Background technology
Key unit is a kind of parts that constitute such as mobile devices such as portable phones, in this mobile device, concentrates and arranged a large amount of switching manipulation keys (button) on a thin sheet surface.A key is to be made of the keycap that sticks to the key mat surface, and keycap is made by animi resin and so on, and key mat is made by soft material such as silicon rubber or thermoplastic elastomer; Key mat has switch to press down projection (common name " pressing down the unit ") at its back side.Each key is interconnected by key mat.The circuit board that switch element is arranged is arranged in the lower surface of the key unit that constitutes as mentioned above, so that form key switch in each relevant position.As the structure of a kind of types of illumination key unit of key unit as mentioned above, the optical illumination that the character of each key, symbol etc. are come by light source.
Because keycap is disposed in the most noticeable position in the actual mobile device, so pay special attention to its design and decoration.By methods such as plating, on whole key cap surface, promptly form metallic film in the face of the bottom surface of key mat and cap surface at keycap, be welcome, because it was not only durable but also give noble sensation.
Usually, on the surface of metallic bond, form the character, symbol of the function show key etc.As the method that forms character, symbol etc. on the metallic bond surface, can consider to handle with laser marking.But, when forming character, symbol etc., on metallic bond, directly use laser marking, be inconvenient, this thickness of metal film has high reflectivity at 0.1 to 30 μ m, be formed on the plastic keycap by methods such as plating, and laser marking is to remove metallic film fully at illuminated portion, thus with simple laser marking or cutting metal coating etc. relatively, difficult point is arranged.
For example, if attempt to use the near infrared light of wavelength 1064nm, fundamental wavelength as widely used solid state laser Nd:YAG (yag crystal of Nd ion doped), there are mirror coating such as chromium to be formed on the keycap of plastic key surface therein, directly form character, symbol etc., can be created in before actual characters etc. forms, the problem that the temperature of non-point of irradiation part rises can not be handled fully because of lower floor's plastic molting etc.Can think that this is that because the near-infrared light wavelength is relatively long, spot diameter is difficult to regulate with lens optical system because the energy density of point of irradiation is not enough.
Because on metallic bond, carry out this difficulty of laser marking, be used to make the key of parcel plating, be that conducts such as character, symbol do not have cladding portion to be blended in key in the coated surface, still continue to use complicated processing procedure (for example JP-A-2001-73154) so far.In other words, according to JP-A-2001-73154, the handling procedure of execution is " molded plastics keycap → rough surface/activation → electrodeless plating copper → at electrodeless plating tin on the copper → handle (exposing the copper electrodeposited coating) → remove copper electrodeposited coating → electrodeless plating nickel (except the character part) → electrogilding on nickel by etching in the character part carrying out laser marking on the tin coating ".
In addition, there is a kind of marking method to be called " Shibo processing ".This method is the set of the plane of very little in a large number concave point (the concave point diameter and the degree of depth are at 10 to 30 μ m), is formed on the metallic film on metallic bond surface.In order to handle the shape represent character etc. with Shibo, generally use electroformed mould as a rule.Electroformed mould is to piece together use by the mould molded keycap, and key cap surface forms the plane set part of very little concave point such as character, has been made to former.
Be the example of handling with electroformed mould below.At first, prepare the keycap matrix of not mark,, on matrix, form the figure that needs, as character or symbol by suitable rough surface device with synthetic resin, copper alloy and so on.Afterwards, attached on the matrix, be release agent the situation of synthetic resin at matrix, also to handle making it conduction with silver mirror, carry out metal plating then, reach several millimeters up to thickness.This electroplating process needs tens of days time, and this process is called " electroforming ".After finishing electroforming, peel from matrix, can obtain an electroformed mould electroplating the part that forms.Then, the resin that can electroplate, inject mould as ABS (acrylonitrile-BS), molded keycap wherein will piece together electroformed mould, to form keycap.Secondly, on key cap surface, form metallic film by electroplating, so, formed the metallic bond of character or symbol thereon, handled obtaining with Shibo.But the shortcoming of electroformed mould is can not the fast adaptation character or the variation of symbol figures.
Therefore, picture directly forms the situation of character or symbol etc. with laser marking, remove the metallic film of illuminated portion fully by mark, can think the metallic film of this part, in other words, have only the surface layer part of this metallic film to be removed, and form the plane set of very little in a large number concave point, finish Shibo and handle by laser marking.In fact, by laser mark on iron plate or aluminium sheet, be to handle with Shibo to form character etc.But,, can not handle with Shibo when thickness of metal film is too thin.In addition, even in the relatively thick situation of film thickness, and simple metallic plate is compared, still had many difficult problems.
Summary of the invention
The problem to be solved in the present invention
The problem to be solved in the present invention provides a kind of marking method, directly with simple process, by laser radiation, mark on metallic film forms predetermined figure such as character or symbol, and this metallic film is on the keycap that synthetic resin is made, keycap is used for the mobile device as portable phone, this marking method is removed the metallic film of illuminated portion fully, or only removes the surface layer part of the metallic film of illuminated portion, forms the plane set of very little in a large number concave point.
The means of dealing with problems
In addressing the above problem, as laser, be to use wavelength 1064nm and be 30 μ m or littler YAG laser at the convergence diameter of illuminated portion, obtain the laser of wavelength 532nm by the second harmonic that extracts the YAG laser, or wavelength 180nm and have molecular level to assemble the excimer laser of diameter at illuminated portion.
In above-mentioned means, adopt mainly the reasons are as follows of above-mentioned laser.At first, in the situation of same-amplitude, laser energy shortens with wavelength and increases.Second, as curve among Fig. 8 (draw from Yu Kanoka " Laser Processing ", nineteen ninety-five May/THE NIKKAN KOGYOSHIMBUN, LTM.) shown in, though the reflectivity of plate surface is nearly 1 in long wavelength's termination, hold declines (absorbing increase) short wavelength near the border of 500nm.The 3rd, also be different from from the near-infrared to the far infrared, from the visible light to the black light, can assemble by scioptics, obtain the spot diameter of 10 to 30 μ m easily.The 4th, in the situation of excimer laser, can obtain the spot diameter of molecular level.
When laser marking, beam and focus (focus) is dragged in the plane, scans character, symbol etc.On the contrary, when metallic film was removed fully, hot spot also moved along the depth direction of metallic film.At this moment, spot diameter is controlled in the most about 30 μ m.In addition, along the moving of depth direction, this moves in the thickness range that must be controlled at metallic film to beam and focus, so that laser is directly beaten on below the plastic layer.Such control can accurately be implemented by enough laser irradiating devices, and in this laser irradiating device, the optical system that forms beam and focus is controlled with computer is strict.
The laser that uses in the above-mentioned laser irradiating device shortens with wavelength and the viewpoint that increases is preferably short from laser energy.Yet energy density also can be improved by reducing spot diameter.
On the other hand, from the light absorption on plated metal surface, hold the viewpoint of increase to see the short wavelength near the border of 500nm, visible light or 550nm or shorter black light are enough.
By using wavelength to satisfy the laser of above-mentioned condition, keep simultaneously is not that point of irradiation temperature partly is in the temperature of permitting or lower, can remove metallic film rapidly, or can only remove the surface portion of illuminated portion metallic film rapidly, form the plane set of very little in a large number concave point, and, form predetermined figure such as character or symbol by mark.In this case, the illumination type of laser can be any of continuous type and impulse type, as long as essential luminous power is provided.
Meet the present invention according to claim 1, because figure such as character or symbol, be to handle by Shibo with laser, mark forms on key cap surface electroplated metal film, so can obtain to be rich in ornamental and figure wherein not because of the super durable key unit of peeling off and disappearing such as using.
The present invention according to claim 2, because the absorption of luminous energy can increase on the point of irradiation, and the beam and focus diameter can be regulated to the keycap mark time, thereby the energy absorption density on the improvement point of irradiation, with can on electrodeposition of metals, carry out quick mark, keep simultaneously be not the temperature of point of irradiation part in the temperature of permission or lower, thereby can obtain not have thermal deformation and be rich in ornamental key unit.
The present invention according to claim 3, because the absorption of luminous energy can increase on the point of irradiation, and the beam and focus diameter can be regulated when keycap being carried out laser markings such as character, symbol, thereby the energy absorption density on the improvement point of irradiation, and only remove the surface portion of metallic film apace at illuminated portion, gather on the plane that forms very little in a large number concave point by mark, and keeping simultaneously is not that point of irradiation temperature partly is in the temperature of permitting or lower.
The present invention according to claim 4, because the absorption of luminous energy can increase on the point of irradiation, and the beam and focus diameter can be regulated to the keycap mark time, thereby the energy absorption density on the improvement point of irradiation, with can on electrodeposition of metals, carry out quick mark, keeping simultaneously is not that the temperature of point of irradiation part is in the temperature of permission or lower.
The present invention according to claim 5, owing to the institute that can implement in the still undetermined state of target all is done in steps, and on the keycap end face in case after being determined with respect to the part of the character/symbol of target, finish institute in steps with laser marking as early as possible, so can after determining target, finish key unit, eliminate the waste stock (wasteful stock) that market output (market production) causes with the shortest time.
Embodiment
This paper back will illustrate embodiments of the invention with reference to the accompanying drawings.
Laser irradiating device at first is described.Fig. 1 and 2 is conceptual figure, is used to the laser irradiating device 1 of explaining that the present invention uses.Laser irradiating device 1 comprises, data input device 2, control device 3, laser oscillation apparatus 4, comprises the optical system 5 of a plurality of speculums and lens, or the like.
Data input device 2 is implemented the input of the data (stereo data (solid data)) of relevant figure such as character or symbol, and storage input data.The input data are to import with the form of for example cad data of computer preparation.Control device 3 produces the data that are used for the actual process use by the data of above-mentioned data input device 2 inputs, the operation of control laser oscillation apparatus 4 and optical system 5.
Laser oscillation apparatus 4 makes the light of wavelength 532nm as laser generation, and it is to change acquisition by the half-wavelength of the first-harmonic of Nd:YAG laser 1064nm wavelength.This half-wavelength conversion is to realize by the second harmonic that extracts the Nd:YAG laser.The laser of Gou Chenging is called " second harmonic YAG laser " like this.The laser of wavelength 532nm also is " green laser ", because it is green.Fig. 2 is a concept map, shows in second harmonic YAG laser, the formation example of laser oscillation apparatus 4 (draw from Haruhiro Kobayashi " Lecture of Laser ", in January, 1992/THE NIKKAN KOGYO SHIMBUN, LTM.).
On the other hand, as above-mentioned laser, also can use the triple-frequency harmonics that extracts the Nd:YAG laser to obtain the black light of wavelength as 355nm.The Nd:YAG laser that this extracts triple-frequency harmonics is called " triple-frequency harmonics YAG laser ".In this case, the formation of laser oscillation apparatus 4, also same as shown in Figure 2 substantially on principle.
Also have, as above-mentioned laser, solid state laser, as the amorphous laser of mixing Nd (neodymium) ion, or YVO
4The secondary of laser also can use to one of four-time harmonic.
As shown in Figure 1, optical system 5 comprises: two speculums (galvanometer scanner) 5a and 5b, in different directions from each other, rotate, and be used to control the direction of illumination of laser; Lens (F0 lens) 5c is used to make laser convergence; Or the like.
The laser irradiating device 1 of structure is as mentioned above arranged, by processing based on input signal, the operation of control optical system etc.The timing that the three-dimensional position by control laser beam hot spot and the ON/OFF of laser radiation concern each other on the metallic film 15 of the end face 12a of key unit 12, is fully automatically carried out the mark of character, symbol etc.
Therefore, by laser irradiating device 1, the end face of each key unit keycap is as explanation after a while, by laser radiation.Beam and focus (focus) is dragged in the plane, scans character, symbol etc.In the situation of removing metallic film fully, beam and focus also moves along the depth direction of metallic film.Thereby the metallic film of illuminated part is removed fully, or only remove the layer segment that shows of illuminated portion metallic film, and form the processing (after this this paper be called for short " Shibo processings ") of the plane set of a large amount of very little concave points, by mark formation figure such as character or symbol.
First example 10 of key unit structure will be described below, and in this example, figure is to use above-mentioned laser irradiating device 1 mark to form as character or symbol.
Though explanation by way of example, wherein, in first example 10, any keycap all has metallic film, and this metallic film is carried out laser marking, and the second example 10A of the key unit that will illustrate below, and the present invention is not subjected to the restriction of these two examples.The key unit that has one or more layers metallic film at least, and these metallic films are carried out mark with laser, can use.In addition, for character, symbol etc. is made the marking method unanimity, in key unit, as the keycap that does not have metallic film, there is the keycap of one deck by the lamination that prints or apply on the most handy surface, and character, symbol etc. then by with laser printing or write, carry out mark to this layer and form.
Generally shown in Fig. 3 and 4, the formation of key unit 10 comprises: the key mat 11 that transparent mollielast such as silicon rubber or thermoplastic elastomer are made; With a large amount of keycaps 12 that place on the key mat 11.Draw figure as character and symbol of Fig. 3 does not still have key unit 10 before the mark.Fig. 4 draws as the key unit 10 after the figure 13 of character and symbol (as an example, drawn those the Arabic characters) mark.About keycap 12, be positioned at center upper portion and have the keycap 12A of largest contours to be used as so-called multidirectional key.
Fig. 6 draws and has used key unit 10 after laser irradiating device 1 mark as the figure 13 of character and symbol in vertical cross section.
In other words, in keycap 12, the metallic film 15 that 0.1 to 30 μ m is thick has been used various metal foil membrane formation devices, as plating, vapour deposition, sputter and CVD (chemical vapor deposition method), plastic end face 12a and the side 12b transparent in appropriateness form.
Various metal foil membrane formation devices except that electroplating in the situation as sputter, are used to produce the metal of metallic film 15, as long as these metal foil membrane formation devices can adapt to, just are not subjected to particular restriction.In brief, if satisfy as various conditions that the mobile device of portable phone requires, such as durability, chemical corrosion stability, so it should with designing requirement, such as color harmony quality maintenance balance.
In addition, form metallic film 15 if be limited to electroplating, then the material of the main body 14 of keycap 12 is limited in the resin (plating grade resins) that can electroplate, as ABS resin.But, if metallic film 15 is that as vapour deposition, sputter and CVD, then various transparent resins as PC (Merlon) resin and PET (polyethylene terephthalate) resin, all can be extensive use of with the formation device except that electroplating.
Normally, in the situation of the thickness relative thin of the metallic film 15 that forms with vapour deposition, sputter or CVD,, on metallic film 15, add the external coatings such as UV (ultraviolet) hardened resin coating that do not draw in order to increase durability, corrosion resistance or the like.Because this external coating is removed together with metallic film 15 at illuminated portion when laser 16 irradiations, so after this external coating is preferably in laser 16 processing, be coated in again on the keycap 12.
Metallic film 15 on the end face 12a of keycap 12, laser 16 irradiations by above-mentioned laser irradiating device 1, remove the metallic film 15 of illuminated portion fully, form figure 13, as character or symbol, so plastic main body 14 surfaces under the metallic film are exposed, and can see when watching keycap 13 from above.In addition, at the keycap 12 bottom surface 12c that do not have metallic film 15, by printing process or spraying method, such as silk screen printing, dip-dye printing, infiltration printing or spraying, the nonferrous layer 17 that formation is suitably colored.
Above-mentioned nonferrous layer 17 can form above-mentioned nonferrous layer 17 at once on the end face of keycap 12 below metallic film 15 (main body 14 surfaces) before metallic film forms, rather than be formed on the bottom surface 12c of keycap 12.When illuminated character when being colourless, do not need above-mentioned nonferrous layer 17.Metallic film 15 thickness according to the formation method, change in about 1 to 30 mu m range.In other words, in the situation that forms with vapour deposition, sputter or CVD etc., the thickness of metallic film 15 is thinner.But in the situation that forms with plating, metallic film 15 has sandwich construction, 0.2 to the thick electrodeless plating d nickel dam of 1 μ m at orlop, the thick copper electrodeposited coating of about 7 to 15 μ m in the above, the thick nickel electrodeposited coating of 4 to 8 μ m again in the above and the thick chromium of 0.1 to 2 μ m, gold etc. in the superiors.Second layer electrodeless plating is the structure of free of pinholes below above-mentioned, in case light leak.Certainly, have many kinds of electrodeposited coating structures, the present invention is not subjected to the restriction of said structure.
In addition, are the situations that form with vapour deposition (vacuum vapor deposition etc.) at metallic film 15, the layer that on keycap 12 main bodys 14 that suitably resin is made, forms, the sandwich construction that has is as follows.In other words, the formation of above-mentioned sandwich construction, for example have: basic (bottoming) cover layer that 10 to 20 μ m are thick is added on the main body 14 as orlop, 1 μ m or thinner metallic film 15 usefulness vapour depositions are formed on the basic cover layer, are the thick clear topcoat of 10 to 20 μ m that is added on the metallic film 15 then.
At metallic film 15 are the situations that form with sputter or CVD, with top similar, and the layer that on keycap 12 main bodys 14 that suitably resin is made, forms, the sandwich construction that has is as follows.The formation of above-mentioned sandwich construction for example has: by sputter or CVD, directly forming 1 μ m or thinner metallic film 15 on the resin that constitutes main body 14, is the thick clear topcoat of 10 to 20 μ m that is added on the metallic film 15 then.
As mentioned above, in the relatively thinner situation of the metallic film that forms with the metal foil membrane formation device, for example vapour deposition, sputter or CVD etc. by being added on the metallic film 15 with external coatings such as UV hardened resin coatings, can improve durability, corrosion resistance of metallic film 15 etc.In addition, by using colored transparent coating, also can make this metallic film 15 be coloured to random color as external coating.
The keycap 12 that said structure is respectively arranged is fixed on the end face of key mat 11 with clear binder 18.On an end face of key mat 11, corresponding with each keycap 12 be provided with each be used to depress dome switch 19 (only drawing) press down projection (pressing down the unit) 11a (only drawing), be integrally formed.Above-mentioned dome switch 19 is positioned in the substrate 20, and substrate 20 has the suitable circuit diagram that comprises unillustrated fixed contact.
Figure 13 as the forming process of character or symbol, is as shown in Figure 6 situations to key unit 10, usually illustrates as follows.In other words, as shown in Figure 1, the end face 12a of key unit 10 each keycap 12 is used as the above-mentioned green laser radiation of the laser 16 of laser irradiating device 1.Then, as shown in Figure 5, on metallic film 15 surfaces, the spot diameter of light beam is adjusted to 10 to 30 μ m, and along the figure 13 that will form, as the flat shape of character or symbol, scanning metallic film 15.At this moment, with the position that changes at the beam and focus depth direction, the reirradiation several times, the metallic film 15 of illuminated portion is removed fully, becomes the shape of figure 13 as character or symbol, and main part 14 is come out.
As a kind of laser different with above-mentioned laser, also can use wavelength 1064nm and be 30 μ m or littler YAG laser at the convergence diameter of illuminated portion, extract the YAG laser of the wavelength 355nm that triple-frequency harmonics obtains, or wavelength 180 μ m and be the excimer laser of molecular level at the convergence diameter of illuminated portion.
Therefore, are the situations that are used in the portable phone at above-mentioned key unit 10, in use, the light that the light source that never draws passes transparent key mat 11, by nonferrous layer 17, enter the bottom surface of keycap 12, and from figure 13 as character or symbol outgoing, arrive outside.Therefore, the user of portable phone can discern character on the keycap 12, symbol etc. easily.When keycap 12 pressed down, key mat 11 is the downward motion distortion of keycap 12 and then, and dome switch 19 is pressed down projection 11a and presses down and be out of shape, and conducts electricity between the unillustrated fixed contact thereby make in the substrate 20.
On the other hand, on laser 16 illuminated portions of keycap 12, can not exclusively remove metallic film 15, and the surface layer part of only removing metallic film at illuminated portion forms the plane set of very little in a large number concave point, in other words, implement so-called Shibo and handle.Because above-mentioned Shibo handles the surface layer part of only removing metallic film 15, at metallic film 15 are the situations that relatively approach the metal foil membrane formation device formation of (the about 1 μ m or thinner of thickness) with film thickness, the situation of for example vapour deposition, sputter or CVD, Shibo handles and can not adapt with it, because thickness is too thin.Therefore, as metallic film in this case, wish metal level by acquisition thickness such as plating thicker (thickness is 3 to 30 μ m).
Fig. 6 is vertical cross section figure, and the part of the second example 10A of the key unit that draws has been carried out the Shibo processing with laser marking thereon.In this second example, with the identical each several part of the top first example key unit 10, use the reference numerals identical on the structure with first example, therefore omit explanation to them.
As shown in Figure 6, under the situation of key unit 10A, figure 21 usually illustrates as follows as the forming process of character or symbol.As shown in Figure 1, the end face 12a of each keycap 12 of key unit 10A is used as the above-mentioned green laser radiation of the laser 16 of laser irradiating device 1.Then, as shown in Figure 6, on metallic film 15 surfaces, the spot diameter of light beam is adjusted to 10 to 30 μ m, and along the figure 13 that will form, as the flat shape of character or symbol, scanning metallic film 15.At this moment, in the irradiation of the fixed position of beam and focus depth direction, the surface layer part of only removing metallic film 15 forms pit, and by form the plane set of very little in a large number concave point in the bottom surface, constitutes figure 21 as character or symbol.In this case, when metallic film 15 waits under the situation that forms with electroplating, because the thickness of metallic film 15 is 10 to 30 μ m, each formation figure 21 is as the very little concave point of character or symbol, and preferably maximum is 20 μ m or littler.
As character or symbol, have a kind of method to be to above-mentioned figure 20, the outside line of character, symbol etc. is to handle with Shibo, does not change.And a kind of method is, outside the outside line of character, symbol etc., handles formation pit, the outside line of surrounding character, symbol etc. with Shibo.In addition, if figure 21 is as the thickness of the metallic film 15 of character or symbol bottom surface, through reduction processing, reaching has the metal sense not lose the degree of transparency again, the light of the light source that enters from keycap 12 bottom surface 12c then, can be from figure 21 as character or symbol outgoing, so font size, symbol etc. belong to types of illumination.In this case, similar with above-mentioned key unit 10, if be provided with chromatograph 17 at keycap 12 bottom surface 12c etc., then character, symbol etc. also can be with any color lightings.
The manufacture method of key unit 10 of the present invention or key unit 10A will be described below.
In other words, as shown in Figure 7, key mat 11 and keycap 12 are with suitable method of moulding, form respectively as injection molding method (step S1 and step S2); Have, metallic film 15 is with various metal foil membrane formation devices again, and as electroplating, vapour deposition, sputter and CVD (in the situation of unit 10A, only forming with electroplating) are formed on the end face 12a and the side 12b (step S3) of keycap 12; And, if necessary, on the 12c of the bottom surface of keycap 12, be formed with chromatograph 17 (step S4).At last, use clear binder 18 etc., bonding keycap 12 (step S5).In key unit 10 or 10A, the keycap 12 that metallic film 15 is arranged, with the situation that superficial layer has the keycap of printing or spraying formation figure such as character and sign flag to mix, then those do not have the keycap of metallic film 15, without above-mentioned steps S3, and the surface is printed or spray at step S4.
When the target of key unit 10 or 10A is determined, when having determined, with each keycap mark (step S6) of 1 pair of key unit 10 of laser irradiating device or 10A with the character relevant, symbol etc. with the language that uses.Keycap 12 is finished after this mark step, and key unit 10 or 10A can deliver separately, or in the predetermined mobile device of packing into.
In above-mentioned key unit first example 10 and the second example 10A, illustrate that any keycap 12 and all font sizes on these keycaps 12, symbol etc. that metallic film 15 is arranged can carry out mark to metallic film 15 with laser and form.But, the invention is not restricted to this point.As the figure 13 or 20 of character or symbol, can use above-mentioned marking method, at least one keycap 12, form.
In addition, because above-mentioned as the figure 13 of character or symbol or 20 difference, only when using laser radiation, along the depth direction of metallic film 15 on the keycap 12, on the control method of beam and focus position, both can suitably mix on a key unit.Also have, not all keycap 12 all will have metallic film 15, has the keycap 12 of metallic film 15 can mix with the keycap that does not have metallic film 15.In the situation that this keycap that different structure arranged mixes, by using the laser of laser irradiating device 1, the mark of all figures such as character and symbol can unify to become a kind of.