Multi-layer Keycap Etching for Wear Resistance
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Solution Overview
Problem
Existing input device keycaps suffer from symbol wear due to printed ink, leading to a low-quality appearance and loss of functionality over time.
Innovation Solution
A multi-layered keycap structure is formed with different colored polymer layers, where the symbol is etched to expose specific colors, and surface treatments are applied to alter the color appearance, ensuring durability and design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If printed ink symbols are used on keycaps, then the initial appearance and color variety are good, but the symbols wear away with extended use leading to faded appearance and loss of functionality
Solution Approach 1:
The keycap is divided into multiple layers (first keycap layer, second keycap layer, third keycap layer) with different colors. The symbol is formed by selectively removing portions of these layers to expose underlying colors, creating a multi-colored symbol that is integral to the keycap structure rather than a surface printing that can wear off.
Solution Approach 2:
The keycap uses composite construction with multiple polymer layers of different colors bonded together. This layered composite structure allows the symbol to be created through selective removal of layers, embedding the symbol within the keycap's structure rather than applying it as a separate surface layer.
2Adaptability or versatility
If multiple colored inks are used to print symbols, then color variety is achieved, but the printing process becomes complex and the symbols still wear away
Solution Approach 1:
Instead of adding colored ink to create symbols on a single-color keycap, the invention inverts the approach by starting with a multi-layered keycap structure where different colors are already present in different layers, and the symbol is revealed by removing material to expose the underlying color layers.
Solution Approach 2:
The solution moves from a two-dimensional surface printing approach to a three-dimensional layered structure. The symbol is created not just on the surface but through the depth of the keycap by selectively removing portions of multiple layers to expose different colored underlying layers.
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 etched symbols on the keycaps are more durable, resistant to wear, and offer a broader range of colors, maintaining a clear and sharp appearance even with extended use.
Implementation Method 1
etching the multi-layered keycap structure may include: removing at least a portion of the third polymer layer; and treating a surface of the second polymer layer... The laser ablation may be performed by a laser beam having a set of parameters including pulse, energy, and time suitable to burn away at least one of the second or third polymer layers
Implementation Method 2
treating the surface of the first or second polymer layers may be performed by a laser beam having a set of parameters including pulse, energy, and time suitable to alter at least one of the first or second polymer layers. In embodiments, altering at least one of the first or second polymer layers may include foaming or carbonizing the at least one of the first or second polymer layers with the laser beam
Data Source
AI summary
Embodiments describing a method of forming a multi-layered keycap structure are disclosed herein. The method includes forming a first polymer layer on a second polymer layer, wherein the first polymer layer includes a first color and the second polymer layer includes a second color, and coupling the first polymer layer and second polymer layer to a substrate layer such that the first polymer layer is closer to the substrate than the second polymer layer. The method may further include forming a third polymer layer on the second polymer layer; and etching the multi-layered keycap structure to form an opening having a bottom surface that exposes at least one of the first or second color.