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TWI471074B - 用於形成具有透光部分之面板之方法及其相關產品 - Google Patents

用於形成具有透光部分之面板之方法及其相關產品 Download PDF

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TWI471074B
TWI471074B TW96119145A TW96119145A TWI471074B TW I471074 B TWI471074 B TW I471074B TW 96119145 A TW96119145 A TW 96119145A TW 96119145 A TW96119145 A TW 96119145A TW I471074 B TWI471074 B TW I471074B
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panel
holes
light transmissive
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TW200806150A (en
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Michael S Nashner
Jeffrey E Howerton
Weixiong Lu
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Electro Scient Ind Inc
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Priority claimed from US11/742,862 external-priority patent/US8394301B2/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B08CLEANING
    • B08BCLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B9/00Cleaning hollow articles by methods or apparatus specially adapted thereto
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00Producing optical elements, e.g. lenses or prisms
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    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
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    • B23K26/38Removing material by boring or cutting
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    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36Removing material
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    • B23K26/402Removing material taking account of the properties of the material involved involving non-metallic material, e.g. isolators
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/10Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings of the optical waveguide type
    • GPHYSICS
    • G09EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09FDISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F13/00Illuminated signs; Luminous advertising
    • G09F13/04Signs, boards or panels, illuminated from behind the insignia
    • GPHYSICS
    • G09EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09FDISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F13/00Illuminated signs; Luminous advertising
    • G09F13/04Signs, boards or panels, illuminated from behind the insignia
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    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/50Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/04Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings formed by bundles of fibres

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Description

用於形成具有透光部分之面板之方法及其相關產品
本發明技術標的物之領域係關於藉由一透光材料填充一通道之方法及藉由使用該等方法製造之產品。
透過一殼體投射光來提供資訊係常見。實例包括但不限於:電腦鍵盤,其包括用於諸如"Caps Lock"或"Num Lock"功能之指示燈;包括"開/關"燈之電腦監視器;汽車,其包括指示加熱座椅是否啟用或氣囊是否打開之指示燈;帶指示燈之電視機;及諸多其他消費者電子器件。
通常提供該種照明之方式係提供投射光,當燈熄滅時該投射光係可見而當燈打開時該投射光係明亮以便進行指示。大量燈或燈用孔可能會破壞業內設計人員之目的。
本發明揭示藉由一使光可透過透明填充劑材料之材料來填充一相對較薄基板或面板內通道之方法及藉由該等方法製造之產品。
根據本文教示之使用一透光材料形成一填充通道之方法之一個實施例,該方法包括在一面板內鑽製一個通道並使用一透光材料來填充該通道。
本發明還揭示了根據本文揭示之方法所製造之面板。舉例而言,本文教示一種具有一透光面板之殼體,其中該透光面板係一由該面板內之至少一個通道捕獲之透光聚合物。
本文教示之另一實施例係一具有透光區段之殼體。該透光區段係由包含以下步驟之方法形成:在該透光區段內鑽製一通道,使用一可固化聚合物填充該通道並固化該聚合物。
參照圖1-18,其中顯示使用一透光材料填充至少一個通道之若干方法且於下文予以闡述。圖19圖解闡釋使用其中一個方法獲得之產品。本發明使用通道鑽製技術來形成一個微型通道,然後使用透光材料來填充該微型通道。通道鑽製在電子器件製造之非相關領域內為人們所知曉。通道形成於多層式互連基板內且加襯有一導體(例如,銅)以在一電路之不同層之間達成一電連接。
圖1圖解闡釋使用透光材料填充一通道之方法10及步驟。提供一面板或基板12。如所示,面板12係一相對較薄之連續材料片。面板12包括界定一面板厚度20之第一或背側14及對置第二或前側18。前側18相對平滑且用肉眼觀察大致完整。可藉由熟悉此項技術者所習知之陽極氧化鋁或其他材料來製造面板12。
方法10包括穿過面板12鑽製一個或複數個微型通道或孔30。如圖2-4、8及9中所示,於該方法之一個態樣中,通道30成圓錐形且具有側壁34及面板第一側14內之第一開口40及面板側18上之對置第二開口44。第一通道開口40之直徑大於第二通道開口44。於一態樣中,第一通道開口40直徑約為90-100微米(μm),而第二通道開口44直徑約為30- 40微米(μm)。應理解,可使用更大或更小之圓錐形開口及其他通道形狀和組態。
使用雷射24(例如,二極體激發式固態脈衝雷射)按照一圓形或螺旋圖案在該面板中鑽製或加工若干通道。據顯示,30kHz脈衝重複率及60奈秒脈衝之Nd:YAG 355奈米光斑22適用於加工較佳圓錐形的通路30。例示性通路30之鑽製係穿過面板12自背側14至前側18來完成。除熟悉此項技術者所習知之鑽製通道外,可使用其他類型之具有不同特性之雷射及其他加工方法來適應特定之應用。
任選地,方法10可包括步驟46:清潔鑽製通道30以移除任何在加工製程期間形成之碎屑或沈積物。據顯示,CO2雪噴清潔及異丙基對清潔該等通道係有效。亦可使用熟悉此項技術者所習知之其他通道清潔技術。舉例而言,可使用(例如)超音波清潔。同樣,可藉由一以類似於鑽孔機24之方式移動定位的源來施加高壓空氣(如,雪噴)以清潔該等通道。
如圖1及5-9中所示,方法10包括將一填充劑材料塗層50施加至通道30內。填充劑材料50可係一可見透光材料。如所示,填充劑材料50係一在施加至面板12時處於液態之光學透明、紫外光(UV)固化之丙烯酸酯聚合物。亦可使用其他具有透光性質之塑膠或聚合物。該例示性UV可固化填充劑材料在固化時大致透明。如圖1中所見,可於通道30之第二(視需要)較小開口44之頂部上將填充劑材料50施加至該面板第二側18。據觀察,如圖1、8及9最佳顯示,由 於例示性液相填充劑材料50相對較低之黏度、圓錐形通道30之幾何形狀及重力,故填充劑材料50自第二側18流入至第二側14並流過通道30,故可有效地填充通道30。如圖1最佳所見,多餘之填充劑材料50可在面板12之第二側18(顯示為66)及第一側14(顯示為62)上擴散。使用一注射器型裝置54來施加所示之填充劑材料50。可使用熟悉此項技術者所習知之其他填充劑材料50施加裝置及技術。實例包括噴墨技術及墊印刷技術。
於一替代態樣中,可將填充劑材料50施加至背側14,以便填充劑材料50以所述之類似方式穿過通道30自背側14流向前側18。
當使用可固化填充劑材料時,方法10可包括步驟76:藉由將填充劑50暴露於UV光來固化例示性之以二氧化矽為主的液相填充劑材料。暴露於UV光76可在通道30內部及穿過通道30起始矽酸鹽填充劑材料50之自由基聚合。於施加UV光之一個方法中,將該UV光施加至背側14及通道30(亦即,大的開口40)以促進填充劑材料50在通道30中之固化。當固化時,例示性填充劑材料50係光學透明,從而允許可見光經由通道30而通過填充劑50及面板12。
方法10包括步驟82:如圖1所示,自面板之可見前側18移除任何多餘或未固化之填充劑材料66。舉例而言,可藉由簡單的異丙醇擦洗自前側18移除填充劑多餘之沈積物66,從而留下一可見平滑及清潔表面。可使用其他移除多餘沈積物66之方法及技術。
方法10可任選地包括步驟90:在移除多餘沈積物66之步驟後,暴露通道30內之毗鄰於可見面板側18之填充劑材料50以幫助通道30內之填充劑材料50固化。參照圖9,最毗鄰面板可見表面18之填充劑材料50可能稍微低於前側18而在填充劑50與前側18之間形成一凹陷94。
如圖10-18中最佳所見,可更改針對直接毗鄰可見面板表面18之填充劑材料的處理,以為使用者改變或增強填充劑材料40之視覺外觀及自其間穿過的可見光。於方法10之替代態樣中,與圖9中所示凹入通道30內相反,已固化之多餘填充劑沈積物66可成一凸形狀或形式。舉例而言,圖10-12及圖13-15圖解闡釋已固化之多餘填充劑沈積物66之兩種突出的形式。於圖10-12中,該凸形延伸超過並環繞第二通道開口44。於圖13-15中,該凸形大致侷限於第二通道開口44之區域。可藉由不同的形狀或構形(類似於改變一透鏡之形狀或構形)來改變穿過填充劑材料50之可見光,以向使用者產生一不同的視覺外觀或效果。作為另一實例,圖16-18圖解闡釋一齊平之填充(而並非一凹形或凸形),亦即,其中填充劑材料50與第二或前側18之表面齊平之實施例。
方法10之固化填充劑材料50及前側18可獲得能夠透光穿過面板12之保護通道30。如圖19中所示,使用通道及光學透明填充劑材料來製作一用肉眼觀察平滑且連續之面板表面,該面板表面能夠顯示自內部照明穿過該等通道之控制影像。圖19圖解闡釋一包括一背光70之面板12,背光70可 係一LED、螢光或白熾燈、或其他發光裝置。如圖19中所示,面板12可係一插入殼體內之區段,或可係殼體72之整體區段。
可將所獲得之面板12用於各種應用中,該等應用包括諸如MP3播放器、電腦、蜂巢式電話、DVD播放器等手持式電子裝置。本文揭示之方法及所獲得之面板可適用於幾乎所有如下之應用:期望使用一視覺連續及不間斷且能夠為使用者產生照明訊息、影像或其他感知特徵之面板表面。
儘管上文結合目前認為最實用及最佳的實施例對該方法進行了闡述,但應理解,該方法並非侷限於所揭示之實施例,相反,本發明意欲涵蓋包含於本發明及任何請求項之精神及範圍內的各種修改及等效步驟和佈置。
12‧‧‧面板、基板
14‧‧‧第一側、背側
18‧‧‧第二側、前側
22‧‧‧光斑
24‧‧‧鑽孔機
30‧‧‧通道
34‧‧‧側壁
40‧‧‧第一開口
44‧‧‧第二開口
50‧‧‧填充劑材料
54‧‧‧注射器型裝置
62‧‧‧第一側
66‧‧‧第二側
70‧‧‧背光
72‧‧‧殼體
94‧‧‧凹陷
本文說明書參照附圖,其中數個視圖中相同之參考編號指代相同之部件,且其中:圖1係本發明方法序列之視圖圖解。
圖2係一圓錐形通道或孔幾何形狀之示意圖;圖3係拍攝具有若干圓錐形通道之SEM顯微照片,其顯示一具有較大通道開口之面板之第一或背側。
圖4係通道之SEM顯微照片,其顯示具有較小圓錐形通道開口之面板之第二或可見側面;圖5係該面板可見側之SEM顯微照片,該面板具有例示性之較小通道開口,其中該通道中填充有填充劑材料。
圖6係該面板可見側之光學顯微照片,該面板具有填充 有填充劑材料之例示性通道,且自該面板之可見側看去具有背光以顯示透過該圓錐形通道之光傳輸。
圖7係圖6中所示面板可見側之放大光學顯微照片;圖8係數個填充有填充劑材料之通道之橫截面的SEM顯微照片;圖9係圖8中所示之填充圓錐形通道之橫截面之放大SEM照片;圖10係該面板可見側上填充劑材料之替代組態之示意圖解;圖11係圖10中所示之替代填充劑材料組態之SEM顯微照片;圖12係圖11中所示之替代填充劑材料組態之光學顯微照片;圖13係該面板可見側上填充劑材料之替代組態之示意圖;圖14係圖12中所示之替代填充劑材料組態之SEM顯微照片;圖15係圖14中所示之替代填充劑材料組態之光學顯微照片;圖16係該面板可見側上填充劑材料之替代組態之示意圖;圖17係圖16中所示之替代填充劑材料組態之SEM照片;圖18係圖17中所示之替代填充劑材料組態之光學顯微照片;且 圖19係一殼體之示意圖,該殼體使用一包含填充通道之透光面板。
12‧‧‧面板、基板
14‧‧‧第一側、背側
18‧‧‧第二側、前側
22‧‧‧光斑
24‧‧‧鑽孔機
30‧‧‧通道
40‧‧‧第一開口
50‧‧‧填充劑材料
54‧‧‧注射器型裝置
62‧‧‧第一側
66‧‧‧第二側

Claims (11)

  1. 一種在一面板的一部份中產生具有透光性之一區域之方法,該方法包括:自該面板之一第一表面鑽製多個微觀孔洞(microscopic holes)之一圖案,並藉由對該面板施加一雷射之一雷射光點以形成該等孔洞之每一者,而通過該面板完全延伸至該面板之一第二表面,其中該等孔洞為圓錐形,俾使其各者在該面板之該第二表面上具有一小直徑開口且在該面板之該第一表面上具有一較大直徑開口;在鑽製該圖案之後用一透光材料填充該等孔洞,該透光材料包含一可固化聚合物(curable polymer);及在填充該等孔洞後固化該透光材料,其中該面板之一材料為非透光性,且該面板位於透光部分之該第二表面對肉眼而言係為一視覺連續且不間斷之面板表面,其可使用照明通過該等孔洞來顯示經控制之影像。
  2. 如請求項1之方法,其中該小直徑開口具有一介於60至200微米之間的第一直徑;且該較大直徑開口具有一介於10至50微米之間的第二直徑。
  3. 如請求項1或2之方法,其進一步包括:在鑽製之後於填充之前使用一CO2雪噴、超音波清潔及高壓空氣中之至少一者來清潔該等孔洞。
  4. 如請求項1或2之方法,其中藉由將該面板之該第一表面暴露於一UV光來固化該透光材料。
  5. 如請求項1或2之方法,其中填充該等孔洞包括僅由該面板之該第二表面填充該等孔洞,該方法進一步包括:在該填充步驟之後清潔該面板之該第一表面或該面板之該第二表面之至少一者;其中固化該透光材料包含在該清潔步驟之後固化該透光材料。
  6. 如請求項1或2之方法,其中該面板之該材料由該第一表面至該第二表面之一厚度大於與該等孔洞之每一者相關聯之該小直徑開口及該較大直徑開口之每一者之一直徑,且該材料係陽極氧化鋁。
  7. 一種具有一透光部分之面板,該透光部分包括:多個微觀孔洞的一圖案,其係自該面板之一第一表面鑽製,並藉由施加一雷射之一雷射光點以形成該等孔洞之每一者,而完全延伸通過該面板之一第二表面,其中該等孔洞為圓錐形,俾使其各者在該面板之該第二表面上具有一小直徑開口且在該面板之該第一表面上具有一較大直徑開口,且該等孔洞係填充一透光材料,該透光材料包含一可固化聚合物,該可固化聚合物在填充該等孔洞後被固化,該面板之一材料為非透光性,且該面板位於透光部分之該第二表面對肉眼而言係為一視覺連續且不間斷之面板表面,其可使用照明通過該等孔洞來顯示經控制之影像。
  8. 如請求項7之面板,其中該可固化填充材料係一UV可固化之丙烯酸酯聚合物,且該面板包含陽極氧化鋁。
  9. 如請求項7或8之面板,其中該較大直徑開口之一直徑介於60與200微米之間且該小直徑開口之一直徑介於10與50微米之間。
  10. 如請求項7或8之面板,其中該面板之該材料由該第一表面至該第二表面之一厚度係大於與該等孔洞之每一者相關聯之該小直徑開口及該較大直徑開口之每一者之一直徑。
  11. 一種包含如請求項7或8之面板之殼體,且進一步包括:一光源,其配置於該殼體之一內部;且其中該面板經配置以使得該等孔洞之該較大半徑開口面對該殼體之內部及該光源。
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