiding microstructures are pre-formed in the light-guiding layer before the light-transmitting layer is added. This preliminary action of creating the microlens array structure first allows light to be directed and distributed uniformly before final diffusion, achieving even light distribution while using a sequential two-step injection molding process that remains manufacturable.
3Illumination intensity
If the light-transmitting layer is made of the same material as the light-guiding layer, then the manufacturing process is simpler, but the light diffusion effect is insufficient for achieving uniform illumination
Solution Approach 1:
The light-transmitting layer incorporates a light diffusing agent (such as titanium dioxide powder) specifically in the region where light diffusion is needed, while the light-guiding layer maintains its microstructure without diffusing agents. This localized material differentiation enables optimal light diffusion for uniform illumination while keeping the overall material system manageable through standard injection molding techniques.
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
The solution achieves full and uniform illumination of the keycap surface, overcoming the limitations of shading and emission angle, resulting in consistent character illumination.
Implementation Method 1
a light-guiding microstructure layer (112) and a light-transmitting layer (114)... the light-guiding microstructure layer includes a base layer (112b) and a plurality of microstructures (112m)
Implementation Method 2
the second material includes a light diffusing agent
Data Source
AI summary
The present disclosure provides a keycap, including: a light-guiding microstructure layer made of a first material, the light-guiding microstructure layer including a base layer and a plurality of microstructures disposed on a lower surface of the base layer; and a light-transmitting layer disposed over the light-guiding microstructure layer and in contact with the base layer, the light-transmitting layer being made of a second material different from the first material. The present disclosure further provides a method of manufacturing the above-mentioned keycap and a key structure including the above-mentioned keycap.