Patent Publication Number: US-2015083561-A1

Title: Metal keycaps with backlighting

Description:
TECHNICAL FIELD 
     This description relates to keycaps for an input and more particularly backlight keycaps for a computer keyboard. 
     BACKGROUND 
     Keycaps are typically used to cover and actuate or activate switches of electronic input devices. For example, keycaps are used to cover and activate the switches or keys of a computer keyboard. The keycaps typically include a symbol, such as a letter or number, which indicates the function or association of the switch that is activated by that particular keycap. For example, on a keyboard, when the keycap marked with the letter “a” is depressed, the switch associated with the “a” keycap is actuated. Often, when the keyboard is in communication with a word processor or a computer that is running word processing software, the depression of the “a” keycap and the associated actuation of the “a” switch causes the letter “a” to be introduced into the document that is being created. 
     Sometimes, the markings on keycaps include an ink or paint marking. Sometimes, the markings on the keycaps are illuminated or are backlight. 
     Keyboards and keycaps that include backlighting, however, tend to be thicker than non-backlight keyboards and keycaps. Such keyboards and keycaps may be undesirable in devices, such as laptop computers, that are intended to be thin. 
     SUMMARY 
     According to one general aspect of the invention, a keyboard of a computing device includes a keycap and a light source. The keycap is configured to actuate a switch of the computing device. The keycap includes a metal material and has an upper surface and a lower surface. The upper surface of the keycap is configured to be viewed by a user while operating the computing device and defines one or more openings in the keycap. The one or more openings in the upper surface is patterned in the shape of an alphanumeric character. The lower surface of the keycap defines one or more openings in the keycap. The keycap defines one or more passageways extending from the one or more openings defined by the upper surface of the keycap through the keycap to the one or more openings defined by the lower surface of the keycap. The light source is configured to emit light through the one or more passageways of the keycap from the lower surface side of the one or more passageways to the upper surface side of the one or more passageways. 
     According to another general aspect of the invention, a keycap includes and upper surface, a lower surface, and a side surface. The upper surface defines one or more openings. The one or more openings defined by the upper surface form an alphanumeric character. The lower surface defines one or more openings. The keycap is configured to actuate a switch of a keyboard of a computing device. The keycap includes a metal material and defines one or more passageways extending from the one or more openings defined by the upper surface through the keycap to the one or more openings defined by the lower surface. 
     According to another general aspect of the invention, a method includes creating a keycap from a metal material and creating a passageway extending through the keycap from a first surface of the keycap to a second surface of the keycap. The first surface being opposite the second surface. 
     The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of a keycap assembly. 
         FIG. 2  is a top view of an example keycap assembly. 
         FIG. 3  is a cross-sectional view of the keycap assembly of  FIG. 2  taken along line A-A of  FIG. 2 . 
         FIG. 3A  is a top view of a portion of a keyboard and a keycap assembly. 
         FIG. 3B  is a cross-sectional view of the portion of the keyboard and keycap assembly of  FIG. 3A . 
         FIG. 4  is a top view of another example keycap assembly. 
         FIG. 5  is a perspective view of a keyboard and an associated computer monitor. 
         FIG. 6  is a perspective view of a laptop computer. 
         FIG. 7  is a flowchart of a method of forming a keycap. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a schematic diagram of a keycap assembly  100 . The keycap assembly  100  includes a keycap  110 , a switch  150 , and a light source  160 . The keycap assembly  100  may be incorporated within an input of an electronic device. The keycap assembly  100  may be included within a keyboard or other type of input device. In some implementations, a keyboard, such as a computer keyboard, includes a plurality of keycaps  110  and keycap assemblies  100 . 
     The keycap  110  includes an upper surface  112 , a lower surface  114  and side surfaces  116 . The upper surface  112  can define an opening (not illustrated), and the lower surface  114  can define an opening. In some implementations, the keycap  110  has a generally rectangular shape (when viewed from a position above the keycap). For example, in some implementations, the upper surface  112  has a rectangular or square shape. 
     The keycap  110  can define a passageway  120  that extends through the keycap  110  from the upper surface  112  to the lower surface  114 . Specifically, in some implementations, the passageway  120  defined by the keycap  110  extends from the opening defined by the upper surface of the keycap  110  to the opening defined by the lower surface of the keycap  110 . 
     In some implementations, the opening defined by the upper surface of the keycap  110  is in the shape of a symbol, such as an alphanumeric character. In some implementations, the opening defined by the upper surface of the keycap  110  is in the shape of a single alphanumeric character. For example, in some implementations, the opening defined by the upper surface  112  of the keycap  110  is in the shape of a letter or is letter shaped. In other implementations, the opening defined by the upper surface  112  of the keycap  110  is in the shape of a number or is number shaped. In yet other implementations, the opening defined by the upper surface  112  of the keycap  110  has the shape of another symbol, such as a symbol typically found on the keys of a computer keyboard. 
     In some implementations, the opening defined by the upper surface  112  of the keycap  110  forms a portion of a symbol, such as a letter or a number. For example, in some implementations, the upper surface of the keycap  110  defines a plurality of openings, the lower surface  114  of the keycap  110  defines a plurality of openings, and the keycap  110  defines a plurality of passageways extending through the keycap  110 . Each of the plurality of passageways extends from an opening defined by the upper surface  112  of the keycap  110  to an opening defined by the lower surface  114  of the keycap  110 . 
     In some implementations, the plurality of openings defined by the upper surface  112  of the keycap  110  collectively form a shape of a symbol. For example, in some implementations, the plurality of openings defined by the upper surface  112  of the keycap  110  form a single letter or alphanumeric shape. In other implementations, the plurality of openings defined by the upper surface  114  of the keycap  110  form a number shape or the shape of another symbol. 
     In some implementations, the upper surface  112  of the keycap  110  defines many openings. For example, in some implementations, the upper surface  112  of the keycap defines 300, 500 or more openings. The individual openings may have a circular or oval shape and may collectively form an alphanumeric symbol. In some implementations, the openings defined by the upper surface  112  of the keycap  110  are microscopic. In some such implementations, the small openings may help prevent dust, dirt, and other unwanted materials from entering the openings and passageways. 
     In some implementations, the keycap  110  is formed of an opaque material (i.e., light does not pass through the material). For example, in some implementations the keycap  110  is formed of a metal material. Specifically, in some implementations the keycap  110  is formed of a material that includes steel, aluminum, titanium, magnesium, copper, brass, nickel or tin. In other implementations, the keycap  110  is formed of carbon, carbon fiber, nano-tube reinforced plastic, glass, or ceramic. In some implementations, the keycap  110  is formed of a mixture of materials. In some implementations, such mixture of materials includes a metal material. 
     In some implementations, the keycap  110  is formed of an opaque material (such as a metal material) and a transparent material. For example, in one implementation, the opaque material of the keycap  110  defines the passageway  120  and a transparent material is coupled to the opaque material and disposed within the passageway  120  defined by the opaque material. In some implementations, the opaque material includes a metal material and the transparent material includes a plastic material. 
     The keycap  110  is configured to actuate the switch  150  when the keycap  110  is selected by a user. For example, in some implementations, a user may select the keycap  110  by depressing the keycap  110  (such as depressing a key on a computer keyboard). The depressed keycap  110  is configured to actuate the switch  150 , which is disposed beneath the keycap  110 . 
     In some implementations, the keycap  110  is biased to its un-depressed state. Thus, a user may apply a force to the keycap  110  to depress the keycap  110  and actuate the switch  150 . Once the user releases or removes the force from the keycap  110 , the keycap  110  returns to its un-depressed state or configuration. In some implementations, the keycap assembly  100  includes a keycap return mechanism that is configured to bias the keycap  110  into its un-depressed configuration. For example, the keycap return mechanism may include a hinge system or a spring that is configured to bias the keycap  110  into its un-depressed configuration. 
     In some implementations, the keycap assembly  100  includes a support structure that is configured to provide support to the keycap. In some implementations, the support structure is configured to help prevent the keycap from tilting. Additionally, in some implementations, the support structure is configured to bias the keycap into its un-depressed state. 
     The switch  150  may be any type of mechanical or electrical switch that is configured to communicate with a display or other device. For example, in some implementations, the switch  150  is an electrical switch and is configured to communicate with a computer system. Specifically, in some implementations, the switch  150  is configured to communicate with a central processing unit and a display device (monitor) or a computer system. 
     For example, in some implementations, the switch  150  is an electrical switch. When such a switch  150  is actuated or activated, a metal contact of the switch contacts and completes an electrical circuit to communicate to the display or other device that the switch  150  has been actuated. 
     The light source  160  is configured to generate light and emit light through the passageway  120  defined by the keycap  120 . In some implementations, the light source  160  is disposed such that the keycap  110  is disposed between the user and the light source  160 . In some implementations, the light source  160  is disposed proximate the lower surface  114  of the keycap  110 . In some implementations the light source  160  is disposed such that the lower surface  114  of the keycap  110  is disposed between the light source  160  and the upper surface  112  of the keycap  110 . 
     As the light source  160  is configured to emit light through the passageway  120  of the keycap  110 , the keycap  110  will be backlight. Accordingly, as the light is emitted through the passageway and out the opening defined by the upper surface  112  of the keycap  110 , the shape of the opening defined by the upper surface  112  of the keycap  110  will be illuminated to the user. Specifically, if the opening defined the upper surface  112  of the keycap  110  is letter shaped, the illumination of the keycap  110  will be shaped like the letter. 
     The light source  160  can be any device that generates or emits a light. For example, in some implementations, the light source  160  is can include a light guide film that guides light from a distant source to under the keycap. In other implementations, the light source  160  can include a light emitting diode positioned approximately under the keycap. 
     In some implementations, the light source  160  is used to emit light through passageways of a plurality of keycaps. For example, a keyboard may include ten keycaps and switches and include one light source. In such an implementation, the passageways defined by each of the keycaps are illuminated by the single light source. 
     In some implementations, the light emitted through the keycap  110  is directed in a specific direction. For example, in some implementations, the light emitted through the openings and passageways of the keycap  110  is directed in a direction of a user of the keyboard or computer system. In some implementations, the light emitted through the openings and passageways of the keycap  110  is directed away from non-users of the keyboard or computer system. 
     For example, in some implementations, the passageway  120  extends in a direction or along an axis that is normal to the upper surface  112  of the keycap  110 . In other implementations, the passageways extend in a direction or along an axis that is not normal or angled with respect to the upper surface  112  of the keycap  110 . For example, in some implementations, the passageways  120  are angled with respect to the upper surface  112  of the keycap  110  and are angled toward a user of the keyboard or computer system. 
     In some implementations, the upper surface  112  of the keycap  110  includes many openings and passageways that extend to openings defined by the lower surface  114  of the keycap  110 . In some implementations, the ratio of the length of the passageways (i.e., the thickness of the keycap  110 ) to the diameter or width of the openings defined by the upper surface  112  is sufficient for light to pass through the passageway. In some implementations, the ratio of the length of the passageways to the diameter of the openings defined by the upper surface is sufficient to allow light to be transmitted through the passageways towards a user located in front of the keyboard or computer system and away from the sides of the keyboard. 
     In some such implementations, the passageways (i.e., the thickness of the keycap  110 ) have a length of about 1 mm. In other implementations, the passageways (i.e., the thickness of the keycap  110 ) have a length of less than about 0.5 mm. For example, in some implementations, the passageways (i.e., the thickness of the keycap  110 ) have a length of between 0.2 mm and 0.5 mm. In some implementations, the openings in the upper surface  112  of the keycap  110  are circular and the diameter of the openings are less than 1 mm. 
       FIG. 2  is a top view of a keycap assembly  200 .  FIG. 3  is a schematic cross-sectional view of the keycap assembly  200  taken along line A-A of  FIG. 2 . The keycap assembly  200  includes a keycap  210 , a switch  250 , and a light source  260 . 
     The keycap  210  includes an upper surface  212 , a lower surface  214 , and side surfaces  216 . The upper surface  212  defines an opening  213 . In the illustrated implementation, the opening  213  defined by the upper surface  212  is in the shape of the letter D. 
     The lower surface  214  of the keycap  210  defines an opening  215 . The keycap  210  defines a passageway  220  that extends through the keycap  210  from the opening  213  defined by the upper surface  212  to the opening  215  defined by the lower surface  214 . 
     In the illustrated implementation, the keycap  210  is formed of an opaque material. Specifically, the keycap  210  is formed of a metal material. For example, in some implementations the keycap  210  is formed of a material that includes steel, aluminum, titanium, magnesium, copper, brass, nickel, or tin. In some implementations, the keycap  210  is formed of a mixture of materials. In some implementations, such mixture of materials includes a metal material. 
     The keycap  210  is configured to actuate the switch  250  when the keycap  210  is selected by a user. In the illustrated implementation, a user may select the keycap  210  by depressing the keycap  210  (such as depressing a key on a computer keyboard). The depressed keycap  210  is configured to actuate the switch, which is disposed beneath the keycap  210 . 
     In the illustrated implementation, the keycap assembly  200  includes a keycap return mechanism  230 . The keycap return mechanism  230  is configured to return the keycap  210  to its normal state after being depressed by a user. In other words, the keycap return mechanism  230  is configured to bias the keycap  210  into a non-depressed state. 
     The keycap return mechanism  230  is a scissor type structure and includes a first arm  232  and a second arm  234  that is pivotally coupled to the first arm  232  at B. The first arm  232  and the second arm  234  are pivotally coupled to a base member (not illustrated) disposed below the keycap return mechanism  230 . In some implementations, the keycap return mechanism  230  is coupled, such as pivotally coupled, to the keycap  210 . 
     The keycap return mechanism  230  is biased to an upright or expanded configuration and may, upon the application of a force be placed in a collapsed configuration. Thus, when the keycap  210  is depressed by a user, the application of force causes the keycap return mechanism  230  to be placed in its collapsed configuration. The removal of the force (for example, when a user is no longer depressing the keycap  210 ) causes the keycap return mechanism  230  to return to its expanded configuration and thus, causes the keycap  210  to return to its non-depressed state. The keycap return mechanism  230  also provides support to the keycap and helps prevent the keycap from tilting. 
     As illustrated in  FIGS. 3A and 3B , in some implementations, the keycap  210  is a cantilever keycap. Specifically, in the illustrated implementation, the keycap  210  is unitarily formed or integral with the material that forms an upper surface  201  of a keyboard.  FIG. 3A  is a top view of a portion of a keyboard and a keycap assembly and  FIG. 3B  is a cross-sectional view of the portion of the keyboard and keycap assembly of  FIG. 3A . 
     The material that forms the upper surface  201  of the keyboard defines an opening  203 . The opening  203  defines the keycap  210 . In the illustrated implementation, the opening  203  is generally “U” shaped and surrounds or defines threes sides of the keycap  210 . In other implementations, the opening  203  is of a different shape and surrounds more or less of the keycap  210 . 
     The keycap  210  includes a flexible or bendable portion  211  that is configured to flex or bend when a force in the direction of F, such as a user depressing the keycap  210 , is applied to the keycap  210 . Accordingly, the keycap  210  is configured to actuate the switch  271  of the keyboard when a force in the direction of F is applied to the keycap  210 . The flexible or bendable portion  211  of the keycap  210  biases the keycap  210  to its non-depressed state. Accordingly, the keycap  210  returns to its non-depressed state when the force is removed from the keycap  210 . 
     In the illustrated implementation, the upper surface  212  of the keycap  210  has a width W. In some implementations, the upper surface  212  forms a rectangle when viewed from the top of the keycap  210 . In some implementations, the width W of the upper surface  212  of the keycap  210  is about 8 mm. In other implementations, the width W of the upper surface  212  of the keycap  210  is less than 8 mm. In yet further implementations, the width W of the upper surface  212  of the keycap  210  is greater than 8 mm. For example in some implementations, the width W of the upper surface is between about 8 mm and 20 mm. 
     In the illustrated implementation, the upper surface  212  of the keycap  210  has a length L. In some implementations, the length L of the upper surface  212  of the keycap  210  is about 8 mm. In other implementations, the length L of the upper surface  212  of the keycap  210  is less than 8 mm. In yet further implementations, the length L of the upper surface  212  of the keycap  210  is greater than 8 mm. For example, in some implementations, the length L of the upper surface  212  of the keycap  210  is between 8 mm and 20 mm or 8 mm and 110 mm. 
     In the illustrated implementation, the side surface  216  of the keycap  210  has a height H. In some implementations, the height of the side surface  216  of the keycap  210  is about 0.5 mm. In other implementations, the height H of the side surface  216  of the keycap  210  is less than 0.5 mm (such as between 0.2 mm and 0.5 mm). In yet further implementations, the height H of the side surface  216  of the keycap  210  is greater than 0.5 mm. 
     The switch  250  may be any type of mechanical or electrical switch that is configured to communicate with a display or other device. In the illustrated implementation, the switch  250  is an electrical switch. When such a switch  250  is actuated or activated, a metal contact (not illustrated) of the switch contacts and completes an electrical circuit (not illustrated) to communicate to the display or other device that the switch  250  has been actuated. 
     The light source  260  is configured to generate light and emit light through the passageway  220  defined by the keycap  210 . The light source  260  is disposed such that the keycap  210  is disposed between the user and the light source  260 . The light source  260  is disposed proximate the lower surface  214  of the keycap  210 . Specifically, the light source  260  is disposed such that the lower surface  214  of the keycap  210  is disposed between the light source  260  and the upper surface  212  of the keycap  210 . 
     As the light source  260  is configured to emit light through the passageway  220  of the keycap  210 , the keycap  210  is backlight. Accordingly, as the light is emitted through the passageway  220  and out the opening  213  defined by the upper surface  212  of the keycap  210 , the shape of the opening  213  defined by the upper surface  212  of the keycap  210  will be illuminated to the user. In the illustrated implementation, the letter “D” is illuminated to the user. 
     The light source  260  can be any device that generates or emits a light. In the illustrated implementation, the light source  260  is a light guide film. 
       FIG. 4  is a top view of another keycap  310 . The keycap  310  includes an upper surface  312 . The upper surface  312  of the keycap  310  defines a plurality of openings  318 . The openings  318  defined by the upper surface  312  of the keycap  310  collectively define a symbol. In the illustrated implementation, the openings  318  defined by the upper surface  312  of the keycap  310  define the letter “D.” 
     The keycap  310  defines passageways that extend through the openings  318  defined by the upper surface  312  of the keycap  310  and through the thickness of the keycap  310 . Thus, a light source may emit light through the passageways and through the plurality of openings  318  defined by the upper surface  312  of the keycap  310 . 
     The upper surface of the keycap may define any number of openings. For example, the upper surface of the keycap may define 2, 3, 4, or more openings. The openings collectively may form a shape of a symbol. In some implementations, the openings defined by the upper surface of the keycap are microscopic. In other words, the individual openings are not individually visible to the naked eye, but collectively may be perceived as the symbol which they collectively form. 
       FIG. 5  is a top view of a keyboard  485 . The keyboard  485  may be coupled to and communicate with a computer or any other device. The keyboard  485  includes a plurality of keycaps  410 . Each of the keycaps  410  is configured actuate a different switch (not illustrated). In the illustrated implementation, the keycaps  410  includes upper surfaces  412  that define openings  413  that form symbols. 
       FIG. 6  is a perspective view of a laptop computer  590  that includes a keyboard  585  and a screen  595 . The keyboard  585  includes a plurality of keycaps  510 . Each of the keycaps  510  is configured actuate a different switch (not illustrated). In the illustrated implementation, the keycaps  510  includes upper surfaces  512  that define openings  513  that form symbols. 
       FIG. 7  is a flow chart that illustrates a method  600  for forming a keycap. At step  610 , the keycap is formed. The keycap may be formed of an opaque material such as a metal material. The keycap may be formed by molding or machining or any other known method for forming objects of a metal material. 
     At step  620 , the keycap is etched to include the symbol that will be represented by the keycap. For example, the keycap may be etched to include a letter, a number, or another symbol. 
     At step  630 , the keycap a passageway is formed through the keycap. In some implementations, the passageway extends from an upper surface of the keycap to a lower surface of the keycap. In some implementations, the passageway is formed by drilling below the etched portion of the keycap. In some implementations, the passageway is microdrilled using a laser. In other implementations, the passageway is formed using another known method or tool. 
     In some implementations, more than one passageway is formed through the keycap. For example, in some implementations, a plurality of microscopic passageways are foamed through the keycap. The openings defined by the upper surface of the keycap collectively form a symbol such as a letter, a number, or another symbol. 
     For example, an etching process may be used to form the passageway or passageways of the keycap. To etch the keycap a typical etching process may be used. The metal keycap may be covered with a resist or ground material that is resistant to acid. The resist or ground material is then removed from desired portions of the keycap. The keycap is then exposed to an acid material that will eat or dissolve the metal material of the keycap that is not covered with the resist. Accordingly, in this implementation, the acid material can be used to form the openings and passageways of the keycap. 
     In some implementations, a sheet of keycaps are formed, stamped out, and then etched individually. In other implementations, a sheet of material is etched with the characters of many keycaps and the keycaps are then stamped from the etched material. 
     In some implementations, the method includes disposing a translucent material into the passageway defined by the keycap. In some implementations, the translucent material is a clear plastic. In some implementations, the method includes treating the surface of the metal material of the keycap to allow a plastic material to adhere to the metal surface and then adhering the plastic material to the metal material. In some implementations, the translucent material is nano-injected into the passageway defined by the passageway of the keycap. 
     While certain features of the described implementations have been illustrated as described herein, many modifications, substitutions, changes and equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the scope of the implementations. It should be understood that they have been presented by way of example only, not limitation, and various changes in form and details may be made. Any portion of the apparatus and/or methods described herein may be combined in any combination, except mutually exclusive combinations. The implementations described herein can include various combinations and/or sub-combinations of the functions, components and/or features of the different implementations described.