Patent Description:
A button, as for example disclosed in <CIT>, <CIT> or <CIT>, on a hardware product may employ illumination in the form of a "ring" of light that surrounds the perimeter of the button. A light ring may be implemented using multiple light-emitting diodes (LEDs) positioned to approximate the shape of a ring. Light rings may also use dedicated optical components, such as light diffusers, light pipes, and/or light guides to direct and channel the light into the desired light pattern. Because the optical components used to achieve the light ring effect occupy the limited space surrounding the button, additional complexity and costs are imposed to ensure that those components do not interfere with the function of the button.

"Dead front" is a design aesthetic where a device's illuminating elements are at least partially obscured when in the off state. Providing a dead front effect for a light ring typically involves additional processing and/or light-reflecting parts, and coatings; all of which add to the cost of the final product.

The proposed solution relates to a hardware product as defined by independent claim <NUM>. According to an embodiment of the disclosed subject matter, the hardware product includes a housing having an opening defined by a perimeter shape. The housing may consist essentially of an optically opaque or semi-opaque material. The hardware product also includes a button configured to be depressed along a depression axis and positioned within the opening. The button is spaced from the perimeter of and centered within the opening within the housing by a first (cosmetic) gap and a second (functional) gap immediately adjacent to the first gap. The first gap tapers to a minimum dimension where it meets the second gap. The second gap may taper to a minimum dimension where it meets the first gap. The maximum dimension of the second gap is less than the maximum dimension of the first gap. The maximum dimension of the first gap may be in a range of <NUM>-<NUM>, <NUM>-<NUM>, approximately <NUM> millimeters, or the like The maximum dimension of the second gap may be <NUM>-<NUM>, <NUM>-<NUM>, approximately <NUM> millimetes, or the like. The second gap may be disposed adjacent to the first gap in parallel with the depression axis of the button. The hardware product lso includes a light-emitting component electrically coupled to a printed circuit board.

The hardware product includes an internal cavity positioned adjacent to the second gap. The printed circuit board and light-emitting component are positioned within the internal cavity, wherein the second gap is located between the first gap and the internal cavity and allows for a constrained movement between the button and the housing and the first gap, being larger at an exterior surface of the housing and tapering to the minimum dimension where it meets the second gap, remains so as to allow light to be projected from the light-emitting component to reach the housing and to maintain a light ring effect even if the second gap is eliminated by a user shifting the button within the opening.

The button may include a first shot of material constructed from a first light-diffusion grade polycarbonate material configured to uniformly disperse light and spaced from the perimeter of the opening by the first gap and the second gap. The first shot of material may be positioned or sized such that it protrudes outward from the housing. The button may also include a second shot constructed from a second polycarbonate or acrylonitrile butadiene styrene material. The second shot material may be optically opaque or semi-opaque. The button may have a radially symmetric molding gating.

The hardware product may also include multiple light-emitting components positioned within a diameter of a circle that is less than or equal to <NUM>-<NUM>%, <NUM>%, or the like of a diameter of an exterior-facing surface of the button.

The hardware product may also include a resilient silicone web configured to cause closure of a circuit upon depression of the button and to return the button to its original position after being depressed. The resilient silicone web may have an opening centrally aligned with the light-emitting component and may be configured to allow light from the light-emitting component to pass to the second shot.

The hardware product may also include a shroud constructed from an optically opaque or semi-opaque material and may be configured to surround at least a portion of the button.

The hardware product may also include a first shot molding gate disposed underneath and obscured from view by the second shot. The hardware product may also include a second shot molding gate disposed on and centered on the underside of the button.

Additional features, advantages, and embodiments of the disclosed subject matter may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary and the following detailed description are illustrative and are intended to provide further explanation without limiting the scope of the claims.

The accompanying drawings, which are included to provide a further understanding of the disclosed subject matter, are incorporated in and constitute a part of this specification. The drawings also illustrate embodiments of the disclosed subject matter and together with the detailed description serve to explain the principles of embodiments of the disclosed subject matter. No attempt is made to show structural details in more detail than may be necessary for a fundamental understanding of the disclosed subject matter and various ways in which it may be practiced.

Creating a light ring effect on a hardware product may be complicated and costly to implement. The light ring effect may be accomplished by providing several dedicated optical components, such as light tubes, guides, and diffusers within a limited space. Concealing these dedicated optical components when the light ring is off to achieve a dead front effect may incur additional expense in terms of processing, parts, and coatings. Compounding the problem, when designing a light ring to surround a button or joystick, care must be taken to avoid negatively impacting the movement of these components.

The present subject matter discloses structures and techniques to achieve a light ring effect and a dead front effect. When used with a button in one example, the button itself may be used as a light diffuser in conjunction with one or more gaps surrounding the button to achieve the light ring effect without multiple LEDs, dedicated optical parts, or additional processes. The disclosed subject matter may be used in conjunction with a variety of handheld, wall-mounted, and free-standing electronic devices, such as a game controller, game console, remote control, set-top box, thermostat control panel, security system control panel, dimmer/switch, audio system control panel, and the like. The disclosed subject matter may provide visual appeal and utility from a variety of angles and distances, and particularly in dark and semi-dark environments where the light ring effect may be more readily observed.

While the subsequent discussion and associated figures will describe the example embodiments in the context of a dead front light ring effect that surrounds a round button, it should be appreciated that the concepts may apply to non-moving, moveable, and moving components of any shape, such as buttons, directional pads, joysticks, trackballs, wheels, switches, sliders, labels, panels, trackpads, and embossments, for example.

The term "optically opaque" as used herein refers to any material that will block all or essentially all visible light, such that the light transmitted, if any, is not noticeable by the human eye. The optical opacity of a plastic material may be function of material thickness and the amount of colorant used in manufacturing the plastic material
The term "optically semi-opaque" as used herein refers to a material that will block at least <NUM>% of all visible light. Any plastic material that may be made opaque may also be made semi-opaque by reducing the thickness of the material or by reducing the amount of colorant used in manufacturing the plastic material.

<FIG> shows an example of a dead front light ring effect surrounding a button <NUM> in both the "on" state <NUM> and "off" state <NUM>. In the on state <NUM>, a ring of light effect may surround button <NUM>, while in off state <NUM>, the ring of light may be eliminated and only a gap <NUM> surrounding button <NUM> may be visible. It should be appreciated from <FIG> that no LEDs, lenses, or other optical components are visible when in the "off" state <NUM>, thereby achieving the desired dead front effect.

<FIG> illustrates an example cutaway perspective view of hardware product <NUM> showing button <NUM> located within the opening <NUM> of housing <NUM>, a first injection molding shot <NUM>, optically opaque shroud <NUM>, and printed circuit board (PCB) <NUM>, which is electrically coupled to the single light-emitting component <NUM> to provide power. Opening <NUM> preferably may be defined by a perimeter shape that substantially follows the footprint of button <NUM> as shown in <FIG>.

<FIG> illustrates an example cross-sectional view of hardware product <NUM>. As in <FIG>, button <NUM> is located within the opening <NUM> of the housing <NUM>. An internal cavity <NUM> exists within hardware product <NUM> where the PCB <NUM> and the single light-emitting component <NUM> are located. A resilient silicone web <NUM> may also be located within the internal cavity <NUM> to provide a spring-like resisting force to return the button <NUM> to its original position after being depressed axially by a user. Light-emitting component <NUM> may be a single LED, single incandescent bulb, or multiple LEDs operating together and confined within a space having a diameter less than or equal to <NUM>-<NUM>%, more preferably about <NUM>% of the diameter of a circle bounding the exterior surfaces of button <NUM>. For example, for a button <NUM> that is about <NUM> in diameter or that otherwise may be bounded by a <NUM> diameter circle, one or more LEDs may be contained within a space of not more than about <NUM> in diameter, or about <NUM><NUM> in area and disposed entirely under the button. In some cases, the light-emitting component <NUM> may be disposed within a smaller region, such as a region entirely under the button and having a diameter of <NUM>%, <NUM>%, <NUM>%, <NUM>%, or smaller relative to the diameter of the button. Light-emitting component <NUM> may be located underneath button <NUM> approximately along the center-line axis of button <NUM> and project light approximately along the center-line axis of button <NUM> in the direction of opening <NUM>. The center-line axis of button <NUM> may be approximately parallel to the direction in which the button <NUM> may be depressed axially and approximately perpendicular to its exterior-facing surface.

Button <NUM> is manufactured using a multiple-shot injection molding process. A first shot of material <NUM> is composed from a light diffusion material that exhibits appropriate amount of light diffusion and transmissivity for the light projected axially from light-emitting component <NUM>. For example, the first shot of material <NUM> may be a light diffusion grade polycarbonate or similar. A second shot of material <NUM> provides a cosmetic surface for the button <NUM>, which is generally viewable to a user and acted upon using a finger or thumb to depress button <NUM> axially. Second shot of material <NUM> may include, for example, an embossed icon, as shown in <FIG> and <FIG>, that represents the function activated by depressing button <NUM>. It should be appreciated that the terms "first shot of material" and "second shot of material" do not imply any particular ordering in terms of how button <NUM> may be molded. For example, the first shot of material <NUM> may be the second material injected, while the second shot of material <NUM> may be the first shot injected. Generally, the materials used in the multiple-shot injection molding process may be injected in order from the material having the highest melting point to the material having the lowest melting point. Second shot of material <NUM> may be optically opaque and moldable with the first shot of material <NUM>, such as acrylonitrile butadiene styrene (ABS) plastic, a combination of polycarbonate and ABS plastic, or similar. Additionally, colorant may be added to the second shot of material <NUM> to increase its opacity. In this way, light from light-emitting component <NUM> may be projected only front the perimeter of button <NUM> to create the desired uniform ring effect. Alternatively, the second shot of material <NUM> may be composed of the same light-diffusing material as the first shot of material <NUM> where illuminating the cosmetic surface of button <NUM> is desired.

<FIG> and <FIG> illustrate respective front and side cross-sectional views of button <NUM>. As shown in <FIG> and <FIG>, the molding gating of the button <NUM> may be preferably radially symmetric to create a uniform light ring effect and to prevent overflow between the first <NUM> and second <NUM> shots. Light-diffusing components that are non-radially symmetric are associated with producing non-uniform light ring effects. For example, where a two-shot light-diffusing button design has been manufactured using a non-radially symmetric tunnel-slide gate positioned on the side of the button, it has been shown that the resulting light ring exhibits a measurably dim region corresponding to the location of the gate. <FIG> illustrates a luminance image <NUM> of a non-uniform light ring effect where a region <NUM> is dim when compared to the remainder of the light ring. The light ring effect shown in <FIG> may be the result of using a non-radially symmetric molding gating. To overcome this issue, the second shot of material <NUM> may be injected through a molding gate centrally located on the underside of button <NUM>, thereby preserving the radial symmetry of the molding gating. The first shot of material <NUM> may be injected through molding gate <NUM>, which may be located underneath and completely obscured by second shot of material <NUM>. In this way, neither molding gate may adversely affect the uniformity of the light ring produced when the light-emitting component <NUM> is powered and emitting light. Additionally, neither molding gate <NUM> used for the first shot of material <NUM> or the molding gate used for the second shot of material <NUM> may be visible from the exterior of product <NUM>. <FIG> illustrates a luminance image <NUM> of a uniform light ring effect according to an embodiment of the disclosed subject matter. Notably, the light ring effect shown in <FIG> appears uniform without any visible gaps or dim regions.

The function of the button <NUM> may be provided by a resilient silicone web <NUM> having a conductive carbon pill, or the like, to cause the closure of a circuit upon depressing button <NUM> axially toward PCB <NUM>. The circuit to be closed may be a momentary-type switch located on PCB <NUM> The silicone web <NUM> may be located between the first shot of material <NUM> of the button <NUM> and the light-emitting component <NUM>. The silicone web <NUM> may constructed from an optically opaque material and include an opening directly above the light-emitting component <NUM> to allow light to pass into the first shot of material <NUM> of the button <NUM>. Silicone web <NUM> may be constructed in a variety of ways to configure the tactile response of the button <NUM> when depressed. For example, by varying the density of the web structure, the resistance of the button may be adjusted. Similarly, the design of the silicone web <NUM> may affect whether the button <NUM> depression occurs smooth and gradually or sharp and rapidly.

With reference to <FIG>, as previously discussed, the light-emitting component <NUM> may project light through the opening in silicone web <NUM> into the light-diffusing first shot of material <NUM>. To provide adequate exposure to the exterior of product <NUM> and to ensure that the light ring may be seen from a variety of angles, first shot of material <NUM> may be preferably sized or positioned such that it protrudes from the exterior surface of housing <NUM>. Alternatively, or in addition, the draft angles of housing <NUM> and first shot of material <NUM> may be adjusted to allow the desired amount of light to reach the exterior of product <NUM>. In an example, the draft angles may range from <NUM> to <NUM> degrees and may be configured based on the position of a parting line located within the annular gap <NUM> and further described in the subsequent discussion. As the second shot of material <NUM> may be made from an optically opaque material, little or no light may be transmitted through it. Therefore, the light may be visible to a user via an annular gap <NUM> that surrounds the button <NUM>. Annular gap <NUM> may be referred to as the "cosmetic gap," since its width affects the cosmetic appearance of the light ring effect. It should be appreciated that where the component with which the ring effect to be achieved is not annular, the surrounding opening may not be annular, but may approximately follow the footprint or perimeter shape of the button, joystick, trackball, or other component.

Light leakage throughout the interior of product <NUM> may be controlled to avoid illuminating undesirable portions of product <NUM> assembly, such as housing seams, fastener holes, and where other moving components emerge. This may be accomplished by including an optically opaque shroud <NUM> that may surround button <NUM> internally, by using optically opaque materials, and by sizing the thickness of the surrounding components so that light cannot pass. For example, the depth of cosmetic gap <NUM>, or stated another way, the thickness of housing <NUM> in the area surrounding button <NUM>, may be sized such that light passing through first shot of material <NUM> cannot leak through housing <NUM>. Light leakage through housing <NUM> and/or second shot of material <NUM> may reduce the contrast of and thereby diminish the light ring effect. Housing <NUM> may be constructed from optically opaque materials to reduce the possibility of light leakage.

The button <NUM> may be centered within opening <NUM> and specifically within cosmetic gap <NUM> to achieve a uniform light ring effect. Where the button <NUM> is not centered, the distance between button <NUM> and housing <NUM> may be uneven, reducing the thickness of the light ring where cosmetic gap <NUM> is smaller and increasing the thickness of the light ring where cosmetic gap <NUM> is larger.

Since the component to be illuminated is a moving component, such as the button <NUM>, a "functional gap" <NUM> is implemented in addition to the cosmetic gap <NUM>. The functional gap <NUM> may not be included where the component to be illuminated is stationary. Functional gap <NUM> is located directly adjacent to and in between cosmetic gap <NUM> and interior cavity <NUM>. Functional gap <NUM> allows for constrained movement between button <NUM> and housing <NUM>. It should be appreciated that the size of functional gap <NUM> may affect the degree to which button <NUM> may be shifted laterally by the user. In an extreme case, a user may shift button <NUM> so that the functional gap <NUM> is reduced to zero on one side of the button <NUM> and the functional gap <NUM> is doubled on the opposite side of the button <NUM>. Because shifting button <NUM> laterally may otherwise diminish the uniformity of the light ring effect, the cosmetic gap <NUM> is preferably larger at the surface of housing <NUM> than where the functional gap <NUM> meets the cosmetic gap <NUM>. In this way, even if a user shifts button <NUM> laterally to eliminate the functional gap <NUM>, the cosmetic gap <NUM> may remain, thereby allowing light projected from light-emitting component <NUM> to reach housing <NUM> and to maintain the light ring effect.

As shown in <FIG>, the cosmetic gap <NUM> is of a larger dimension at the exterior surface of housing <NUM> and tapers to its minimum dimension where it meets functional gap <NUM>. Similarly, functional gap <NUM> is of a larger dimension where it meets interior cavity <NUM> and taper to its minimum dimension where it meets cosmetic gap <NUM> above. Both the cosmetic gap <NUM> and the functional gap <NUM> each exhibit their respective minimum dimensions where they meet, forming a parting, line and creating a substantially hourglass-shaped gap when viewed together as a whole. The maximum dimension of functional gap <NUM> may be less than the maximum dimension of cosmetic gap <NUM>. The cosmetic gap <NUM> may be between <NUM> and <NUM> millimeters, while functional gap <NUM> may be in the range of <NUM>-<NUM>, more preferably <NUM>-<NUM>, or more preferably between <NUM> and <NUM> millimeters. In an example, the functional gap may be approximately <NUM> millimeters, and the cosmetic gap may be approximately <NUM> millimeters. By designing the cosmetic gap <NUM> and functional gap <NUM> in this manner, any friction resulting from laterally shifting button <NUM> toward housing <NUM> during depression may be reduced since the point of contact between button <NUM> and the housing <NUM> may be minimal.

The embodiments disclosed herein may reduce the number of components and associated costs of producing a light ring effect with a dead front effect than conventional light ring designs. The embodiments disclosed herein may be applicable to non-moving, moveable, and moving components of any shape, such as buttons, directional, pads, joysticks, trackballs, wheels, switches, sliders, labels, panels, trackpads, and embossments, for example. Embodiments disclosed herein may be useful in the context of product safety and reliability since there are no paints or coatings that may fail or degrade over time. The disclosed subject matter may be scalable in size, space efficient, and may be used in a greater variety of types of products to produce a light ring effect with a dead front than previously possible.

Although examples and descriptions provided herein use terminology that may be associated with specific fabrication techniques, such as a "shot" of material, it will be understood that a variety of manufacturing techniques may be used to fabricate devices disclosed herein without departing from the scope or content of the disclosed subject matter. For example, devices disclosed herein may be fabricated using techniques such as single injection-shot molding, multi-shot injection molding, gas-assist molding, coinjection techniques, reaction-injected molding, rotational molding, thermoforming, compression molding, or any other suitable technique that is capable of achieving the physical components disclosed herein.

Claim 1:
A hardware product comprising:
a housing (<NUM>) having an opening (<NUM>) defined by a perimeter shape;
a printed circuit board (<NUM>);
a light-emitting component (<NUM>) electrically coupled to the printed circuit board (<NUM>);
a button (<NUM>) configured to be depressed along a depression axis and positioned within the opening (<NUM>) of the housing (<NUM>), the button (<NUM>) spaced from the perimeter of the opening (<NUM>) within the housing (<NUM>) by a first gap (<NUM>) and a second gap (<NUM>) immediately adjacent to the first gap (<NUM>), the first gap (<NUM>) tapering to a minimum dimension where it meets the second gap (<NUM>), the button (<NUM>) being manufactured using a multiple-shot injection molding process and, for projecting light from the light-emitting component (<NUM>) only from the perimeter of the button (<NUM>) thereby creating a light ring effect surrounding the perimeter, comprising:
a first shot (<NUM>) of material spaced from the perimeter of the opening (<NUM>) by the first gap (<NUM>) and the second gap (<NUM>) and comprising a first light diffusion material configured to disperse light from the light emitting component (<NUM>); and
a second shot (<NUM>) of material comprising a second optically opaque material providing a cosmetic surface for the button (<NUM>),
characterized in that an internal cavity (<NUM>) is positioned adjacent to the second gap (<NUM>), wherein the printed circuit board (<NUM>) and the light-emitting component (<NUM>) are positioned within the internal cavity (<NUM>), and
wherein the second gap (<NUM>) is located between the first gap (<NUM>) and the internal cavity (<NUM>) and allows for a constrained movement between the button (<NUM>) and the housing (<NUM>) and the first gap (<NUM>), being larger at an exterior surface of the housing (<NUM>) and tapering to the minimum dimension where it meets the second gap (<NUM>), remains so as to allow light to be projected from the light-emitting component (<NUM>) to reach the housing (<NUM>) and to maintain the light ring effect even if the second gap (<NUM>) is eliminated by a user shifting the button (<NUM>) within the opening (<NUM>).