Micro-sized Unpackaged LEDs for Fabric Keyboard Backlighting
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Solution Overview
Problem
Backlighting devices with fabric or non-fabric covers poses challenges due to the material structure, as conventional LEDs are thicker and less suitable for effective illumination.
Innovation Solution
The use of micro-sized unpackaged LEDs placed behind the legend on a keyboard key or similar apparatus, with a fabric or non-fabric cover, to achieve illumination through selective placement and combination with phosphor for light diffusion, and a method involving additive and removal processes to create translucent regions for enhanced light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional packaged LEDs are used for backlighting, then the LED provides protective features and interface integration, but the LED height increases to 12.5-200 microns which reduces light diffusion effectiveness through fabric covers
Solution Approach 1:
The patent extracts the essential light-emitting function from the conventional packaged LED by using unpackaged semiconductor devices. These unpackaged devices provide the necessary light emission while eliminating the protective enclosure and interface structures that increase height, thereby achieving effective backlighting through fabric covers with much smaller device heights
Solution Approach 2:
The patent changes the physical parameter of LED height by transitioning from packaged LEDs (12.5-200 microns) to unpackaged semiconductor devices (25-100 microns or 50-80 microns). This parameter change enables the light source to be thin enough to effectively illuminate through fabric covers while maintaining reliable operation through proper mounting and electrical connection
2Reliability
If fabric covers are used on keyboard keys, then the cover provides aesthetic and protective functions, but the fabric material structure impedes effective backlighting transmission
Solution Approach 1:
The patent changes the illumination parameter by using unpackaged semiconductor devices that emit light with sufficient intensity and appropriate spectral characteristics to penetrate fabric material. The reduced device height allows the light to be generated closer to the fabric cover, improving transmission effectiveness while maintaining the fabric's protective and aesthetic functions
Solution Approach 2:
The patent applies local quality by positioning the unpackaged semiconductor devices in specific locations beneath the fabric cover where optimal light transmission is needed. The devices are mounted on the key switch assembly in positions that maximize backlight visibility through the fabric while preserving its overall protective and aesthetic properties
3Length of moving object
If unpackaged semiconductor devices are used instead of packaged LEDs, then the device height is reduced to 25-100 microns improving light diffusion, but the device lacks protective features and interface integration
Solution Approach 1:
The patent applies universality by using the unpackaged semiconductor device to serve multiple functions: light emission, compact form factor for fabric backlighting, and integration with the keyboard key assembly. The device is mounted on the key switch assembly which provides mechanical support and electrical connection, thereby achieving reliability through system integration rather than device-level packaging
Solution Approach 2:
The patent uses the key switch assembly as an intermediary between the unpackaged semiconductor device and the final application requirements. The key switch assembly provides the mechanical mounting structure and electrical connections that would normally be part of an LED package, enabling the unpackaged device to function reliably while maintaining its compact height
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 solution enables effective backlighting of fabric or non-fabric covered devices by using micro-sized LEDs to illuminate legends from behind, enhancing light diffusion and transmission, thus overcoming the structural challenges of conventional LED thickness and material limitations.
Implementation Method 1
The unpackaged LEDs may be extremely small. Indeed, the height of the LEDs may range from 12.5 to 200 microns, or from 25 to 100 microns, or from 50 to 80 microns.
Implementation Method 2
with a fabric or non-fabric cover, to achieve illumination through selective placement and combination with phosphor for light diffusion
Data Source
AI summary
A keyboard apparatus includes a key cover having a plurality of holes that extend through a thickness of the cover from a top side of the cover to a bottom side of the cover. The plurality of holes are arranged to collectively form a predetermined shape. A mask layer is disposed at the bottom side of the cover. A first region of the mask layer is opaque and a second region of the mask layer allows light to pass therethrough to the plurality of holes. A light source is disposed beneath the mask layer and positioned such that light emitted from the light source passes through the second region of the mask layer to the plurality of holes. A sensory contact terminal is disposed beneath the mask layer, and the terminal detects a keystroke movement.