TWI683330B - 薄膜結構製造方法 - Google Patents

薄膜結構製造方法 Download PDF

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TWI683330B
TWI683330B TW107147039A TW107147039A TWI683330B TW I683330 B TWI683330 B TW I683330B TW 107147039 A TW107147039 A TW 107147039A TW 107147039 A TW107147039 A TW 107147039A TW I683330 B TWI683330 B TW I683330B
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film
keycap
mold
key
fabric layer
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TW202025193A (zh
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歐陽亞元
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世洋科技股份有限公司
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Priority to US16/434,416 priority patent/US11309146B2/en
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Abstract

本發明揭露一種製造鍵盤裝置之按鍵之鍵帽的方法，該方法包括：提供面料層及設置於面料層下方的塑形薄膜；塑形該塑形薄膜及面料層以形成具有薄膜結構下表面的薄膜結構；以及提供具有上表面的鍵帽本體，其中上表面之輪廓符合薄膜結構下表面之輪廓，以形成鍵帽。在本發明中，以塑膠射出或黏合技術將薄膜結構及鍵帽本體一同成形為鍵帽、再加工為按鍵並以鐳射雕刻在薄膜結構上表面形成符號，使用者可察知光線通過符號而穿透薄膜結構或按鍵，並識別該按鍵的符號。

Description

薄膜結構製造方法
本發明關於薄膜結構製造方法。
人們所使用的機械設備常配置實體鍵盤，使用者敲擊鍵盤上表明特定符號的鍵帽而輸入文字、數字或圖案。其中一種實體鍵盤為配備於筆記型電腦上的背光鍵盤。發光二極體自背光鍵盤底部發出白光，穿透鍵帽上方的鐳射雕刻符號，讓使用者可清晰地看到鍵帽上的符號。
目前業界是將網版印刷、電腦噴塗、烤漆或鐳射雕刻等技術實施於硬度薄膜的底面上以形成符號，接著在模具中施以射出技術，在成形膜的底面上射出塑膠材料並形成鍵帽本體，而成為半成型的鍵帽。帶有符號的成形膜在模具中的位置發生偏差，使得在壓印為鍵帽形狀時符號並無法維持在固定位置，產生變形、拉扯，而最終鍵盤上整排鍵帽上的符號將參差不齊，產生良率不佳的問題。此外，射出技術的熱及壓力也容易使得已形成的符號發生變形，同樣產生良率不佳的問題。此外，對按鍵進行烤漆在全球業界面臨環保問題，且治具的選用也將可能產生公差。因此，現有技術所製作的鍵帽將容易產生瑕疵，無法滿足業界高良率、極低誤差的要求。
在另一技術中，是在硬度薄膜的表面上鐳射雕刻出符號，再對帶有符號的硬度薄膜進行塑膠射出，以形成半成型的鍵帽。然而，鐳射雕刻的高熱能將使得符號發生泛黃變色及產生毛邊的情形。
本案申請人鑑於習知技術中的不足，經過悉心試驗與研究，並一本鍥而不捨的精神，終構思出本案，能夠克服先前技術的不足，以下為本案的簡要說明。
為了克服現有技術製作鍵盤的鍵帽時的符號錯位、泛黃及變形等問題，本發明提供一種新穎及進步的鍵帽製造方法，其是將面料層(例如聚氨酯(PU)層或紡織層)貼合於塑形薄膜，以形成鍵帽的薄膜結構，薄膜結構可先形成塑形膜，再將此塑形膜進一步以塑膠射出本體來製成鍵帽，或是與事先製造好的鍵帽本體以黏合或卡扣等方式結合，而成為鍵盤裝置的鍵帽，該等鍵帽再製成按鍵或在其表面鐳射雕刻供光線穿透該鍵帽的符號。或者，薄膜結構可置於模具間，同時進行塑形及塑膠射出步驟，而成為鍵帽。
因此，本發明揭露一種製造鍵盤裝置的鍵帽的方法，包含：提供面料層；提供模內成型薄膜或模內裝飾薄膜；將面料層貼合於模內成型薄膜或模內裝飾薄膜，俾形成薄膜結構；在第一模具中將薄膜結構塑形為成形膜，其中成形膜具有面料層所在的上表面以及模內成型薄膜或模內裝飾薄膜所在的下表面；在第二模具中射出塑膠至下表面上而形成本體，且本體與成形膜結合為鍵帽；以及在上表面上以鐳射雕刻符號，俾光線通過該符 號而穿透鍵帽。
在一具體實施例中，模內成型薄膜或模內裝飾薄膜的材料選自由聚對苯二甲酸乙二酯(PET)、聚碳酸酯(PC)、聚氯乙烯(PVC)、聚丙烯(PP)、聚乙烯(PE)及丙烯腈-丁二烯-苯乙烯共聚物(ABS樹脂)所組成的群組中之一，且面料層位於鍵帽的外層。在一具體實施例中，塑膠為熱塑性塑膠或熱固性塑膠。
本發明還揭露一種製造鍵帽的方法，其中鍵帽用於鍵盤裝置的按鍵，且按鍵設置於鍵盤裝置上，該方法包括：提供面料層；提供塑形薄膜於面料層下方；塑形該塑形薄膜及面料層以形成成形膜，其中成形膜具下表面；以及提供模具，用以置入該成形膜，並射出成形鍵帽本體，其中鍵帽本體具鍵帽本體上表面，且鍵帽本體上表面之輪廓符合下表面之輪廓，以形成鍵帽。
在一具體實施例中，面料層為聚氨酯(PU)層或紡織層。
本發明還揭露一種製造鍵帽的方法，其中鍵帽用於鍵盤裝置的按鍵、該按鍵具薄膜結構、且按鍵設置於鍵盤裝置上，該方法包括：提供面料層；提供塑形薄膜於面料層下方；塑形該塑形薄膜及面料層以形成薄膜結構，其中薄膜結構具薄膜結構內表面；以及提供鍵帽本體，其中鍵帽本體具鍵帽本體上表面，且鍵帽本體上表面之輪廓符合薄膜結構內表面之輪廓，以形成鍵帽。
在一具體實施例中，鍵帽本體具鍵帽本體內表面；以及按鍵具按鍵結構本體，其中按鍵結構本體包括按鍵結構本體外表面，且按鍵結構本體外表面與鍵帽本體內表面具相符合之輪廓。在一具體實施例中，按鍵結構本體還包括支腳，鍵盤裝置包 括卡扣部，且支腳與卡扣部相互卡接而設置於鍵盤裝置上。
本發明還揭露一種製造鍵盤裝置的鍵帽的方法，包含：提供面料層及塑形薄膜；將面料層貼合於塑形薄膜，俾形成薄膜結構，其中薄膜結構的上表面為面料層所在的表面，且薄膜結構的下表面為塑形薄膜所在的表面；將薄膜結構置於模具之間，並對薄膜結構塑形及同時射出塑膠至下表面上而形成本體，且該本體與薄膜結構結合為鍵帽；以及在上表面上以鐳射雕刻符號，俾光線通過該符號而穿透鍵帽。
在一具體實施例中，膜具包括公模具及母模具，且塑膠是射出至薄膜結構的下表面上與公模具之間。
本文用語「塑形薄膜」指可在面料層(例如PU層)的表面上形成的薄膜，塑形薄膜包括但不限於在一平面上塗佈熱固型樹脂等而形成的薄膜、與面料層貼合的薄膜、模內成型(IMF)薄膜或模內裝飾(IMD)薄膜。
本文用語「模內成型(IMF)薄膜」指透過成型機成型，再經過剪裁於模具內生產之薄膜，其通常可包含：PET、PC、PVC、PP、PE、ABS樹脂或膠合材料。本文用語「模內裝飾(IMD)薄膜」指具有文字或圖案印刷或轉印於其上之薄膜上，其通常可包含：PET、PC、PVC、PP、PE、ABS樹脂或膠合材料。
本文用語「符號」是指在鍵盤裝置上表明一特定意義的符號，使用者敲擊鍵帽或按鍵、經電腦裝置處理而在螢幕上呈現該符號。「符號」包括但不限於文字、數字或圖案。
1、21‧‧‧薄膜結構
2‧‧‧面料層
3、23‧‧‧塑形薄膜
4‧‧‧第一面
5‧‧‧第二面
6、35‧‧‧成形膜
6a‧‧‧上表面
6b‧‧‧下表面
7‧‧‧母模具
8‧‧‧公模具
9‧‧‧本體
9a‧‧‧鍵帽本體上表面
10、36‧‧‧鍵帽
11‧‧‧符號
13‧‧‧中間層
20‧‧‧按鍵
22‧‧‧聚氨酯(PU)層
23‧‧‧塑形薄膜
24‧‧‧薄膜結構外表面
25‧‧‧薄膜結構內表面
26‧‧‧鍵帽本體
27‧‧‧鍵帽本體上表面
28‧‧‧鍵帽本體上表面輪廓
29‧‧‧鍵帽本體內表面
30‧‧‧按鍵結構本體
31‧‧‧按鍵結構本體外表面
32‧‧‧鍵盤裝置
33‧‧‧支腳
34‧‧‧卡扣部
A-A’‧‧‧虛線
本發明的上述目的及優點在參閱以下詳細說明及附 隨圖式之後對那些所屬技術領域中具有通常知識者將變得更立即地顯而易見。
第1圖為本發明的薄膜結構側視圖。
第2圖為本發明的薄膜結構塑形為成形膜的示意圖。
第3圖為本發明的成形膜在模具中與塑膠射出本體塑形為鍵帽的示意圖。
第4圖為本發明具有鐳射雕刻符號的鍵帽的示意圖。
第5圖為本發明具有鐳射雕刻符號的鍵帽的俯視圖。
第6圖為本發明的鍵盤裝置的按鍵之示意圖。
本案所提出的發明將可由以下的實施例說明而得到充分瞭解，使得所屬技術領域中具有通常知識者可以據以完成，然而本案的實施並非可由下列實施例而被限制其實施型態，所屬技術領域中具有通常知識者仍可依據除既揭露的實施例的精神推演出其他實施例，該等實施例皆當屬於本發明的範圍。
請參閱第1圖，其為本發明的薄膜結構側視圖。在第1圖中，背光鍵盤的鍵帽的薄膜結構1包括面料層2以及塑形薄膜3，而面料層2可為聚氨酯(PU)層或紡織層。面料層2的第一面4為形成鍵帽後可供鐳射雕刻出符號的一面，面料層2的第二面5為與塑形薄膜3貼合的一面。面料層2中可含有熱熔膠，面料層2受熱釋出熱熔膠，進而第二面5與塑形薄膜3貼合成為薄膜結構1。替代地，面料層2中並不含熱熔膠，而是在面料層2或塑形薄膜3上施加熱熔膠，加熱面料層2及塑形薄膜3所處的環境並將此二層彼此貼合。可選用的塑形薄膜3包括模內成型薄膜(IMF)或模內裝飾 (IMD)薄膜，其材料包括但不限於聚對苯二甲酸乙二酯(PET)、聚碳酸酯(PC)、聚氯乙烯(PVC)、聚丙烯(PP)、聚乙烯(PE)或丙烯腈-丁二烯-苯乙烯共聚物(ABS樹脂)。
請參閱第2圖，其為本發明的薄膜結構塑形為成形膜的示意圖。在第2圖中，片材的薄膜結構1被加熱至成形溫度，拉伸到突起或凹形的單表面模具(未示出)，並藉由壓向模具的方式(真空吸入)使薄膜結構1塑形為成形膜6，成形膜6的一面為面料層2材料所在的上表面6a，另一面為塑形薄膜3材料所在的下表面6b，此成形膜6可在後續塑膠射出步驟中作為射出成形基材。成形膜6中的塑形薄膜3呈現出符合鍵帽的上表面輪廓形狀，與塑形薄膜3貼合的面料2亦呈現出鍵帽的上表面，以供後續在上表面鐳射雕刻出符號。在第2圖中，此成形膜6被繪示為單一的方形鍵帽形狀，但所屬技術領域中具有通常知識者可知，成形膜6亦可被塑形為長形鍵帽(例如空白鍵)或圓形按鈕狀的鍵帽形狀。而且，一片薄膜結構可被塑形出具有一或複數個鍵帽形狀的成形膜，複數個鍵帽形狀的成形膜有助於大量製作鍵帽及按鍵。
請參閱第3圖，其為本發明的成形膜在模具中與塑膠射出本體塑形為鍵帽的示意圖。在第3圖中，成形膜6被設置於由母模具7及公模具8所組成的閉合模具中，以塑膠射出技術將熔融的熱塑性塑膠或熱固性塑膠壓縮注入在塑形薄膜3下方的公模具8中，冷卻及凝固而形成本體9(或稱為鍵帽本體)，本體9與成形膜6塑形為鍵帽10(參見第4圖)。由於本體9是以塑膠射出方式與成形膜6塑形，因此本體9的上表面(又稱為鍵帽本體上表面9a)的輪廓符合成形膜6的下表面6b之輪廓，以共同形成鍵帽10。
替代地，片材的薄膜結構1無須經過先塑形為成形膜6的製程(第2圖)，而直接於閉合模具中同時進行塑形及塑膠射出製程來製出鍵帽10。亦即，將片狀的薄膜結構1置於未閉合的公模具8及母模具7之間，當公模具8及母模具7彼此靠近、閉合時，薄膜結構1依公模具8及母模具7之凹凸結構而被塑形，同時熔融的熱塑性塑膠或熱固性塑膠被射出至薄膜結構1下方的公模具8中，冷卻及凝固而形成本體9，此時薄膜結構1與本體9共同形成鍵帽10。
請繼續參閱第4圖，對由母模具7及公模具8卸下的鍵帽10的第一面4進行鐳射雕刻，而雕刻出一符號11。如第5圖所示，光線能夠通過此符號11而穿透鍵帽10。當鍵帽10再被製作為按鍵且被裝設於鍵盤裝置(例如背光鍵盤)上時，鍵盤裝置底部的發光二極體(LED)發出的光線通過符號11而穿透鍵帽10，使用者眼睛看到鍵盤裝置的按鍵上的符號呈現透光效果。尤其，在暗處或背景亮度較低的地方，透光效果更明顯。
在本發明中，PU層厚度介於0.1mm至0.5mm之間，且模內薄膜或模內裝飾薄膜的厚度介於0.1mm至0.5mm之間或介於0.8mm至1.0mm之間。所屬技術領域中具有通常知識者可依實際需要選擇材料的厚度。
上述製作的鍵帽各自獨立，且可各自加工為鍵盤裝置的按鍵。
除了以塑膠射出技術製作鍵帽，本發明亦可將塑形膜與機構件透過黏著劑黏合成為透光件，此透光件再進一步製造為鍵盤裝置的按鍵。
請參閱第6圖，其為本發明的鍵盤裝置的按鍵之示意 圖。在第6圖中，鍵盤裝置32的按鍵20包括薄膜結構21、鍵帽本體26及按鍵結構本體30。其中，按鍵結構本體30具有按鍵結構本體外表面31及支腳33，且透過支腳33與鍵盤裝置32的卡扣部34相互卡接而設置於鍵盤裝置32上。按鍵結構本體30的一個具體結構為如第6圖所示的剪刀狀結構，組裝後之按鍵20受力向下壓時，按鍵結構本體30的剪刀狀結構即呈現上下壓縮的變形；按鍵20之受力消失時，按鍵結構本體30的形變也消失回復原狀。鍵帽本體26為一開模製成的機構件，包括鍵帽本體上表面27、鍵帽本體上表面輪廓28及鍵帽本體內表面29，鍵帽本體內表面29可與按鍵結構本體外表面31配合。「配合」是指按鍵結構本體外表面31與鍵帽本體內表面29在結構上彼此卡扣、黏合或樞設，以使按鍵結構本體30與鍵帽本體26彼此之間有物理上的接觸或黏接，必要時彼此之間能夠受外力而移動位置或產生物理上的變形。此外，具有薄膜結構外表面24及薄膜結構內表面25的薄膜結構21在設置於鍵帽本體26上之前被模具塑形為成形膜35。薄膜結構內表面25與鍵帽本體上表面27結合而使得塑膠射出方式成形的鍵帽本體26與成形膜35成為鍵帽36(較佳地是以黏著劑黏合兩者)，且代表按鍵20之符號被雕刻於薄膜結構外表面24上，鍵帽36整體而言則可作為背光件。因此，薄膜結構21、鍵帽本體26及按鍵結構本體30以A-A’虛線依序組裝為鍵盤裝置32上的按鍵20。
進一步而言，按鍵20的薄膜結構21更包括塑形薄膜23及聚氨酯(PU)層22，PU層22則設置於塑形薄膜23上，塑形薄膜23設置於鍵帽本體上表面27上、與之結合並呈現符合鍵帽本體上表面輪廓28之形狀。
實施例：
1.一種製造鍵盤裝置的鍵帽的方法，包含：提供面料層；提供模內成型薄膜或模內裝飾薄膜；將面料層貼合於模內成型薄膜或模內裝飾薄膜，俾形成薄膜結構；在第一模具中將薄膜結構塑形為成形膜，其中成形膜具有面料層所在的上表面以及模內成型薄膜或模內裝飾薄膜所在的下表面；在第二模具中射出塑膠至下表面上而形成本體，且本體與成形膜結合為鍵帽；以及在上表面上以鐳射雕刻符號，俾光線通過該符號而穿透鍵帽。
2.如實施例1所述的方法，其中模內成型薄膜或模內裝飾薄膜的材料選自由聚對苯二甲酸乙二酯(PET)、聚碳酸酯(PC)、聚氯乙烯(PVC)、聚丙烯(PP)、聚乙烯(PE)、丙烯腈-丁二烯-苯乙烯共聚物(ABS樹脂)所組成的群組中之一，且面料層位於鍵帽的外層。
3.如實施例1或2所述的方法，其中塑膠為熱塑性塑膠或熱固性塑膠。
4.一種製造鍵帽的方法，其中鍵帽用於鍵盤裝置的按鍵，且按鍵設置於鍵盤裝置上，該方法包括：提供面料層；提供塑形薄膜於面料層下方；塑形該塑形薄膜及面料層以形成一成形膜，其中成形膜具下表面；以及提供模具，用以置入該成形膜，並射出成形鍵帽本體，其中鍵帽本體具鍵帽本體上表面，且鍵帽本體上表面之一輪廓符合下表面之一輪廓，以形成鍵帽。
5.如實施例4所述的方法，其中面料層為聚氨酯(PU)層或紡織層。
6.一種製造鍵帽的方法，其中鍵帽用於鍵盤裝置的按鍵、該按 鍵具薄膜結構、且按鍵設置於鍵盤裝置上，該方法包括：提供面料層；提供塑形薄膜於面料層下方；塑形該塑形薄膜及面料層以形成薄膜結構，其中薄膜結構具薄膜結構內表面；以及提供鍵帽本體，其中該鍵帽本體具鍵帽本體上表面，且鍵帽本體上表面之輪廓符合薄膜結構內表面之輪廓，以形成鍵帽。
7.如實施例6所述的方法，其中鍵帽本體具鍵帽本體內表面；以及按鍵具按鍵結構本體，其中按鍵結構本體包括按鍵結構本體外表面，且按鍵結構本體外表面與鍵帽本體內表面具相符合之輪廓。
8.如實施例6或7所述的方法，其中按鍵結構本體還包括支腳，鍵盤裝置包括卡扣部，且支腳與卡扣部相互卡接而設置於鍵盤裝置上。
9.一種製造鍵盤裝置的鍵帽的方法，包含：提供面料層及塑形薄膜；將面料層貼合於塑形薄膜，俾形成薄膜結構，其中薄膜結構的上表面為面料層所在的表面，且薄膜結構的下表面為塑形薄膜所在的表面；將薄膜結構置於模具之間，並對薄膜結構塑形及同時射出塑膠至下表面上而形成本體，且該本體與薄膜結構結合為鍵帽；以及在上表面上以鐳射雕刻符號，俾光線通過該符號而穿透鍵帽。
10.如實施例9所述的方法，其中膜具包括公模具及母模具，且塑膠是射出至薄膜結構的下表面上與公模具之間。
本發明實屬難能的創新發明，深具產業價值，援依法提出申請。此外，本發明可以由所屬技術領域中具有通常知識者做任何修改，但不脫離如所附申請專利範圍所要保護的範圍。
20‧‧‧按鍵
21‧‧‧薄膜結構
22‧‧‧聚氨酯(PU)層
23‧‧‧塑形薄膜
24‧‧‧薄膜結構外表面
25‧‧‧薄膜結構內表面
26‧‧‧鍵帽本體
27‧‧‧鍵帽本體上表面
28‧‧‧鍵帽本體上表面輪廓
29‧‧‧鍵帽本體內表面
30‧‧‧按鍵結構本體
31‧‧‧按鍵結構本體外表面
32‧‧‧鍵盤裝置
33‧‧‧支腳
34‧‧‧卡扣部
A-A’‧‧‧虛線

Claims (9)

  1. 一種製造一鍵盤裝置的鍵帽的方法，包含：提供一面料層；提供一模內成型薄膜或一模內裝飾薄膜；將該面料層貼合於該模內成型薄膜或該模內裝飾薄膜，俾形成一薄膜結構；在一第一模具中將該薄膜結構塑形為一成形膜，其中該成形膜具有該面料層所在的一上表面以及該模內成型薄膜或一模內裝飾薄膜所在的一下表面；在一第二模具中射出一塑膠至該下表面上而形成一本體，且該本體與該成形膜結合為該鍵帽；以及在該上表面上以鐳射雕刻一符號，俾一光線通過該符號而穿透該鍵帽。
  2. 如申請專利範圍第1項所述的方法，其中該模內成型薄膜或該模內裝飾薄膜的一材料選自由聚對苯二甲酸乙二酯(PET)、聚碳酸酯(PC)、聚氯乙烯(PVC)、聚丙烯(PP)、聚乙烯(PE)及丙烯腈-丁二烯-苯乙烯共聚物(ABS樹脂)所組成的群組中之一，且該面料層位於該鍵帽的外層。
  3. 如申請專利範圍第1項所述的方法，其中該塑膠為熱塑性塑膠或熱固性塑膠。
  4. 如申請專利範圍第1項所述的方法，其中該面料層為一聚氨酯(PU)層或一紡織層。
  5. 一種製造鍵帽的方法，其中該鍵帽用於一鍵盤裝置的按鍵、該按鍵具一薄膜結構、且該按鍵設置於該鍵盤裝置上，該方法包括：提供一面料層； 提供一塑形薄膜於該面料層下方；塑形該塑形薄膜及該面料層以形成該薄膜結構，其中該薄膜結構具一薄膜結構內表面；提供一鍵帽本體，其中該鍵帽本體具一鍵帽本體上表面，且該鍵帽本體上表面之一輪廓符合該薄膜結構內表面之一輪廓，以形成該鍵帽；以及在該上表面上以鐳射雕刻一符號，俾一光線通過該符號而穿透該鍵帽。
  6. 如申請專利範圍第5項所述的方法，其中：該鍵帽本體具一鍵帽本體內表面；以及該按鍵具一按鍵結構本體，其中該按鍵結構本體包括一按鍵結構本體外表面，且該按鍵結構本體外表面與該鍵帽本體內表面具相符合之輪廓。
  7. 如申請專利範圍第6項所述的方法，其中該按鍵結構本體還包括一支腳，該鍵盤裝置包括一卡扣部，且該支腳與該卡扣部相互卡接而設置於該鍵盤裝置上。
  8. 一種製造一鍵盤裝置的鍵帽的方法，包含：提供一面料層及一塑形薄膜；將該面料層貼合於該塑形薄膜，俾形成一薄膜結構，其中該薄膜結構的一上表面為該面料層所在的表面，且該薄膜結構的一下表面為該塑形薄膜所在的表面；將該薄膜結構置於一模具之間，並對該薄膜結構塑形及同時射出一塑膠至該下表面上而形成一本體，且該本體與該薄膜結構結合為該鍵帽；以及在該上表面上以鐳射雕刻一符號，俾一光線通過該符號而穿 透該鍵帽。
  9. 如申請專利範圍第8項所述的方法，其中該膜具包括一公模具及一母模具，且該塑膠是射出至該薄膜結構的該下表面上與該公模具之間。
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