CROSS REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application Number 62/279,461, filed on January 15, 2016, which application is hereby incorporated by reference in its entirety. Furthermore, this application incorporates U.S. Patent Application Number 14/939,896, filed on November 12, 2015, entitled "Method and Apparatus for Transfer of Semiconductor Devices," in its entirety by reference.

BACKGROUND

Technical Field

[0002] The following description relates to backlighting a device and particularly to backlighting keys of a keyboard having a fabric-based cover. Further, the principles herein may be applied to other devices having covers that are fabric or non-fabric based.

Background

[0003] Devices such as keyboards may have a fabric-based cover or a non-fabric based cover. Fabrics (e.g., natural fiber fabric such as cotton, wool, etc. or synthetic fiber fabric such as polyester, acrylic, rayon, carbon fiber, etc.) are widely used in covering many items. However, due to the material structure of many fabrics, backlighting a device having a fabric cover may be challenging to produce effect or desired results. Not surprisingly, similar challenges exist with other non-fabric materials as well.

[0004] With respect to the light sources used in backlighting devices, LEDs have been used. The LEDs currently implemented for backlighting are "packaged" LEDs. The "packaged" modifier refers to the enclosure and protective features built into the final LED as well as the interface that enables the LED in the package to be incorporated into an ultimate circuit. Notably, the conventional fabrication process for LEDs, or other semiconductor devices, starts with handling a semiconductor wafer. The wafer is diced into a multitude of "unpackaged" semiconductor devices. The "unpackaged" modifier refers to an unenclosed semiconductor device without protective features. The "packaging" of an LED makes the LED substantially thicker than an unpackaged LED.

[0005] The unpackaged LEDs may be extremely small. Indeed, the height of the LEDs may range from 12.5 to 200 microns, or from 25 to 100 microns, or from 50 to 80 microns.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The Detailed Description is set forth with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items. Furthermore, the drawings may be considered as providing an approximate depiction of the relative sizes of the individual components within individual figures. However, the drawings are not to scale, and the relative sizes of the individual components, both within individual figures and between the different figures, may vary from what is depicted. In particular, some of the figures may depict components as a certain size or shape, while other figures may depict the same components on a larger scale or differently shaped for the sake of clarity.

[0007] FIG. 1 illustrates an exploded perspective view of a keyboard key assembly according to an embodiment of the instant application.

[0008] FIG. 2 illustrates a cross-sectional view of a keyboard key assembly according to another embodiment of the instant application.

[0009] FIG. 3 illustrates an exploded cross-sectional view of a keyboard key assembly according to another embodiment of the instant application.

[0010] FIG. 4 illustrates a method of manufacturing an apparatus having a backlit cover.

DETAILED DESCRIPTION

Overview

[0011] This disclosure is directed generally to backlit illumination of an image, symbol, character, or other design in a surface cover of an apparatus. In many instances, the features of this disclosure are described with respect to illumination of a legend (e.g., an image, symbol, character, or other design) on a key(s) of a keyboard, where the cover of the key(s) may be a fabric or a non-fabric material. In general, backlighting may be achieved via one or more unpackaged, micro-sized LEDs disposed behind the legend from a first-person perspective view, which means that the legend (e.g., symbol, character, design, etc.) is illuminated from a light source located behind the legend such that the light of the light source diffuses through the legend in a direction toward the individual looking at the legend. For example, the light sources for lighting the keys on a keyboard are behind the cover of the keys from the perspective of an individual looking at the legend on the key(s) of the keyboard. Moreover, in an instance where the backlit apparatus is not a keyboard, the light source is similarly hidden from the direct view of the individual looking at the apparatus.

[0012] As indicated above, other implementations of the features described herein are contemplated. For example, the features described herein may be implemented in the illumination of legends on the cover of other apparatuses including apparel, displays, banners, flags, decor, signs, toys, keypads, electronics, etc. Furthermore, the concepts and designs of the features described herein as they relate to illumination of keys of a keyboard having a fabric-based cover may, in many instances, be similarly applied to the illumination of non-fabric-based materials.

Illustrative Embodiments of Illumination through a Fabric or Non-Fabric Cover

[0013] FIG. 1 depicts an exploded view of at least some of the elements of an apparatus to illuminate a portion of a fabric material. More specifically, an apparatus 100, such as a key on a keyboard, for example, may include a cover 102 (e.g., keycap) having a legend 104. The cover 102 may be entirely formed of, or may at least partially include, a fabric material such as a polymer-based fabric. In some instances, the fabric material of the cover 102 may be a natural fiber, synthetic fiber, or blended type of material, such as a cotton, silk, or wool-based fabric, any of which may be used alone or blended with a polyester, acrylic, rayon, etc. or other material capable of a durable fabric-type of manufacture. Furthermore, while FIG. 1 depicts the cover 102 having a substantially planar appearance with squared edges and rounded corners, the apparatus 100 is not limited to the configuration depicted and may be formed into a variety of shapes and dimensions for a desired purpose. For example, the cover 102 may take on shapes that are rippled, rounded, spherical, triangular, cylindrical, or otherwise curved and/or pointed. [0014] The legend 104 may be indicative of a character or grouping of characters including individual letters, numbers, and/or whole words, phrases, or sequences of numbers. In some instances, the legend 104 may indicate a form of punctuation, a symbol including emoticons and/or cultural/universal symbols, an image, a design, a shape, or other graphic to indicate a function or convey a particular meaning. As an example, the legend 104 in FIG. 1 depicts a letter "L."

[0015] Moreover, the legend 104 of cover 102 may be formed in a multitude of ways. In some instances, the legend 104 may be created via an additive type of process where an element is added to the cover 102, via a removal process where material is removed from the cover 102, or a combination of material removal and an additive process. Alternatively, the legend 104 may be formed via a molding process where the cover 102 is molded to include a legend 104 within the molded cover 102. Regardless of the method used, the end result is that the cover 102 includes a first region that is a relatively opaque portion and a second region that is a relatively translucent portion. In some instances, the translucent second region includes the legend 104 so that the legend 104 is illuminated in the midst of the opaque first region. Alternatively, one may desire to have the legend 104 display as opaque in the first region and illuminate the cover 102 around the legend 104 in the second region.

[0016] Example embodiments of additive processes for creating the legend 104 include adding a separate layer 104a that is a layer of paint, a sticker, an ink graphic applied via a printing process, a coating of either a translucent or opaque substance, an adhesive, a film, an embedded element, etc. Printing processes that may be used include inkjet, laser, dye sublimation, etc. Despite the depiction in FIG. 1 of the legend 104a on the top side of the cover 102, the above additive type processes may be used, as suitable, to create the legend 104a on the underside of the cover as well. Furthermore, while legend 104a is depicted as the desired legend shape, the layer 104a may be added as the complementary negative of the desired legend shape.

[0017] To create the legend 104 via a removal process, material of the cover 102 is removed to allow light to emit directly or diffuse more clearly through a predetermined portion the cover 102. For example, small amounts of material may be removed by creating a plurality of micro-sized holes 106 through the cover 102. The holes 106 may be closely spaced and arranged within a predetermined perimeter such that, collectively, the arrangement of the plurality of holes 106 corresponds in shape to the shape of a desired legend 104b to be illuminated. For example, the holes 106 in FIG. 1 are arranged within a perimeter designating the predetermined shape of the letter "L" to form the legend 104b. Similarly, material may be removed by creating a plurality of cavities in either the top or bottom surface of the apparatus, which cavities are not cut completely through the cover 102. Additionally, a top or bottom surface of the cover 102 may be etched such that at least a portion of the thickness of the cover 102 is removed to form a shape of the desired legend 104b. Thus, in the case of material removal, a portion of the cover 102 is thinned or cut out entirely to enhance the transmission of light therethrough. Moreover, an entirety of the predetermined shape of the desired legend may be cut out of the cover 102.

[0018] In some instances, methods of material removal include punching, cutting, and/or the use of a laser. For example, holes 106 may be formed via a laser to extend through the cover 102 from a top side of the cover 102 to a bottom side of the cover 102. The holes 106 may range in diameter from 0.1 mm to 0.2 mm, for example, or may be even smaller or larger.

[0019] As indicated above, the legend 104 may be created via a combination of material removal and an additive process. Thus, in instances where material is removed from the cover 102, the space from which material was removed may be filled, covered, or coated by an added material that helps to diffuse and enhance the backlighting as it illuminates the portion of the cover from which material was removed.

[0020] With further respect to the illumination of legend 104, as illustrated in FIG. 1, apparatus 100 may include a stenciled mask layer 108 in addition to, or in place of, legend 104a and/or legend 104b. The mask layer 108 may include a dark-colored/light-blocking substrate (e.g., a thin film, etc.), in which a portion of the substrate is removed, thereby creating an aperture 108a in the substrate. The aperture 108a may correspond directly in shape and dimensions with the perimeter of the shape of the legend 104 in the cover 102, or the shape and dimensions of aperture 108a may be larger or smaller than the perimeter of the shape of the legend 104 to increase or decrease the amount of illumination. The mask layer 108 may be adhered or otherwise placed on the underside of the cover 102. [0021] As depicted, apparatus 100 may further include a keycap stiffener 110. The stiffener 110 may be formed of a clear material, or alternatively, of a tinted or colored material, while maintaining translucent properties. In addition to providing stability and protection of sensitive components, the stiffener 110 may further function as a light diffusion element. That is, the stiffener 110 may be textured, colored, formed, or shaped in a manner that enhances light diffusion. Furthermore, the stiffener 110 may include phosphor and/or other elements that modify the light before it passes to the legend 104. Additionally, the stiffener 110 may have a translucent center portion and opaque or not fully translucent side edges. In some instances, the stiffener 110 may be formed with two different colored materials, where the center portion is lighter than the edge portion, e.g., a white plastic planar center molded to a black plastic ring or perimeter. In other instances, the stiffener 110 may be formed from a single, translucent material, e.g., white plastic, and have the side edges thereof coated, painted, colored, or otherwise masked with a darker substance. Such embodiments of the stiffener 110 may provide some light-blocking properties, which may assist in preventing leakage of the light from undesirable areas of the apparatus.

[0022] Apparatus 100 may further include a dome 112, which is an electrically- connected, reflexive sensory contact terminal that connects with a circuit element (not shown) when force is applied to the cover 102 of apparatus 100. The dome 112 itself may include one or more flexible cross support members 114 that extend across the terminal from one side to the other forming a generally dome shaped profile. Note, for convenience, in this application, the dome 112 may be referred to herein as the "terminal" as well. Under the applied force, the cross support members 114 of the dome 112 flex elastically to make contact with the circuit element and a signal is relayed to output the intended function of the legend 104. Thus, in the example embodiment of FIG. 1, applied force on the cover 102 would relay a signal to a connected computing device to output the letter "L." Additional details regarding the functionality associated with a keyboard or other electronic circuitry are not provided herein.

[0023] Illumination of the legend 104 is achieved via selective placement of one or more light sources 116. As shown in FIG. 1, light sources 116 may be placed within a perimeter or outside of the perimeter of the dome 112. The light sources 1 16 may include unpackaged LEDs powered via direct or indirect attachment to one or more circuit elements provided in the apparatus 100. The unpackaged LEDs may be placed by any suitable means, including via direct transfer according to the method and apparatus described in US Application Serial No. 14/939,896. Additional details regarding position of placement of the light sources 116 are discussed further herein below with respect to FIG. 3.

[0024] In FIG. 2, a perspective view of a cross-section of a backlit keyboard 200 is depicted. Further, emphasis of a cross-sectional side view of a single key 202 of the keyboard 200 is provided. Specific elements of the structure of the key 202 include a base 204 that may include electronic circuitry elements (not shown) to interact and power aspects of the keyboard 200. Thus, the base 204 may serve as a foundation to support the structure of the key 202 thereon. The key 202 may further include a dome 206, a dome cage 208, a dome cover sheet 210, a key stiffener 212, and a cover 214.

[0025] The dome 206 functions as the sensory contact terminal, like terminal 112 described above. The dome 206 may be surrounded, or fenced in, at the sides thereof by the framed dome cage 208. For example, in some instances, the dome cage 208 may have a rectangular shape, or circular shape, or other shape having a plurality of sides that are connected to form a closed shape so that the dome 206 is surrounded or enclosed on all lateral sides of the dome 206. The dome cage 208 may be a sturdy material that is structurally firm to provide protection from damage to the dome 206. The dome cage 208 may be formed as a shaped frame resting on short leg posts (see FIG. 3) and is open at the top side thereof to allow a force to be applied to the top of the dome 206. Alternatively, sides of the dome cage 208 may be consistent in height at a side and all the way around the dome 206, so as to be like a solid wall. However, the dome cover sheet 210 may be placed over the open top of the dome cage 208 so as to cover the dome 206, and thereby prevent direct contact between the dome 206 and the key stiffener 212. Additionally, the key stiffener 212 is covered by the cover 214, and the barrier between key 202 and an adjacent key (K) may be supported by a frame 216.

[0026] Due to the micro-size of the light sources used in this application, there are many locations where the light sources, such as unpackaged LEDs measuring between 25- 50 microns, may be disposed. Additionally, as described in US Application Serial No. 14/939,896, the light sources may be electrically powered and connected via a thin conductive trace disposed on the components of the apparatus. Thus, several layouts are possible. In the following description of the exploded cross-section 300 of key 202 in FIG. 3, the use of the term "light source" (whether or not preceded by "a") may indicate one or more light sources. Furthermore, it is contemplated that any one or a combination of more than one of the following descriptions of light source layouts may be implemented according to a desired strength of backlighting the apparatus. As such, the descriptive statement of a layout where the base 204 of key 202 may have a light source 302 disposed thereon and positioned to be under the dome 206, indicates that the block identified by reference numeral 302 may be a single light source or may represent a plurality of light sources, all of which are contained somewhere within a perimeter defined by an outer periphery of the dome 206. Accordingly, while the light source 302 is depicted in the center of the dome, the light source(s) 302 may actually be off center and distributed beneath the dome where the light source(s) 302 will not interfere with the electrical contact between the dome 206 and electronic circuitry on the base 302 when force is applied to the cover 214.

[0027] Additional potential light source layouts may include the following: a light source 304 on the base 204 in between the dome 206 and the dome cage 208; a light source 306 on the base 304 around the outside of the dome cage 208; a light source 308 embedded in the dome cage 208; a light source 310 disposed on the dome cage 308; a light source 312 disposed on the dome cover sheet 210; a light source 314 disposed underneath the key stiffener 212; a light source 316 disposed on the key stiffener 212; and/or a light source 318 disposed directly on an underside of the cover 214. In one instance, a series of light sources may be disposed directly aligned with the shape of the legend on or under the cover 214. It is noted that while the above description of potential light source layouts describes the light sources (302-318) as being "under," "in," "around," "on," "embedded," or "underneath" various components, it is further contemplated by the inventors that the light sources may be disposed in various other manners with respect to each of the individual components. That is, for example, where a light source is described as being "on" a component, the light source may alternatively, or additionally, be "embedded in," "underneath," "in," etc. the component where possible. [0028] In connection with the above descriptions of potential light source layouts, multiple embodiments of phosphor application (for light emission modification) are contemplated. In general, phosphor may be applied to modify the color and dispersion of the light emitted from the light sources. Thus, the phosphor may be applied in or on components, or portions of those components, through which light may shine. In some instances, phosphor may be applied directly on the light source(s) 302-318 and/or on or mixed into the material of the dome cage 208, the dome cover sheet 210, the key stiff ener 212, or the cover 214. For example, phosphor may be applied (not shown explicitly) to an upper surface of one or more sides of the dome cage 208, and a light source, such as one or more unpackaged LEDs, may be connected to a thin circuit on the base and aligned directly beneath the one or more sides of the dome cage 208.

[0029] Figure 4 depicts a method 400 of creating an apparatus, such as key of a keyboard that is to be backlit. In particular, method 400 may include forming a cover 402 for the apparatus. For example, in some instances, step 402 may include forming a fabric key cover for a key of a keyboard device. The formation of the cover may include creating a first opaque region on the cover and a second translucent region on the cover 404. The creation of the first and second regions may be performed in a single act or may involve two or more acts. The formation of the cover may further include creating a legend in one of the first region and the second region of the cover 406. Note that the possibility remains that the legend may be formed partly in the first region and partly in the second region. Additionally, the legend may be formed via many methods as discussed above. In some instances, the legend may be formed via an additive process 408 such as dye sublimation, via a material removal process 410 using a laser or any suitable cutting or etching device, or via a combination of an additive process and a material removal process 412.

[0030] In step 414, a plurality of light sources may be electrically connected beneath or behind the cover of the apparatus. For example, in a keyboard device, the plurality of light sources may be electrically connected beneath the fabric key cover to illuminate the translucent region of the keys from underneath the covers. In other apparatuses, the light sources also illuminate the translucent region of the covers.

[0031] Method 400 may further include a step 416 of applying a phosphor in or on a material of a structural component and/or the light sources of the apparatus. The application of phosphor may be executed in any order with respect to the other steps of method 400, including prior to integrating the light sources into the apparatus. In some instances, one or more of the components of the key(s) in FIGs. 2 and 3 may include phosphor in the material composition or on the component(s) (i.e., deposited on a surface of the component(s) via spraying, printing, coating, dipping, thermal forming, etc.).

Example Clauses

[0032] A: A keyboard apparatus comprising: a fabric key cover having a plurality of holes that extend through a thickness of the cover from a top side of the cover to a bottom side of the cover, the plurality of holes being arranged to collectively form a predetermined shape; a mask layer disposed at the bottom side of the cover, a first region of the mask layer being opaque and a second region of the mask layer allowing light to pass therethrough to the plurality of holes; a light source disposed beneath the mask layer and positioned such that light emitted from the light source passes through the second region of the mask layer to the plurality of holes; and a sensory contact terminal disposed beneath the mask layer, the terminal detecting a keystroke movement.

[0033] B: The apparatus according to paragraph A, wherein the plurality of holes are formed within a perimeter of the predetermined shape of one of a character, number, symbol, image, or graphic.

[0034] C: The apparatus according to any of paragraphs A-B, wherein the second region of the mask layer is an aperture within the mask layer.

[0035] D: The apparatus according to any of paragraphs A-C, wherein the aperture in the second region of the mask layer has a peripheral shape that is aligned with and shaped substantially similar to a perimeter of the predetermined shape within which the plurality of holes are formed.

[0036] E: The apparatus according to any of paragraphs A-D, wherein the first region of the mask layer is sized and shaped to block light from passing outside of a perimeter of the predetermined shape within which the plurality of holes in the cover are formed.

[0037] F: The apparatus according to any of paragraphs A-E, wherein the second region of the mask layer is a translucent material. [0038] G: The apparatus according to any of paragraphs A-F, wherein the second region of the mask layer includes a material containing phosphor.

[0039] H: The apparatus according to any of paragraphs A-G, further comprising a keycap stiffener disposed between the mask layer and the light source.

[0040] I: The apparatus according to any of paragraphs A-H, wherein the keycap stiffener is translucent.

[0041] J: The apparatus according to any of paragraphs A-I, wherein the keycap stiffener includes phosphor.

[0042] K: The apparatus according to any of paragraphs A-J, wherein a material of the keycap stiffener diffuses the light from the light source.

[0043] L: The apparatus according to any of paragraphs A-K, wherein an internal surface of the plurality of holes in the fabric key cover are fused by a laser that forms the plurality of holes.

[0044] M: The apparatus according to any of paragraphs A-L, wherein a diameter of each of the plurality of holes ranges from 0.1 to 0.2 mm.

[0045] N: The apparatus according to any of paragraphs A-M, wherein the light source includes LEDs arranged adjacent to the sensory contact terminal.

[0046] O: The apparatus according to any of paragraphs A-N, wherein the light source includes direct-transferred LEDs disposed adjacent a base of the sensory contact terminal.

[0047] P: The apparatus according to any of paragraphs A-O, wherein the sensory contact terminal includes a reflexive dome that responds reflexively upon the keystroke movement.

[0048] Q: The apparatus according to any of paragraphs A-P, wherein the light source includes LEDs having a height ranging from 12.5 microns to 200 microns.

[0049] R: The apparatus according to any of paragraphs A-Q, wherein the fabric key cover includes a plastic material.

[0050] S: The apparatus according to any of paragraphs A-R, wherein the mask layer is printed onto the back of the cover.

[0051] T: The apparatus according to any of paragraphs A-S, wherein the mask layer is etched onto the back of the cover. [0052] U: The apparatus according to any of paragraphs A-T, wherein the mask layer includes a colored substrate.

[0053] V: The apparatus according to any of paragraphs A-U, further comprising a transparent film or substrate that covers at least a portion of the top side of the cover.

[0054] W: The apparatus according to any of paragraphs A-V, wherein the portion of the top side covered by the transparent film or substrate includes an area within a perimeter of the predetermined shape within which the plurality of holes are formed.

[0055] X: An apparatus comprising: a cover having a legend formed in a predetermined shape and being visible from a top side of the cover, a first region of the cover being opaque and a second region of the cover being translucent to be illuminated, the legend being located in one of the first and second regions; a light source disposed beneath the cover and positioned such that light emitted from the light source passes through the second region of the cover to show the legend; and a sensory contact terminal disposed beneath the cover, the light source being disposed within an inner perimeter of a footprint of the terminal.

[0056] Y: The apparatus according to paragraph X, wherein the cover includes a fibrous fabric.

[0057] Z: The apparatus according to any of paragraphs X-Y, wherein the legend is printed into fibers of the fabric via dye sublimation printing.

[0058] AA: A method comprising: forming a fabric key cover for a key of a keyboard device, the forming including creating a first opaque region on the cover and a second translucent region on the cover, and creating a legend in one of the first region and the second region of the key cover; electrically connecting a plurality of light sources beneath the fabric key cover.

[0059] AB: The method according to paragraph AA, further comprising applying a phosphor in or on a material of a structural component of the key.

[0060] AC: The method according to any of paragraphs AA-AB, wherein the creating the legend includes printing the legend via dye sublimation.

[0061] AD: The method according to any of paragraphs AA-AC, wherein the creating the legend includes removing material from the key cover. [0062] AE: The method according to any of paragraphs AA-AD, wherein the removing material from the key cover includes applying a laser to the key cover to etch or cut through the key cover.

Conclusion

[0063] Although several embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the claims are not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the claimed subject matter.