TWI907870B - Keycap structure and manufacturing method thereof - Google Patents

Abstract

A keycap structure includes a main body, a first coat layer and a cover layer. The main body is formed of a base material and a laser blowing agent. The first coat layer is coated on an upper surface of the main body. The cover layer is disposed above the first coat layer. Laser engraving is performed on the main body, the first coat layer and the cover layer to form an accommodating portion on the first coat layer and the cover layer, and to form a pattern convex portion on the main body. The pattern convex portion is disposed in the accommodating portion.

Description

Keycap structure and its manufacturing method

This invention relates to a keycap structure and a method of manufacturing the same, and more particularly to a keycap structure for a keyboard and a method of manufacturing the same.

Generally, a keyboard consists of multiple keys. To facilitate user operation, the keycaps have markings with text or other symbols to indicate the corresponding input signal after being pressed. Because different countries use different texts or symbols, such as different characters for different languages, currently the required text or symbols are laser-engraved onto the keycaps before shipment.

Figure 1 is a cross-sectional view of a conventional keycap manufactured by laser engraving. Please refer to Figure 1. The main structure of the conventional keycap 9 includes a body 91, a primer layer 92, and a protective layer 93. After the body 91 is formed, the primer layer 92 and the protective layer 93 are applied sequentially. Finally, according to the desired character pattern, hollow areas 94 are formed on the primer layer 92 and the protective layer 93 by laser engraving. Generally, the color of the body 91 is different from the color of the primer layer 92, and they are usually contrasting colors. The primer layer 92 is the overall color of the keycap 9, while the body 91 is the color of the character pattern. Therefore, the color of the primer layer 92 can be revealed and corresponding character patterns can be formed from the hollowed-out portion 94 created by laser engraving.

As shown in Figure 1, the hollow portion 94 creates a stepped indentation on the surface of the keycap 9. Therefore, after prolonged use by the user, the keyboard may accidentally get stuck at the stepped area (as indicated by the arrow), causing the protective layer 93 or the primer layer 92 to peel off, and making the character patterns blurry and difficult to read.

In view of the above problems, the main purpose of this invention is to provide a keycap structure and its manufacturing method, which solves the problem that the characters on conventional keycaps are easily damaged and difficult to identify by using a base material and a laser foaming agent to form the body of the keycap structure.

To achieve the above objectives, the present invention provides a keycap structure comprising a body, a primer layer, and a protective layer. The body is formed from a substrate material and a laser foaming agent. The primer layer is applied to an upper surface of the body. The protective layer is disposed above the primer layer. The body, primer layer, and protective layer are laser-engraved to form a receiving portion in the primer layer and the protective layer, and a patterned protrusion is formed in the body, the patterned protrusion being received within the receiving portion.

To achieve the above objectives, the present invention also provides a method for manufacturing a keycap structure, comprising the following steps: providing a substrate material and a laser foaming agent, and forming a body; applying a primer layer to an upper surface of the body; disposing a protective layer above the primer layer; and performing laser engraving on the body, the primer layer and the protective layer to form a receiving portion in the primer layer and the protective layer, and forming a patterned protrusion in the body, the patterned protrusion being received within the receiving portion.

According to one embodiment of the present invention, the height of the patterned protrusion is greater than or equal to the depth of the receiving portion.

According to one embodiment of the present invention, the substrate material and the laser foaming agent are mixed together and then formed into a body by injection molding.

According to one embodiment of the present invention, the substrate material and the laser foaming agent are formed into a body by two-part injection molding. Furthermore, the body includes a substrate layer and a laser-etched layer, and the laser-etched layer is located on an upper surface of the substrate layer.

According to one embodiment of the present invention, the base material is a plastic material, and the laser foaming agent includes a mica powder.

According to one embodiment of the present invention, the proportion of laser foaming agent is between 0.5% and 1%.

According to one embodiment of the present invention, the color of the raised part of the pattern is different from the color of the body.

According to one embodiment of the invention, the color of the body is different from the color of the primer layer.

According to one embodiment of the present invention, the body is formed of a base material, a laser foaming agent and a coloring material.

According to one embodiment of the present invention, the step of providing a substrate material and a laser foaming agent further includes providing a coloring material, and causing the substrate material, the laser foaming agent and the coloring material to jointly form the body.

According to one embodiment of the present invention, the keycap structure further includes a paint layer. The paint layer is disposed between the primer layer and the protective layer.

According to one embodiment of the present invention, the method of manufacturing the keycap structure further includes the following steps: applying a color paint layer to an upper surface of a primer layer; and applying a protective layer to an upper surface of the color paint layer, such that the protective layer is disposed above the primer layer.

As described above, according to the keycap structure and manufacturing method of this invention, the keycap structure includes a body, a primer layer, and a protective layer, with the primer layer and protective layer located on top of the body. Since the body is formed from a substrate material and a laser foaming agent, when laser engraving is performed on the body, primer layer, and protective layer, a receiving portion can be formed in the primer layer and protective layer, and a pattern protrusion can be formed in the body. Furthermore, the pattern protrusion is housed within the receiving portion, thereby preventing the keycap structure from developing recessed steps. Therefore, even after prolonged use by the user, the protective layer or primer layer will not peel off due to getting stuck at a step. Furthermore, it also prevents damage to the character patterns that would make them difficult to read, and improves the durability of the keycap structure.

To better understand the technical content of this invention, the following are some preferred specific embodiments.

Figure 2 is a flowchart of the manufacturing method of the keycap structure of the first embodiment of the present invention, and Figures 3A to 3D are schematic diagrams of the keycap structure of the first embodiment prepared according to the manufacturing method shown in Figure 2. Figure 3D is also a cross-sectional schematic diagram of the keycap structure of the first embodiment of the present invention. The structure of the keycap structure 1 of the present embodiment will be further described below according to the steps shown in Figure 2.

Step S10: Provide a base material and a laser foaming agent, and form a body 10.

Please refer to Figure 3D. The keycap structure 1 of this embodiment includes a body 10, a primer layer 20, and a protective layer 30. The body 10 is mainly formed by a substrate material and a laser foaming agent, as shown in Figure 3A. For example, the substrate material and the laser foaming agent are mixed together and then injection molded to form the body 10.

In this embodiment, the base material is a plastic material, such as a copolymer with methyl methacrylate (MMA), acrylonitrile, butadiene, and styrene as the main raw materials. The laser foaming agent can be mica powder, whose main components include compounds such as alumina and yttrium oxide. Preferably, the proportion of the laser foaming agent is between 0.5% and 1%. In other words, the laser foaming agent accounts for 0.5% to 1% of the total material. Furthermore, the laser foaming agent can generate bubbles due to the heat effect produced during laser engraving, thereby creating a bulge at the engraved area. Related details are further explained in step S40.

Preferably, in addition to the substrate material and the laser foaming agent, a color material can also be provided, so that the substrate material, laser foaming agent, and color material together form the body 10. In this embodiment, the color material can be white pigment. After the substrate material, laser foaming agent, and color material are mixed together, the body 10 is formed by injection molding.

Step S20: Apply a primer layer 20 to an upper surface 11 of the body 10.

A primer layer 20 is applied to the upper surface 11 of the body 10, as shown in Figure 3B. The color of the body 10 is different from the color of the primer layer 20. In this embodiment, the primer layer 20 is the overall color of the keycap structure 1, which is usually the same as the color of the keyboard. For example, if the keyboard and its keys are to be black, a black primer can be applied to the upper surface 11 of the body 10 to form a black primer layer 20. Correspondingly, the color material of the body 10 can be selected as a contrasting color that differs significantly from the color of the primer layer 20, such as the aforementioned white paint.

Step S30: Apply a protective layer 30 over the primer layer 20.

In this embodiment, a protective layer 30 is applied directly to the upper surface 21 of the primer layer 20, as shown in FIG. 3C. The protective layer 30 may be, for example, but not limited to, an ultraviolet curing paint, often referred to as a UV paint. Therefore, the keycap structure 1 of this embodiment has two coating layers above its body 10: the primer layer 20 and the protective layer 30.

Step S40: Laser engraving is performed on the body 10, the primer layer 20 and the protective layer 30 to form a receiving part A on the primer layer 20 and the protective layer 30, and a patterned protrusion 12 on the body 10.

Figure 4 is an enlarged schematic diagram of the keycap structure shown in Figure 3D at the pattern protrusion. Please refer to both Figure 3D and Figure 4. In step S40, laser engraving is performed on the body 10, primer layer 20, and protective layer 30 according to the desired character pattern. First, the heat generated by the laser forms hollow holes in the primer layer 20 and protective layer 30, which are called receiving portions A. The edges of receiving portions A are marked in Figures 3D and 4. Next, the laser contacts the body 10 at the receiving portion A and forms the pattern protrusion 12 on the body 10.

Specifically, the body 10 comprises a plastic substrate material and a laser foaming agent. The laser foaming agent absorbs laser energy and converts the laser beam into heat. During laser engraving, the body 10 is locally melted, causing a recess to form on its upper surface 11. Preferably, the depth of the recess is controlled to be less than 0.05 millimeters (mm). The thermal decomposition of the substrate material (i.e., the plastic material) generates bubbles, while the laser foaming agent components (e.g., alumina and yttrium oxide) and coloring materials (e.g., white pigment) undergo carbon oxidation, resulting in whitish protrusions. Specifically, the bubbles are sealed on the surface layer of the body 10, and the accumulation of bubbles forms protrusions on the upper surface 11 of the body 10 (as shown in Figure 4). Furthermore, the air bubbles are also confined within the receiving portion A to form character-shaped protrusions, hence the name pattern protrusion 12. It should be noted that the pattern protrusion 12 refers to the portion protruding from the upper surface 11 of the body 10. In addition, when the color material decomposes, evaporates, or becomes colorless, bleaching marks are produced, which makes the pattern protrusion 12 appear as a whitish protrusion. That is to say, the pattern protrusion 12 and the body 10 are different in color, and the color of the pattern protrusion 12 is also different from the color of the primer layer 20, so as to form characters or patterns that can be recognized by the user on the keycap structure 1.

Through the aforementioned manufacturing process, the pattern protrusion 12 is housed within the receiving portion A after molding, thereby preventing the keycap structure 1 from developing a recessed step on its surface (i.e., the upper surface 31 of the protective layer 30). Preferably, the height of the pattern protrusion 12 is greater than or equal to the depth of the receiving portion A. Therefore, even after prolonged use by the user, the protective layer 30 or the primer layer 20 will not peel off due to getting stuck at the step. Furthermore, preventing the protective layer 30 or the primer layer 20 from peeling off also prevents damage to the character pattern, making it difficult to read, and improves the durability of the keycap structure 1.

Figures 5A to 5D are schematic diagrams of the keycap structure of the second embodiment prepared according to the manufacturing method shown in Figure 2. Figure 5D is also a cross-sectional schematic diagram of the keycap structure of the second embodiment of the present invention. Please refer to Figures 2 and 5A to 5D. The keycap structure 1a of this embodiment also includes a body 10a, a primer layer 20a, and a protective layer 30a. The body 10a is also made of a substrate material and a laser foaming agent. The difference from the aforementioned embodiment is that the body 10a includes a substrate layer 13a and a laser-engraved layer 14a, and the laser-engraved layer 14a is located on an upper surface 131a of the substrate layer 13a, as shown in Figure 5A. Similarly, the substrate material can be a plastic material as in the aforementioned embodiments, and the laser foaming agent can be mica powder. Furthermore, the proportion of the laser foaming agent can be between 0.5% and 1%. In step S10, the substrate material and the laser foaming agent can be formed into the body 10a by two-part injection molding, so that the laser-engraved layer 14a is formed on the upper surface 131a of the substrate layer 13a.

Preferably, the body 10a may also include a color material, such as white pigment. In step S10, the substrate material is first mixed with the color material, and then mixed with a laser foaming agent to form the body 10a by two-part injection molding. Similarly, the laser-engraved layer 14a is also located on the upper surface 131a of the substrate layer 13a.

In step S20, a primer layer 20a is applied to the upper surface 11a of the body 10a, that is, to the upper surface 141a of the laser-etched layer 14a, as shown in Figure 5B. In step S30, a UV-curable coating is applied to the upper surface 21a of the primer layer 20a as a protective layer 30a, as shown in Figure 5C. Therefore, the keycap structure 1a of this embodiment has two coating layers on the body 10a, namely the primer layer 20a and the protective layer 30a.

In step S40, laser engraving is performed on the laser-engraved layer 14a, primer layer 20a, and protective layer 30a of the body 10a according to the desired character pattern. First, the primer layer 20a and protective layer 30a can be formed with hollowed-out receiving portions A (marked on the edge of receiving portion A in Figure 5D). Next, the laser contacts the upper surface 141a of the laser-engraved layer 14a, and first forms a concave portion in the laser-engraved layer 14a before foaming, thereby producing raised pattern protrusions 12a. The upper surface 141a of the laser-engraved layer 14a is the upper surface 11a of the body 10a. Therefore, the patterned protrusion 12a in this embodiment is a part protruding from the upper surface 141a of the laser-engraved layer 14a, and also a part protruding from the upper surface 11a of the body 10a. The mechanism by which laser engraving creates a protrusion in the body 10a can be referred to the description of the aforementioned embodiment, and will not be repeated here.

Similarly, in this embodiment, the patterned protrusion 12a is housed within the receiving portion A after molding. Preferably, the height of the patterned protrusion 12a is greater than or equal to the depth of the receiving portion A. Therefore, the surface of the keycap structure 1a will not have a recessed step, and even after prolonged use by the user, the protective layer 30a or the primer layer 20a will not peel off due to being stuck at the step.

Figure 6 is a flowchart of the manufacturing method of the keycap structure of the second embodiment of the present invention, and Figures 7A to 7D are schematic diagrams of the keycap structures of the three embodiments prepared according to the manufacturing method shown in Figure 6. Figure 7D is also a cross-sectional schematic diagram of the keycap structure of the third embodiment of the present invention. Please refer to Figures 6 and 7A to 7D. The keycap structure 1b also includes a body 10b, a primer layer 20b, and a protective layer 30b, and the keycap structure 1b of this embodiment further includes a color paint layer 40b. The color paint layer 40b is disposed between the primer layer 20b and the protective layer 30b. In step S10, the body 10b is also formed using a substrate material and a laser foaming agent. The substrate material can be plastic, as in the aforementioned embodiments, and the laser foaming agent can be mica powder. Preferably, the body 10b can also contain a coloring material, such as white pigment. In step S20, a primer layer 20b is also applied to the upper surface 11b of the body 10b, as shown in Figure 7A.

The difference between the manufacturing method of the keycap structure 1b of this embodiment (as shown in Figure 6) and the manufacturing method of the keycap structures 1 and 1a of the aforementioned embodiments (as shown in Figure 2) lies in steps S21 to S41, and the differences will be explained one by one below.

Step S21: Apply a layer of paint 40b to one upper surface 21b of the primer layer 20b.

In this embodiment, a color paint layer 40b is applied to the upper surface 21b of the primer layer 20b, such that the color paint layer 40b is located on the upper surface 21b of the primer layer 20b, as shown in Figure 7B. The color paint layer 40b is the color of the keycap structure 1b, which is different from the color of the body 10b.

Step S31: Apply a protective layer 30b to an upper surface 41b of the paint layer 40b, so that the protective layer 30b is disposed above the primer layer 20b.

A protective layer 30b is applied to the upper surface 41b of the paint layer 40b, such that the protective layer 30b is positioned above the primer layer 20b, as shown in Figure 7C. In other words, as in the aforementioned embodiment, the protective layer 30b is also positioned above the primer layer 20b and is the outermost coating layer of the keycap structure 1b. Furthermore, the keycap structure 1b of this embodiment has three coating layers on its body 10b: the primer layer 20b, the paint layer 40b, and the protective layer 30b.

Step S41: Perform laser engraving on the body 10b, primer layer 20b, color paint layer 40b, and protective layer 30b to form a receiving portion A on the primer layer 20b, color paint layer 40b, and protective layer 30b, and form a patterned protrusion 12b on the body 10b.

In step S41, laser engraving is performed according to the desired character pattern. Compared to the aforementioned embodiment, the keycap structure 1b of this embodiment includes a paint layer 40b, and therefore laser engraving is performed on the body 10b, the primer layer 20b, the paint layer 40b, and the protective layer 30b. Specifically, a hollowed-out receiving portion A is first formed on the primer layer 20b, the paint layer 40b, and the protective layer 30b. Then, a recess is first formed on the body 10b, followed by foaming, thereby creating a pattern protrusion 12b protruding from the upper surface 11b. Therefore, the pattern protrusion 12b of this embodiment is a portion protruding from the upper surface 11b of the body 10b. The mechanism by which laser engraving creates a protrusion on the body 10b can be found in the description of the aforementioned embodiments, and will not be repeated here.

Similarly, in this embodiment, the patterned protrusion 12b is housed within the receiving portion A after molding. Preferably, the height of the patterned protrusion 12b is greater than or equal to the depth of the receiving portion A. Therefore, the surface of the keycap structure 1b will not have a recessed step, and even after prolonged use by the user, the protective layer 30b, the paint layer 40b, or the primer layer 20b will not peel off due to being stuck at the step.

In summary, according to the keycap structure and manufacturing method of this invention, the keycap structure includes a body, a primer layer, and a protective layer, with the primer layer and protective layer located on top of the body. Since the body is formed from a substrate material and a laser foaming agent, when laser engraving is performed on the body, primer layer, and protective layer, a receiving portion can be formed in the primer layer and protective layer, and a patterned protrusion can be formed in the body. Furthermore, the patterned protrusion is housed within the receiving portion, thereby preventing the keycap structure from developing recessed steps on its surface. Therefore, even after prolonged use by the user, the protective layer or primer layer will not peel off due to sticking at a step. Furthermore, it can also prevent the characters and patterns from being damaged and becoming difficult to identify, and can improve the durability of the keycap structure.

It should be noted that the above examples are for illustrative purposes only, and the scope of the claims made by this invention should be based on the scope of the patent application, and not limited to the above examples.

1. 1a, 1b: Keycap structure 10. 10a, 10b, 91: Body 11. 11a, 11b: Top surface 12. 12a, 12b: Pattern protrusions 13a: Substrate layer 131a: Top surface 14a: Laser engraving layer 141a: Top surface 20. 20a, 20b, 92: Primer layer 21. 21a, 21b: Top surface 30. 30a, 30b, 93: Protective layer 31: Top surface 40b: Color paint layer 41b: Top surface 9: Keycap 94: Hollowed-out portion A: Receiving portion S10～S41: Steps

Figure 1 is a cross-sectional schematic diagram of a conventional keycap manufactured by laser engraving. Figure 2 is a flowchart of the manufacturing process of the keycap structure of the first embodiment of the present invention. Figures 3A to 3D are schematic diagrams of the keycap structure of the first embodiment manufactured according to the manufacturing method shown in Figure 2. Figure 4 is an enlarged schematic diagram of the patterned protrusion of the keycap structure shown in Figure 3D. Figures 5A to 5D are schematic diagrams of the keycap structure of the second embodiment manufactured according to the manufacturing method shown in Figure 2. Figure 6 is a flowchart of the manufacturing process of the keycap structure of the second embodiment of the present invention. Figures 7A to 7D are schematic diagrams of the keycap structures of the third embodiment manufactured according to the manufacturing method shown in Figure 6.

1: Keycap Structure

10: The Body

11: Top surface

12: Patterned raised parts

20: Primer layer

30: Protective layer

31: Upper surface

A: Storage compartment

Claims (18)

A keycap structure includes: a body formed of a base material and a laser foaming agent, the proportion of the laser foaming agent being between 0.5% and 1%; a primer layer applied to an upper surface of the body; and a protective layer disposed above the primer layer; wherein the body, the primer layer, and the protective layer are laser-engraved, and the heat generated by the laser forms a hollowed-out receiving portion in the primer layer and the protective layer, and a recess with a depth of less than 0.05 mm is formed on the upper surface of the body, the base material and the laser foaming agent are heated to form a patterned protrusion, the patterned protrusion being received within the receiving portion. The keycap structure as described in claim 1, wherein the height of the patterned protrusion is greater than or equal to the depth of the receiving portion. The keycap structure as described in claim 1, wherein the substrate material and the laser foaming agent are mixed together and then the body is formed by injection molding. The keycap structure as described in claim 1, wherein the substrate material and the laser foaming agent are formed into the body by two-part injection molding, and the body includes a substrate layer and a laser-etched layer, the laser-etched layer being located on an upper surface of the substrate layer. The keycap structure as described in claim 1, wherein the substrate material is a plastic material and the laser foaming agent includes a mica powder. The keycap structure as described in claim 1, wherein the color of the patterned protrusion is different from the color of the body. The keycap structure as described in claim 1, wherein the color of the body is different from the color of the primer layer. The keycap structure as described in claim 1, wherein the body is formed of the substrate material, the laser foaming agent and a coloring material. The keycap structure as described in claim 1 further includes: a single-color paint layer disposed between the primer layer and the protective layer. A method for manufacturing a keycap structure includes the following steps: providing a substrate material and a laser foaming agent, and forming a body, wherein the proportion of the laser foaming agent is between 0.5% and 1%; applying a primer layer to an upper surface of the body; disposing a protective layer on top of the primer layer; and performing laser engraving on the body, the primer layer, and the protective layer, wherein the heat generated by the laser forms a hollowed-out receiving portion in the primer layer and the protective layer, and a recess with a depth of less than 0.05 mm is formed on the upper surface of the body, and the substrate material and the laser foaming agent are heated to form a patterned protrusion, the patterned protrusion being received within the receiving portion. A method for manufacturing a keycap structure as described in claim 10, wherein a height of the patterned protrusion is greater than or equal to a depth of the receiving portion. The method for manufacturing a keycap structure as described in claim 10, wherein the substrate material and the laser foaming agent are mixed together and then the body is formed by injection molding. The method of manufacturing a keycap structure as described in claim 10, wherein the substrate material and the laser foaming agent are formed into the body by two-part injection molding, and the body includes a substrate layer and a laser-etched layer, the laser-etched layer being located on an upper surface of the substrate layer. The method of manufacturing a keycap structure as described in claim 10, wherein the substrate material is a plastic material and the laser foaming agent comprises a mica powder. A method for manufacturing a keycap structure as described in claim 10, wherein the color of the patterned protrusion is different from the color of the body. A method for manufacturing a keycap structure as described in claim 10, wherein the color of the body is different from the color of the primer layer. The method for manufacturing a keycap structure as described in claim 10, wherein the step of providing the substrate material and the laser foaming agent further includes providing a color material, and causing the substrate material, the laser foaming agent and the color material to jointly form the body. The method of manufacturing the keycap structure as described in claim 10 further includes the following steps: applying a color paint layer to an upper surface of the primer layer; and applying the protective layer to an upper surface of the color paint layer, such that the protective layer is disposed above the primer layer.