Keycap Out-Mold Transfer for Uniform Protection and Light Leakage Prevention
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Solution Overview
Problem
Conventional methods for manufacturing keycaps are time-consuming, result in uneven protection layers, and are not suitable for mass production of keycaps of different sizes, leading to increased costs and light leakage issues in lighting keyboards.
Innovation Solution
A method involving out-mold transfer techniques using jigs to selectively apply ink and protection layers onto keycaps, ensuring uniform coverage and preventing light leakage, while allowing for simultaneous processing of multiple keycaps of varying sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spray coating technique is used to form protection layer, then coverage is achieved, but non-uniform thickness and waste are caused due to spraying angle
Solution Approach 1:
The keycaps are pre-positioned in a jig at predetermined locations before the protection layer formation process. This preliminary positioning ensures that the protection layer can be applied uniformly to exposed portions without waste from overspraying, directly resolving the contradiction between coverage and material efficiency
2Loss of substance
If printing technique is used to form protection layer, then material waste is reduced, but the protection layer cannot extend to the side face of the keycap
Solution Approach 1:
The protection layer is applied selectively to different regions of the keycap based on local requirements: the top face receives protection layer through printing technique, while the side face (skirt) receives protection layer through spray coating. This localized approach allows each region to receive the appropriate treatment, achieving both material efficiency and operational smoothness
3Manufacturing precision
If conventional sequential printing and laser etching process is used, then symbols and characters can be formed, but production time is increased
Solution Approach 1:
The ink layer formation and protection layer formation are merged into a single simultaneous process. The ink layer is printed on the top face while the protection layer is sprayed on the side face and exposed portions in one operation, eliminating the sequential steps of printing, drying, etching, and then protecting. This combination dramatically reduces production time while maintaining symbol and character quality
4Reliability
If IMR technique is used to form ink layer, then connection between ink layer and keycap is improved, but protection layer cannot be formed and mold complexity increases
Solution Approach 1:
The ink layer is formed using printing technique as an intermediary process after injection molding, rather than integrating it into the mold itself. This allows the mold to remain simple while still achieving reliable ink layer attachment through adhesive application, separating the ink formation function from the molding function
Data Source
AI summary
A method of manufacturing keycaps, each keycap having a top and a skirt, includes: providing a first jig having a plurality of positioning units; arranging correspondingly a plurality of keycaps onto the plurality of positioning units; attaching a first film including an ink layer and a first release layer to the plurality of keycaps by using an out-mold transfer technique, such that the first film covers respective upper surfaces of the tops and respective side surfaces of the skirts of keycaps; removing the first release film; laser-engraving the ink layer; and forming a protection layer on the laser-engraved ink layer. A keycap manufactured by the method of the present invention is also disclosed.