Backlit button by thermoformed cap process

Claim 2

A backlit button produced within a thermoforming die comprising a female mold by performing the following sequence of method steps of: providing a sheet of thermoformable material having a first side and a second side; providing a graphic display upon one of said first and second sides of said thermoformable sheet; introducing said thermoformable sheet into said thermoforming die and securing said thermoformable sheet within said die such that said graphic display is disposed at a predetermined position within said die; preheating said thermoformable sheet; evacuating said female mold of said thermoforming die, toward which one side of said thermoformable sheet is disposed, so as to reduce the gas pressure therein and cause movement of said thermoformable sheet into said female mold of said die, and elevating the gas pressure upon the other opposite side of said thermoformable sheet so as to assist said movement of said thermoformable sheet into said female mold of said die and thereby cause formation of a thermoformed cap of said backlit button from said thermoformable sheet; retaining said thermoformed cap within said die until cooled; transferring said thermoformed cap into an injection molding apparatus; inserting a light pipe into said thermoformed cap; and injection molding a resin compound into said thermoformed cap and about said light pipe so as to integrally bond said light pipe and said thermoformed cap together; said thermoformed cap, said light pipe, and said resin compound comprising said backlit button.

Claim 3

A backlit button as set forth in claim 1, wherein: said graphic display comprises a screen-printed graphic display.

Claim 4

A backlit button as set forth in claim 1, wherein: said thermoformable sheet is preheated to a temperature which is within the range of 335° F.-480° F.

Claim 5

A backlit button as set forth in claim 1, wherein: said thermoformable sheet comprises a polyester-polycarbonate polymer blend.

Claim 6

A backlit button as set forth in claim 4, wherein: said graphic display comprises a screen-printed graphic display comprising an ink having a cross-link component which is adherent to and compatible with said polyester-polycarbonate sheet.

Claim 7

A backlit button as set forth in claim 1, wherein: said pressure of said gas disposed upon said opposite side of said thermoformable sheet is at least 25 pounds per square inch.

Claim 8

A backlit button produced within a thermoforming die comprising a female mold by performing the following sequence of method steps of: providing a sheet of thermoformable material having a first side and a second side; providing a graphic display upon a portion of one of said first and second sides of said thermoformable sheet; positioning and securing said thermoformable sheet within said thermoforming die such that said graphic display is disposed at a predetermined position within said thermoforming die; heating said thermoformable sheet to a first temperature while maintaining said portion of said thermoformable sheet upon which said graphic display is disposed at a second temperature which is less than said first temperature so as to effectively heat insulate said portion of said thermoformable sheet upon which said graphic display is disposed and thereby prevent variation and distortion of said graphic display as a result of heating said thermoformable sheet to said first temperature; evacuating siad female mold of said thermoforming die, toward which one side of said thermoformable sheet is disposed, so as to reduce the gas pressure within said female mold and cause movement of said thermoformable sheet into said female mold of said die, and elevating the gas pressure upon the other opposite side of said thermoformable sheet so as to assist said movement of said thermoformable sheet into said female mold of said die and thereby cause formation of a thermoformed cap of said backlit button from said thermoformable sheet; retaining said thermoformed cap within said die until cooled; transferring said thermoformed cap into an injection molding apparatus; inserting a light pipe into said thermoformed cap; and injection molding a resin compound into said thermoformed cap and about said light pipe so as to secure said light pipe within said thermoformed cap, said thermoformed cap, said light pipe, and said resin compound comprising said backlit button.

Claim 9

A backlit button produced within a thermoforming die comprising a female mold by performing the following sequence of method steps of: providing a sheet of thermoformable material having a first side and a second side; providing a graphic display upon a portion of one of said first and second sides of said thermoformable sheet; positioning and securing said thermoformable sheet within said thermoforming die such that said graphic display is disposed at a predetermined position within said thermoforming die; heating said thermoformable sheet to a first temperature while maintaining said portion of said thermoformable sheet upon which said graphic display is disposed at a second temperature which is less than said first temperature so as to effectively heat insulate said portion of said thermoformable sheet upon which said graphic display is disposed and thereby prevent variation and distortion of said graphic display as a result of heating said thermoformable sheet to said first temperature; evacuating siad female mold of said thermoforming die, toward which one side of said thermoformable sheet is disposed, so as to reduce the gas pressure within said female mold and cause movement of said thermoformable sheet into said female mold of said die, and elevating the gas pressure upon the other opposite side of said thermoformable sheet so as to assist said movement of said thermoformable sheet into said female mold of said die and thereby cause formation of a thermoformed cap of said backlit button from said thermoformable sheet; retaining said thermoformed cap within said die until cooled; transferring said thermoformed cap into an injection molding apparatus; inserting a light pipe into said thermoformed cap; and injection molding a resin compound into said thermoformed cap and about said light pipe so as to secure said light pipe within said thermoformed cap, said thermoformed cap, said light pipe, and said resin compound comprising said backlit button.

Claim 10

A backlit button as set forth in claim 7, wherein: said graphic display comprises a screen-printed graphic display.

Claim 11

A backlit button as set forth in claim 7, wherein: said first temperature is within the range of 335°F.-480° F.

Claim 12

A backlit button as set forth in claim 7, wherein: said thermoformable sheet comprises a polyester-polycarbonate polymer blend.

Claim 13

A backlit button as set forth in claim 10, wherein: said graphic display comprises a screen-printed graphic display comprising an ink having a cross-link component which is adherent to and compatible with said polyester-polycarbonate sheet.

Claim 14

A backlit button as set forth in claim 7, wherein: said pressure of said gas disposed upon said opposite side of said thermoformable sheet is at least 25 pounds per square inch.

Claim 15

A backlit button produced within a thermoforming die comprising a female mold by performing the following sequence of method steps of: providing a sheet of thermoformable material having a first side and a second side; providing a graphic display upon one of said first and second sides of said thermoformable sheet; introducing said thermoformable sheet into said thermoformable die and securing said thermoformable sheet within said die such that said graphic display is disposed at a predetermined position within said die; preheating said thermoformable sheet; evacuating said female mold of said thermoforming die, toward which one side of said thermoformable sheet is disposed, so as to reduce the gas pressure therein and cause movement of said thermoformable sheet into said female mold of said die, and elevating the gas pressure upon the other opposite side of said thermoformable sheet so as to assist said movement of said thermoformable sheet into said female mold of said die and thereby cause formation of a thermoformed cap of said backlit button from said thermoformable sheet; retaining said thermoformed cap within said die until cooled; transferring said thermoformed cap into an injection molding apparatus; and injection molding a resin compound into said thermoformed cap so as to define a longitudinal light passageway, within said molded resin and therefore within said thermoformed cap, which is linear along its longitudinal extent and which is axially aligned with said graphic display of said thermoformed cap so as to conduct light from a light source to said graphic display and thereby illuminate said graphic display, said thermoformed cap, said light passageway, and said resin compound comprising said backlit button.

Claim 16

A backlit button produced within a thermoforming die comprising a female mold by performing the following sequence of method steps of: providing a sheet of thermoformable material having a first side and a second side; providing a graphic display upon one of said first and second sides of said thermoformable sheet; introducing said thermoformable sheet into said thermoformable die and securing said thermoformable sheet within said die such that said graphic display is disposed at a predetermined position within said die; preheating said thermoformable sheet; evacuating said female mold of said thermoforming die, toward which one side of said thermoformable sheet is disposed, so as to reduce the gas pressure therein and cause movement of said thermoformable sheet into said female mold of said die, and elevating the gas pressure upon the other opposite side of said thermoformable sheet so as to assist said movement of said thermoformable sheet into said female mold of said die and thereby cause formation of a thermoformed cap of said backlit button from said thermoformable sheet; retaining said thermoformed cap within said die until cooled; transferring said thermoformed cap into an injection molding apparatus; and injection molding a resin compound into said thermoformed cap so as to define a longitudinal light passageway, within said molded resin and therefore within said thermoformed cap, which is linear along its longitudinal extent and which is axially aligned with said graphic display of said thermoformed cap so as to conduct light from a light source to said graphic display and thereby illuminate said graphic display, said thermoformed cap, said light passageway, and said resin compound comprising said backlit button.

Claim 17

A backlit button produced within a thermoforming die comprising a female mold by performing the following sequence of method steps of: providing a sheet of thermoformable material having a first side and a second side; providing a graphic display upon a portion of one of said first and second sides of said thermoformable sheet; positioning and securing said thermoformable sheet within said thermoforming die such that said graphic display is disposed at a predetermined position within said thermoforming die; heating said thermoformable sheet to a first temperature while maintaining said portion of said thermoformable sheet upon which said graphic display is disposed at a second temperature which is less than said first temperature so as to effectively heat insulate said portion of said thermoformable sheet upon which said graphic display is disposed and thereby prevent variation and distortion of said graphic display as a result of heating said thermoformable sheet to said first temperature; evacuating said female mold of said thermoforming die, toward which one side of said thermoformable sheet is disposed, so as to reduce the gas pressure within said female mold and cause movement of said thermoformable sheet into said female mold of said die, and elevating the gas pressure upon the other opposite side of said thermoformable sheet so as to assist said movement of said thermoformable sheet into said female mold of said die and thereby cause formation of a thermoformed cap of said backlit button from said thermoformable sheet; retaining said thermoformed cap within said die until cooled; transferring said thermoformed cap into an injection molding apparatus; and injection molding a resin compound into said thermoformed cap so as to define a light passageway within said thermoformed cap which is axially aligned with said graphic display of said thermoformed cap so as to conduct light from a light source to said graphic display and thereby illuminate said graphic display, said thermoformed cap, said light passageway, and said resin compound comprising said backlit button.

Claim 18

A backlit button produced within a thermoforming die comprising a female mold by performing the following sequence of method steps of: providing a sheet of thermoformable material having a first side and a second side; providing a graphic display upon a portion of one of said first and second sides of said thermoformable sheet; positioning and securing said thermoformable sheet within said thermoforming die such that said graphic display is disposed at a predetermined position within said thermoforming die; heating said thermoformable sheet to a first temperature while maintaining said portion of said thermoformable sheet upon which said graphic display is disposed at a second temperature which is less than said first temperature so as to effectively heat insulate said portion of said thermoformable sheet upon which said graphic display is disposed and thereby prevent variation and distortion of said graphic display as a result of heating said thermoformable sheet to said first temperature; evacuating said female mold of said thermoforming die, toward which one side of said thermoformable sheet is disposed, so as to reduce the gas pressure within said female mold and cause movement of said thermoformable sheet into said female mold of said die, and elevating the gas pressure upon the other opposite side of said thermoformable sheet so as to assist said movement of said thermoformable sheet into said female mold of said die and thereby cause formation of a thermoformed cap of said backlit button from said thermoformable sheet; retaining said thermoformed cap within said die until cooled; transferring said thermoformed cap into an injection molding apparatus; and injection molding a resin compound into said thermoformed cap so as to define a light passageway within said thermoformed cap which is axially aligned with said graphic display of said thermoformed cap so as to conduct light from a light source to said graphic display and thereby illuminate said graphic display, said thermoformed cap, said light passageway, and said resin compound comprising said backlit button.

Claim 19

A backlit button, to be produced within a thermoforming die comprising a female mold, comprising: a sheet of thermoformable material which is capable of being heated within said thermoforming die and which has a first side and a second side wherein one of said first and second sides is disposed within said thermoforming die so as to be subjected to a gas having a first pressure while a second one of said first and second sides is disposed within said thermoforming die so as to be subjected to a second reduced gas pressure so as to cause movement of said thermoformable sheet material into said female mold of said thermoforming die and thereby cause formation of a thermoformed cap within said female mold of said thermoforming die; a graphic display disposed at a predetermined position upon one side of said thermoformable sheet so as to be disposed at a predetermined position upon said thermoformed cap when said thermoformable sheet is formed into said thermoformed cap within said female mold of said thermoforming die; a light pipe disposed within said thermoformed cap so as to be axially aligned with said graphic display portion of said thermoformed cap so as to conduct light from a light source to said graphic display portion of said thermoformed cap and thereby illuminate said graphic display portion of said thermoformed cap; and resin compound material injection molded within said thermoformed cap and about said light pipe disposed within said thermoformed cap for integrally bonding said light pipe and said thermoformed cap together, said thermoformed cap, said light pipe, and said resin compound material comprising said backlit button.

Claim 20

A backlit button, to be produced within a thermoforming die comprising a female mold, comprising: a sheet of thermoformable material which is capable of being heated within said thermoforming die and which has a first side and a second side wherein one of said first and second sides is disposed within said thermoforming die so as to be subjected to a gas having a first pressure while a second one of said first and second sides is disposed within said thermoforming die so as to be subjected to a second reduced gas pressure so as to cause movement of said thermoformable sheet material into said female mold of said thermoforming die and thereby cause formation of a thermoformed cap within said female mold of said thermoforming die; a graphic display disposed at a predetermined position upon one side of said thermoformable sheet so as to be disposed at a predetermined position upon said thermoformed cap when said thermoformable sheet is formed into said thermoformed cap within said female mold of said thermoforming die; a light pipe disposed within said thermoformed cap so as to be axially aligned with said graphic display portion of said thermoformed cap so as to conduct light from a light source to said graphic display portion of said thermoformed cap and thereby illuminate said graphic display portion of said thermoformed cap; and resin compound material injection molded within said thermoformed cap and about said light pipe disposed within said thermoformed cap for integrally bonding said light pipe and said thermoformed cap together, said thermoformed cap, said light pipe, and said resin compound material comprising said backlit button.

Claim 21

A backlit button as set forth in claim 15, wherein: said graphic display comprises a screen-printed graphic display.

Claim 22

A backlit button as set forth in claim 15, wherein: said thermoformable sheet material is heated to a temperature which is within the range of 335° F.-480° F.

Claim 23

A backlit button as set forth in claim 15, wherein: said thermoformable sheet material comprises a polyester-polycarbonate polymer blend.

Claim 24

A backlit button as set forth in claim 18, wherein: said graphic display comprises a screen-printed graphic display comprising an ink having a cross-linked component which is adherent to and compatible with said polyester-polycarbonate sheet.

Claim 25

A backlit button as set forth in claim 15, wherein: said first pressure of said gas disposed upon said one of said first and second sides of said thermoformable sheet is at least 25 pounds per square inch.

Claim 26

A backlit button, to be produced within a thermoforming die comprising a female mold, comprising: a sheet of thermoformable material which is capable of being heated to a first temperature within said thermoforming die and which has a first side and a second side wherein one of said first and second sides is disposed within said thermoforming die so as to be subjected to a gas having a first pressure while a second one of said first and second sides is disposed within said thermoforming die so as to be subjected to a second reduced gas pressure so as to cause movement of said thermoformable sheet material into said female mold of said thermoforming die and thereby cause formation of a thermoformed cap within said female mold of said thermoforming die; a graphic display disposed at a predetermined position upon one side of said thermoformable sheet so as to be disposed at a predetermined position upon said thermoformed cap when said thermoformable sheet is formed into said thermoformed cap within said female mold of said thermoforming die such that said graphic display is subjected to a second temperature within said thermoforming die which is less than said first temperature to which said thermoformable sheet is heated within said thermoforming die so as to effectively heat insulate said graphic display portion of said thermoformable sheet and thereby prevent variation and distortion of said graphic display as a result of said heating of said thermoformable sheet to said first temperature within said thermoforming die; a light pipe disposed within said thermoformed cap so as to be axially aligned with said graphic display portion of said thermoformed cap so as to conduct light from a light source to said graphic display portion of said thermoformed cap and thereby illuminate said graphic display portion of said thermoformed cap; and resin compound material injection molded within said thermoformed cap and about said light pipe disposed within said thermoformed cap for securing said light pipe within said thermoformed cap, said thermoformed cap, said light pipe, and said resin compound material comprising said backlit button.

Claim 27

A backlit button, to be produced within a thermoforming die comprising a female mold, comprising: a sheet of thermoformable material which is capable of being heated to a first temperature within said thermoforming die and which has a first side and a second side wherein one of said first and second sides is disposed within said thermoforming die so as to be subjected to a gas having a first pressure while a second one of said first and second sides is disposed within said thermoforming die so as to be subjected to a second reduced gas pressure so as to cause movement of said thermoformable sheet material into said female mold of said thermoforming die and thereby cause formation of a thermoformed cap within said female mold of said thermoforming die; a graphic display disposed at a predetermined position upon one side of said thermoformable sheet so as to be disposed at a predetermined position upon said thermoformed cap when said thermoformable sheet is formed into said thermoformed cap within said female mold of said thermoforming die such that said graphic display is subjected to a second temperature within said thermoforming die which is less than said first temperature to which said thermoformable sheet is heated within said thermoforming die so as to effectively heat insulate said graphic display portion of said thermoformable sheet and thereby prevent variation and distortion of said graphic display as a result of said heating of said thermoformable sheet to said first temperature within said thermoforming die; a light pipe disposed within said thermoformed cap so as to be axially aligned with said graphic display portion of said thermoformed cap so as to conduct light from a light source to said graphic display portion of said thermoformed cap and thereby illuminate said graphic display portion of said thermoformed cap; and resin compound material injection molded within said thermoformed cap and about said light pipe disposed within said thermoformed cap for securing said light pipe within said thermoformed cap, said thermoformed cap, said light pipe, and said resin compound material comprising said backlit button.

Claim 28

A backlit button, to be produced within a thermoforming die comprising a female mold, comprising: a sheet of thermoformable material which is capable of being heated within said thermoforming die and which has a first side and a second side wherein one of said first and second sides is disposed within said thermoforming die so as to be subjected to a gas having a first pressure while a second one of said first and second sides is disposed within said thermoforming die so as to be subjected to a second reduced gas pressure so as to cause movement of said thermoformable sheet material into said female mold of said thermoforming die and thereby cause formation of a thermoformed cap within said female mold of said thermoforming die; a graphic display disposed at a predetermined position upon one side of said thermoformable sheet so as to be disposed at a predetermined position upon said thermoformed cap when said thermoformable sheet is formed into said thermoformed cap within said female mold of said thermoforming die; and resin compound material means disposed within said thermoformed cap for defining a longitudinal light passageway, within said resin compound material means and therefore within said thermoformed cap, which is linear along its longitudinal extent and which is axially aligned with said graphic display of said thermoformed cap so as to conduct light from a light source to said graphic display and thereby illuminate said graphic display, said thermoformed cap, said light passageway, and said resin compound material means comprising said backlit button.

Claim 29

A backlit button, to be produced within a thermoforming die comprising a female mold, comprising: a sheet of thermoformable material which is capable of being heated within said thermoforming die and which has a first side and a second side wherein one of said first and second sides is disposed within said thermoforming die so as to be subjected to a gas having a first pressure while a second one of said first and second sides is disposed within said thermoforming die so as to be subjected to a second reduced gas pressure so as to cause movement of said thermoformable sheet material into said female mold of said thermoforming die and thereby cause formation of a thermoformed cap within said female mold of said thermoforming die; a graphic display disposed at a predetermined position upon one side of said thermoformable sheet so as to be disposed at a predetermined position upon said thermoformed cap when said thermoformable sheet is formed into said thermoformed cap within said female mold of said thermoforming die; and resin compound material means disposed within said thermoformed cap for defining a longitudinal light passageway, within said resin compound material means and therefore within said thermoformed cap, which is linear along its longitudinal extent and which is axially aligned with said graphic display of said thermoformed cap so as to conduct light from a light source to said graphic display and thereby illuminate said graphic display, said thermoformed cap, said light passageway, and said resin compound material means comprising said backlit button.

Claim 30

A backlit button as set forth in claim 22, wherein: said graphic display comprises a screen-printed graphic display.

Claim 31

A backlit button as set forth in claim 22, wherein: said thermoformable sheet material is heated to a temperature which is within the range of 335° F.-480° F.

Claim 32

A backlit button as set forth in claim 22, wherein: said thermoformable sheet material comprises a polyester-polycarbonate polymer blend.

Claim 33

A backlit button as set forth in claim 25, wherein: said graphic display comprises a screen-printed graphic display comprising an ink having a cross-linked component which is adherent to and compatible with said polyester-polycarbonate sheet.

Claim 34

A backlit button as set forth in claim 22, wherein: said first pressure of said gas disposed upon said one of said first and second sides of said thermoformable sheet is at least 25 pounds per square inch.

Claim 35

A backlit button, to be produced within a thermoforming die comprising a female mold, comprising: a sheet of thermoformable material which is capable of being heated to a first temperature within said thermoforming die and which has a first side and a second side wherein one of said first and second sides is disposed within said thermoforming die so as to be subjected to a gas having a first pressure while a second one of said first and second sides is disposed within said thermoforming die so as to be subjected to a second reduced gas pressure so as to cause movement of said thermoformable sheet material into said female mold of said thermoforming die and thereby cause formation of a thermoformed cap within said female mold of said thermoforming die; a graphic display disposed at a predetermined position upon one side of said thermoformable sheet so as to be disposed at a predetermined position upon said thermoformed cap when said thermoformable sheet is formed into said thermoformed cap within said female mold of said thermoforming die such that said graphic display is subjected to a second temperature within said thermoforming die which is less than said first temperature to which said thermoformable sheet is heated within said thermoforming die so as to effectively heat insulate said graphic display portion of said thermoformable sheet and thereby prevent variation and distortion of said graphic display as a result of said heating of said thermoformable sheet to said first temperature within said thermoforming die; and resin compound material means disposed within said thermoformed cap for defining a light passageway within said thermoformed cap which is axially aligned with said graphic display of said thermoformed cap so as to conduct light from a light source to said graphic display so as to illuminate said graphic display, said thermoformed cap, said light passageway, and said resin compound material means comprising said backlit button.

Claim 36

A backlit button, to be produced within a thermoforming die comprising a female mold, comprising: a sheet of thermoformable material which is capable of being heated to a first temperature within said thermoforming die and which has a first side and a second side wherein one of said first and second sides is disposed within said thermoforming die so as to be subjected to a gas having a first pressure while a second one of said first and second sides is disposed within said thermoforming die so as to be subjected to a second reduced gas pressure so as to cause movement of said thermoformable sheet material into said female mold of said thermoforming die and thereby cause formation of a thermoformed cap within said female mold of said thermoforming die; a graphic display disposed at a predetermined position upon one side of said thermoformable sheet so as to be disposed at a predetermined position upon said thermoformed cap when said thermoformable sheet is formed into said thermoformed cap within said female mold of said thermoforming die such that said graphic display is subjected to a second temperature within said thermoforming die which is less than said first temperature to which said thermoformable sheet is heated within said thermoforming die so as to effectively heat insulate said graphic display portion of said thermoformable sheet and thereby prevent variation and distortion of said graphic display as a result of said heating of said thermoformable sheet to said first temperature within said thermoforming die; and resin compound material means disposed within said thermoformed cap for defining a light passageway within said thermoformed cap which is axially aligned with said graphic display of said thermoformed cap so as to conduct light from a light source to said graphic display so as to illuminate said graphic display, said thermoformed cap, said light passageway, and said resin compound material means comprising said backlit button.