Sheet-like key top

Abstract: A high-yield, high-quality sheet-like key top wherein a protective film (4) is laminated to the backside of a display layer (3) during the forming of a key top consisting of thermoplastic resin to preclude the pressure and the heat of the molten resin from directly affecting the display layer, thereby preventing the display portion from being distorted and the display layer from being cracked.

Description: The present invention relates to a sheet-like key top used for pushbutton switches for equipment such as electronics, portables, and remote controls. The construction of pushbutton switches used for the input portion of equipment such as electronics and portables has been diversified into a wide variety of designs. For example, pushbutton switches comprising key tops made from synthetic rubber, pushbutton switches in which key tops made from resin and key pads made from synthetic rubber are integrally attached together, and pushbutton switches in which a film is integrally attached to one surface of each key top made from resin are widely used. Above all, there has been an increasing demand for pushbutton switches in which a film is integrally attached to one surface of each key top made from resin, since in the case of switches of this type, a rich variety of display layers can be designed, the thickness can be made small, and prices are low. The construction of a pushbutton switch in which a film is integrally attached to one surface of a key top made from resin is mentioned in the Japanese Patent Gazette Laid-Open No. HEI 2-14726. The above-mentioned construction is such that a film, on the back of which is present a display layer formed by printing, is deformed by bending to the same form as that of the key top main body and is integrally attached to the upper side of the key top. Documents JP-A-11 224561 and EP-A-0 847 067 are also acknowledged Furthermore, by way of one of the methods of manufacturing the above-mentioned key top is described in the Japanese Patent Gazette Laid-Open No. HEI 6-44859 a manufacturing method whereby a film having a printed display layer is firmly held by means of a mold for forming key top main bodies, and is deformed by the action of the pressure and the heat of the molten resin which are generated during the forming of the key top, thus being pushed upward, then is removed from the mold after the molten resin is cured. However, a pushbutton switch in which a film is integrally attached to one surface of a key top made from resin has had a problem in that the display layer softens by the action of the pressure and the heat of the molten resin generated during the forming of thermoplastic resin, resulting in the display portion 2 for characters, symbols, and the like being liable to get distorted or in a crack 6 being liable to occur in the display layer 3, as shown in Figure 2. Furthermore, there has been another problem in that in a case where a metallic-looking display layer with metal filler mixed is present, the display layer softens by the action of the pressure and the heat of the molten resin generated during the forming of thermoplastic resin, resulting in an uneven dispersion 7 being liable to occur, as shown in Figure 5. For the purpose of solving the above-mentioned problems, the present invention provides a high-yield, high-quality sheet-like key top in which a protective film is laminated to the backside of the display layer so that the heat of the molten resin generated during the forming of thermoplastic resin will not directly affect the display layer, thereby preventing display portion from being distorted and the display layer from being cracked. Namely, the present invention provides a sheet-like key top comprising a main body of a key top; a base film of which entire backside is povided with a display layer, and a protective film laminated to an entire backside of the display layer, wherein the display layer is formed to the same shape as that of an upper surface of the main body of the key top; and the protective film is integrally attached to the upper surface and a side surface of the main body of the key top. Any and every flexible, heat-resistant film may be used as a protective film of the present invention. For example, polyethylene terephthalate (PET) films, polyamide films, polycarbonate films, and fluorine films may be enumerated. Furthermore, any protective film with a thickness of 15 µm or more is capable of protecting a display layer from molten resin. Reference being had to drawings, typical embodiments of the present invention are explained. Figure 1 : (a) shows a longitudinal sectional view and (b) shows a top view of an embodiment of a sheet-like key top of the present invention. Figure 2 : (a) shows a longitudinal sectional view and (b) shows a top view of a comparative example of a prior art sheet-like key. Figure 3 : (a) shows a longitudinal sectional view and (b) shows a top view of an embodiment of a sheet-like key top of the present invention. Figure 4 : (a) shows a longitudinal sectional view and (b) shows a top view of an embodiment of a sheet-like key top of the present invention. Figure 5 shows a top view of a prior art metallic-looking sheet-like key top. The manufacturing method whereby a protective film of the present invention is laminated is not specifically limited. For example, after a display layer has been formed on a base film, a protective film coated with an adhesive layer may be laminated to one surface of the display layer, thereby accomplishing lamination. Embodiments of the present invention are mentioned below for more detailed explanations. Embodiment 1 As shown in Figure 3, the whole of one surface of a polycarbonate film with a thickness of 100 µm was printed in vinyl chloride or vinyl acetate base black shading ink except for the portion to be printed with lettering, and a display portion 2 was printed on the above-mentioned lettering portion in vinyl chloride or vinyl acetate base colored translucent ink, thereby forming a display layer 3. A protective film 4, which was a 20 µm thick PET film with one surface coated with acrylic base adhesive compound, was laminated to that side where the display layer 3 was formed, thereby creating a film lamination. This film lamination was deformed to the shape of the key top by means of a mold for temporary drawing, and then was firmly held by means of a mold for injection molding. Thereafter, polycarbonate resin was injected onto the above-mentioned film lamination to produce a sheet-like key top in which a key top main body 5 is formed. Thus was obtained a high-quality sheet-like key top in which the display portion was not distorted and the display layer was not cracked, thereby preventing illumination leakage. Embodiment 2 As shown in Figure 4, a thin film layer was formed, by means of deposition, on one surface of a 70 µm thick PET film, which was chosen as a protective film 4, and then was coated with an epoxy base deposited protective layer. Thereafter, a display portion 2 containing characters, symbols, and the like was printed the above-mentioned protective layer portion in vinyl chloride or vinyl acetate base colored ink, thereby forming a display layer 3. A base film 1, which was a 100 µm thick carbonate film comprising an adhesive layer 8 coated with acrylic adhesive compound, was laminated to that side where the display layer 3 was formed, thereby creating a film lamination. This film lamination was deformed to the shape of the key top by means of a mold for temporary drawing, and then was firmly held by means of a mold for injection molding. Thereafter, polycarbonate resin was injected onto the above-mentioned film lamination to produce a sheet-like key top in which a key top main body 5 is formed. Thus was obtained a high-quality sheet-like key top having mirror finish characteristics, in which the display portion was not distorted and the display layer was not cracked. Embodiment 3 As shown in Figure 1, a circular display portion 2 was printed on one surface of a base film 1, which was a 100 µm thick carbonate film, in vinyl chloride or vinyl acetate base black shading ink, and then the whole printed surface of the above-mentioned display portion 2 was subjected to printing in metallic-looking ink to which vinyl chloride or vinyl acetate base aluminum powder was added, thereby forming a display layer 3. A protective film 4, which was a 20 µm thick PET film coated with acrylic adhesive compound, was laminated to that side where the display layer 3 was formed, thereby creating a film lamination. This film lamination was deformed to the shape of the key top by means of a mold for temporary drawing, and then was firmly held by means of a mold for injection molding. Thereafter, polycarbonate resin was injected onto the above-mentioned film lamination to produce a sheet-like key top in which a key top main body 5 is formed. Thus was obtained a high-quality sheet-like key top, in which aluminum powder was not dispersed unevenly, the display portion was not distorted, and the display layer was not cracked. According to the present invention, by laminating a protective film to the backside of a display layer, the pressure and the heat of molten resin which are generated during the forming of a key top consisting of thermoplastic resin are prevented from directly affecting the display layer, thereby making it possible to provide a high-yield, high-quality sheet-like key top in which the display portion is not distorted and the display layer is not cracked. Moreover, in the case of a metallic-looking display layer in which metal filler is mixed, uneven dispersion of the metal filler is eliminated. Furthermore, in the case of a sheet-like key top is of the illumination type, if a transparent protective film is used, this protective film also serves effectively as a light-transmitting layer.

Claims: A sheet-like key top, comprising: a main body (5) of a key top; a base film (1) of which entire backside is provided with a display layer (3), and a protective film (4) laminated to an entire backside of the display layer (3), wherein the display layer (3) is formed to the same shape as that of an upper surface of the main body (5) of the key top; and the protective film (4) is integrally attached to the upper surface and a side surface of the main body (5) of the key top. The sheet-like key top as claimed in Claim 1, wherein the display layer (3), which is provided in an entire area between the base film (1) and the protective film (4), has a display portion (2) at a position corresponding to the upper surface of the main body (5) of the key top.

Inventors: NAKAJO MASARU, NAKAJO, MASARU, Nakajo, Masaru, R&amp;D Center of Polymatech Co., Ltd.
Applicants: POLYMATECH CO LTD, POLYMATECH CO., LTD.
Application year: 2000
Main classification: H01H13
IPC codes: H01H13, H01H11