Patent Application
20100258419
Mobile computing devices such as cellular telephones (cell phones) and personal digital assistants (PDAs) demand very high functional performance in relatively small packaging. Similar demands are placed on the aesthetics and appearance of such devices. An optical keypad is one component within a mobile computing device that requires both high functionality and appearance. To provide a high quality appearance and increased functionality, many keypads are backlit so that the characters on the individual keys are illuminated and easy to read. There are two basic forms of backlighting: direct and indirect.
Conventionally, direct backlighting implements several light emitting diodes (LEDs) mounted directly behind the keypad. These LEDs emit light directly towards the back of the keys, so that a portion of the emitted light passes through translucent portions (e.g., the characters) of the keys. While direct backlighting can provide good backlighting for the keypad, direct illumination is typically expensive because many LEDs are distributed behind the keypad. Also, direct backlighting typically consumes a significant amount of power because of the number of LEDs that are used to generate the backlight illumination.
In contrast to direct backlighting, conventional indirect backlighting uses one or more LEDs mounted at an edge of a light guide behind the keypad. The LEDs emit light into the light guide, which transfers the light through total internal reflection (TIR) across the length and/or width of the keypad. In general, TIR keeps all of the light inside the light guide, so that the light can travel across the length and/or width of the keypad, as long as the light is reflected at relatively large angles (i.e., angles of incidence which are larger than the critical angle, as measured from the surface normal) within the light guide. However, there is a balance between facilitating TIR and allowing some light to escape from the light guide in order to provide backlight illumination for the keypad. If all of the light were to reflect inside the light guide through TIR, then there would be no light to illuminate the keypad. Conversely, if none of the light reflects inside the light guide, then the light would not reach the far side of the light guide and the keypad, and the backlight illumination of the keypad would be imbalanced with bright spots close to the LEDs and dark spots away from the LEDs. Hence, some of the light inside the light guide should be internally reflected, while the remaining light uniformly exits the light guide at the various key locations.
Both direct and indirect backlighting arrangements can suffer from inadequate illumination. In particular, some arrangements result in relatively low brightness because of limitations in the beam distribution pattern of the LEDs. In other words, the LEDs have limited beam distribution patterns, which makes uniform backlighting difficult to achieve, especially in indirect backlighting arrangements where the LEDs are located around the perimeter of the light guide and keypad.
One conventional way to improve the light distribution uniformity is to use surface feature patterns which are aligned with the individual keys of the keypad. The surface feature patterns are typically groups of raised or depressed surface features which cause the light to scatter in an approximately diffuse manner. However, such surface feature patterns can be insufficient to provide sufficient uniformity, especially for areas that are outside of the limited beam distribution pattern of the LEDs.
Another conventional way to increase light distribution uniformity is to add an adhesive to the surface of the light guide, similar to a surface feature pattern. However, adding adhesives can increase the cost of production of the device. In particular, the process of applying adhesives is not suitable for mass production. Also, it is difficult using adhesives to control the consistency of the brightness within the light guide.
Another conventional way to increase light distribution uniformity is to add serrations in front of the LEDs. Specifically, the serrations present a non-planar surface for the light to enter the light guide. The non-planar nature of the serrations causes the light to distribute the light across a wider angle within the light guide, because the serrations direct some of the light toward the near corners (i.e., dark zones) of the light guide. However, consistently implementing serrations in the proper locations is difficult because it is hard to control the serration tooling after running for some period. In particular, the shape of the serration tooling easily wears over time due to the small and irregular size of the serration tooling.
Another conventional way to increase light distribution uniformity is to use higher intensity LEDs, or to include more LEDs. However, these solutions increase the cost of production of the device.
Embodiments of an apparatus are described. In one embodiment, the apparatus is a light guide for an optical keypad. An embodiment of the light guide includes a light interface surface, top and bottom surfaces, a surface feature pattern, and a cut line. The light interface surface receives light into the light guide from a light source. The light received through the light interface surface reflects according to total internal reflection (TIR) within the light guide between portions of the top and bottom surfaces. The surface feature pattern disrupts the TIR and scatters at least some of the light outside of at least one surface of the top and bottom surfaces. The cut line redirects at least some of the light from a first direction to a second direction within the light guide. The first direction is a direction other than towards the surface feature pattern, while the second direction is a direction substantially towards the surface feature pattern. Other embodiments of the apparatus are also described.
Embodiments of a system are also described. In one embodiment, the system is an optical keypad system for an electronic computing device. An embodiment of the optical keypad system includes a keypad, a light guide film, and a light source. The keypad includes a plurality of push buttons corresponding to a plurality of inputs. At least a portion of the keypad is at least partially translucent. The light guide film is located approximately adjacent to a back side of the keypad. In one embodiment, the light guide film includes a light interface surface, a surface feature pattern, and a cut line. The light interface surface receives light into the light guide film. The surface feature pattern is disposed on at least one surface of the light guide film approximately parallel to the back side of the keypad. The surface feature pattern disrupts total internal reflection (TIR) within the light guide film and scatters at least some of the light outside of the light guide film towards the keypad. The cut line redirects at least some of the light from a first direction to a second direction within the light guide film. The first direction is a direction other than towards the surface feature pattern, while the second direction is a direction substantially towards the surface feature pattern. The light source emits the light towards the light interface surface of the light guide film. Other embodiments of the system are also described.
Embodiments of a method are also described. In one embodiment, the method is a method for making a light guide for backlighting an optical keypad. An embodiment of the method includes forming a light guide film from a substantially translucent film. The light guide film includes a light interface surface to receive light from a light source. The method also includes forming a surface feature pattern on a surface of the substantially translucent film. The surface feature pattern disrupts total internal reflection (TIR) of light within the light guide film and scatters at least some of the light outside of the light guide film. The method also includes forming a cut line in the light guide film. The cut line redirects at least some of the light from a first direction to a second direction within the light guide film. The first direction is a direction other than towards the surface feature pattern, while the second direction is a direction substantially towards the surface feature pattern. Other embodiments of the method are also described.
Other aspects and advantages of embodiments of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrated by way of example of the principles of the invention.
Throughout the description, similar reference numbers may be used to identify similar elements.
While many embodiments are described herein, at least some of the described embodiments facilitate increased backlight illumination for an optical keypad system, compared with conventional optical keypad systems. In order to increase keypad brightness, some embodiments described herein implement one or more cut lines close to a desired area of backlight illumination, for example, in the vicinity of a button or key on the keypad. Each cut line is a physical depression, or channel, in a surface of the light guide film. In some embodiments, the cut lines may be at a right angle, relative to the propagation direction of light within the light guide film. At some angles, the cut lines act as mirrors to reflect incident light back towards the desired location of backlight illumination in order to supplement the incident light from the light source. Alternatively, the cut lines may direct light to “dark” areas outside of the normal beam distribution pattern of the light source that is used to illuminate the light guide film. Although the specific benefits of each embodiment may vary, some embodiments may offer an increase of approximately 30% to 40% in brightness of the backlight illumination due to the reflected light from the cut lines. Additionally, since the cut lines do not require additional components (e.g., more light sources) within the optical keypad system, embodiments which use cut lines can benefit from increased backlight illumination at relatively low cost. Also, the use of cut lines can maintain optical performance with less power consumption or, alternatively, improve optical performance with the same amount of power consumption as conventional backlight illumination devices.
The shapes and sizes of the cut lines can vary greatly depending on the purpose of each cut line and the type of light guide in which the cut line is implemented. In some embodiments, the cut lines may be implemented by cutting the light guide by a die cut in knife type. In other embodiments, other methods and tools may be used to form the cut lines in the light guide. The cut lines may be linear or curvilinear.
The illustrated optical keypad system 100 includes a keypad 102, a switch circuit 104, a light guide 106, and a light source 108. Although the optical keypad system 100 is shown and described with certain components and functionality, other embodiments of the optical keypad system 100 may include fewer or more components to implement less or more functionality.
In general, the keypad 102 provides a tactile interface for a user to contact and make various input selections such as alphanumeric or symbolic selections. The optical keypad system 100 described herein is not limited to any particular types of input selections. To facilitate such input selections, the keypad 102 includes a base layer 110 and raised portions 112. Each of the raised portions corresponds to one or more input selections. Other embodiments may use a keypad 102 which does not have raised portions or which has depressed portions corresponding to the input selections.
The switch circuit 104 includes a substrate 114 and various switching devices 116 which are aligned with the keys of the keypad 102. The switching devices 116 may be any type of switching devices, including dome switches or other mechanical, electromechanical, or optical switching devices. Upon depression of a key on the keypad 102, the corresponding switching device 116 is activated to generate a switching signal indicative of the key that is depressed.
The light guide 106 is interposed between the keypad 102 and the switch circuit 104 to provide backlight illumination for the keypad 102. In one embodiment, the light source 108 emits light to illuminate the light guide 106, which propagates the light by total internal reflection (TIR) across the length and/or width of the keypad 102. More specifically, the light source 108 emits light into the light guide 106 through a light interface surface 128 of the light guide 104. The light source 108 may be any type of light source, including a light emitting diode (LED), a laser, or another type of light source. Although the optical keypad system 100 is shown with a single light source 108, other embodiments may include more than one light source.
The illustrated light guide 106 includes a substantially translucent layer 118, multiple surface feature patterns 120, and multiple cut lines 122. The substantially translucent layer 118 has a top surface 124 and a bottom surface 126, which are in corresponding major planes of the substantially translucent layer 118, at least when the substantially translucent layer 118 is disposed in a relatively flat configuration (i.e., not bent or deformed). The substantially translucent layer 118 propagates light internally through TIR between the top and bottom surfaces 124 and 126 of the substantially translucent layer 118.
In some embodiments, the substantially translucent layer 118 is a flexible film that conforms to the shape of the back side of the keypad 102. The translucent layer 118 may be fabricated from any number of materials, including but not limited to polycarbonate (PC), polyurethane (PU), polyethylene terephthalate (PET), or acrylic glass (polymethyl methacrylate ((PMMA)). Additionally, the thickness of the translucent layer 118 may vary, although some examples of thicknesses are 0.1 mm, 0.125 mm, 0.2 mm, 0.25 mm, 0.3 mm, 0.38 mm, 0.5 mm, 0.6 mm, 0.8 mm, and 1.0 mm. Other embodiments may use another type of flexible or semi-flexible material and/or have other physical dimensions.
The surface feature patterns 120 of the light guide 106 are generally located at one or both surfaces of the substantially translucent layer 118. In the depicted embodiment, the surface feature patterns 120 are located on the bottom surface 126 of the substantially translucent layer 118. However, other embodiments may include surface feature patterns 120 on the top surface 124 of the substantially translucent layer 118 instead of, or in addition to, the surface feature patterns 120 on the bottom surface 124 of the substantially translucent layer 118.
Each surface feature pattern 120 includes a plurality of non-planar surface features such as raised portions (as shown in
As one example of a surface feature pattern, the illustrated embodiment includes raised bumps which protrude out of the plane of the bottom surface 126 of the substantially translucent film 118. In other embodiments, the surface feature patterns 120 could include a pattern of dimples, or depressions, that penetrate above the plane of the bottom surface 126 of the substantially translucent film 118.
In general, each surface feature pattern 120 disrupts the TIR within the substantially translucent layer 118. The change in surface area and angle of incidence resulting from the raised or depressed surface features allows at least some of the light in the substantially translucent layer 118 to exit the substantially translucent layer 118 at approximately the locations of the surface feature patterns 120. In
In the illustrated embodiment of
Each cut line 122 is a physical depression, or channel that has a length, L, a width, W, and a depth, D. In mathematical terms, the length is much greater than the width (i.e., L>>W). Thus, the geometrical shape of the physical depression is a line, either straight or curvilinear (i.e., curved), or a combination of straight and curvilinear, when viewed along the top or bottom surfaces 124 and 126 of the substantially translucent layer 118. Generally, the length of each cut line 122 corresponds to the size of the area toward which light is directed. The width of each cut line 122 depends on the size and configuration of the tool used to form the cut line 122. For example, the size of a cut line 122 formed by a die cut knife (not shown) depends on the size and shape of the die cut knife. One example knife width is about 0.04 mm, although any size of die cut knife or other tool may be used. The depth of the cut lines 122 may vary. The depth of each cut line 122 can be expressed as a percentage of the total thickness of the substantially translucent layer 118. In some embodiments, the depth of each cut line 122 is about two thirds of the total thickness of the substantially translucent layer 118. In other embodiments, the depth of the cut line 122 is more or less than about two thirds of the total thickness of the substantially translucent layer 118. For example, some embodiments may implement cut lines 122 that extend through the entire thickness of the substantially translucent layer 118, although such a through cut may alter the physical stability of the substantially translucent layer 118. Additionally, embodiments which implement multiple cuts lines 122 may perform as well as embodiments which use through cuts, without as drastic of an impact on the physical stability of the substantially translucent layer 118. The minimum displacement between multiple cut lines 122 arranged within a group of cut lines 122 depends on the precision of the tools used to create the cut lines 122.
In general, the cut lines 122 redirect at least some of the light towards one or more of the surface feature patterns 120. In particular, the cut lines 122 may act like a reflective mirror to reflect light from a first direction (e.g., traveling away from a surface feature pattern 120) so that the light is redirected towards a second direction (e.g., traveling back towards the surface feature pattern 120). In another embodiment, the cut lines 122 redirect light from a direction passing by a surface feature pattern 120 to a different direction towards the surface feature pattern 120. In at least one embodiment, the cut lines 122 redirect light from the beam distribution pattern of the light source 108 to a surface feature pattern 122 that is outside of the beam distribution pattern of the light source 108. By redirecting the light towards the surface feature patterns 120 of the light guide 106, embodiments of the light guide 106 can provide better backlight illumination for the keypad 102, compared with conventional light guides that do not use such cut lines.
In one embodiment, at least a portion of a cut line 122 extends into the substantially transparent layer 118 of the light guide 108 approximately at a right angle relative to at least on one of the top and bottom surfaces 124 and 126 of the substantially transparent layer 118. For example, the cut lines of
In the illustrated embodiment, four cut lines 122 are arranged in pairs on either side of the surface feature pattern 120. Each pair of cut lines 122 is arranged so that the cut lines 122 are parallel to one another. However, in other embodiments, the cut lines 122 may be in another non-parallel arrangement. Also, the cut lines 122 in each pair are arranged in an order of increasing distance away from the light interface surface 128. In other words, in each pair of cut lines 122, one cut line 122 is farther away than the other cut line 122 from the light interface surface 128. Also, the cut lines 122 depicted in
As light from the light sources 108 reaches the surface feature pattern 120, the surface feature pattern 120 disrupts the TIR of the light guide film 118 and, hence, allows some of the light to exit from the light guide film 118. However, some of the light (shown by the dotted arrows) passes by the region at the surface feature pattern 120 and continues to propagate towards the cut lines 122. Upon reaching the cut lines 122, the light is reflected back towards the surface feature pattern 120, which allows additional light to exit from the light guide film 118 at the region of the surface feature pattern 120. As a result, the amount of light that exits the light guide film 118 at the region of the surface feature pattern 120 is increased due to the light reflected back towards the surface feature pattern 120 by the cut lines 122.
As in the previous example of
Similar to the embodiment of
In the embodiment shown in
Also, the cut lines 122 of
Also, the cut lines 122 of
At block 132, a light guide film 118 is formed from a substantially translucent film. At block 134, a surface feature pattern 120 is formed on a surface of the substantially translucent film. As explained above, the surface feature pattern 120 disrupts the TIR of light within the light guide film 118. Hence, the surface feature pattern 120 facilitates scattering of light outside of the light guide film 118. At block 136, a cut line 122 is formed in the light guide film 118. The cut line 122 redirects at least some of the light from a first direction to a second direction within the light guide film 118. In some embodiments, the light is redirected from a direction other than towards the surface feature pattern 120 to a direction towards the surface feature pattern 120. As a result, the amount of light that exits the light guide film 118 at the corresponding region of the surface feature pattern 120 may be increased due to the light reflected back towards the surface feature pattern 120 by the cut line 122.
Although the operations of the method(s) herein are shown and described in a particular order, the order of the operations of each method may be altered so that certain operations may be performed in an inverse order or so that certain operations may be performed, at least in part, concurrently with other operations. In another embodiment, instructions or sub-operations of distinct operations may be implemented in an intermittent and/or alternating manner.
Although specific embodiments of the invention have been described and illustrated, the invention is not to be limited to the specific forms or arrangements of parts so described and illustrated. The scope of the invention is to be defined by the claims appended hereto and their equivalents.
