Abstract: Various embodiments are disclosed herein that relate to the molding of an item having a non-uniform thickness and an undercut structure. One disclosed embodiment provides an injection molding device for molding a part having a non-uniform thickness and an undercut structure, the injection molding device comprising a pair of opposing end walls, a first mold surface being stationary with respect to the pair of opposing end walls, and a second mold surface being movable toward the first mold surface such that a first end of the second mold surface is movable a larger travel distance toward the first mold surface than a second end during a molding process. Further, the pair of opposing end walls comprises a slider with an undercut mold surface that is movable in a direction transverse to a direction in which the second mold surface is movable toward the first mold surface.

Abstract: Various embodiments are disclosed relating to fabrication of an optical wedge. For example, one embodiment provides a method for manufacturing an optical wedge comprising inserting a wedge blank into a vacuum molding tool and applying a vacuum to the vacuum molding tool to temporarily hold the wedge blank against a molding surface of the vacuum molding tool. The method further comprises removing a layer from a top surface of the wedge blank to expose a machined surface of the wedge blank, and casting a finish layer on the machined surface to form a finish layer of a finished optical wedge.

Abstract: Various embodiments are disclosed herein that relate to the molding of an item having a non-uniform thickness and an undercut structure. One disclosed embodiment provides an injection molding device for molding a part having a non-uniform thickness and an undercut structure, the injection molding device comprising a pair of opposing end walls, a first mold surface being stationary with respect to the pair of opposing end walls, and a second mold surface being movable toward the first mold surface such that a first end of the second mold surface is movable a larger travel distance toward the first mold surface than a second end during a molding process. Further, the pair of opposing end walls comprises a slider with an undercut mold surface that is movable in a direction transverse to a direction in which the second mold surface is movable toward the first mold surface.

Abstract: In one or more embodiments, wedge light guides are constructed that are monolithic in nature and include integrally-formed optical concentrators. The wedge light guide and its associated optical concentrators are defined by a mold. In at least some embodiments, structure within the mold that defines the optical concentrators can be used as injection ports through which formation material can be injected to form the monolithic wedge light guide.

Abstract: Embodiments related to the fabrication of a light guide are provided. One disclosed embodiment comprises extruding a thermoplastic polymer through a die to form an extrusion, machining the extrusion to one or more fixed dimensions, and maintaining a face of the extrusion in contact with a heated mold surface to soften or melt the face of the extrusion while applying pressure to the extrusion.

Abstract: Embodiments are disclosed that relate to casting of an optical part having a non-uniform thickness. For example, one disclosed embodiment provides a method for casting an optical part having a non-uniform thickness, the method including adding a fluid material into a first cavity and into a second cavity separated from the first cavity by a separator. The first and second cavities may each have a non-uniform thickness and the separator may have a configuration complementary to shapes of the first and second cavities such that the first cavity, the second cavity, and the separator form a combined structure having a uniform thickness during a casting process. The method further comprises solidifying the fluid material in the first and second cavities to form the first and second optical parts.

Abstract: Injection molding of a part having a nonuniform thickness is provided. One disclosed embodiment of an injection molding device includes one or more side walls, a first mold surface intersecting the side walls and being stationary with respect to the side walls, and a second mold surface intersecting the side walls so as to define with the side walls and the first mold surface a cavity configured to receive a metered amount of injected molten thermoplastic material. The second mold surface is moveable toward the first mold surface in such a manner that a first end of the second mold surface moves a larger physical travel distance toward the first mold surface than does a second end of the second mold surface during a molding process.

Abstract: Embodiments are disclosed that relate to fabrication of a laminated optical wedge. One embodiment provides a method comprising inserting a wedge blank into a vacuum molding tool, applying a vacuum to the vacuum molding tool, and removing a layer from a top surface of the wedge blank to expose a machined surface of the wedge blank. The method further comprises laminating a finish piece to the machined surface via an adhesive, wherein the finish piece comprises a smoother surface than the machined surface, and curing the adhesive to form a finished optical wedge. The method further comprises removing the finished optical wedge from the vacuum molding tool.

Abstract: Various embodiments are disclosed herein that relate to the molding of an item having a non-uniform thickness and an undercut structure. One disclosed embodiment provides an injection molding device for molding a part having a non-uniform thickness and an undercut structure, the injection molding device comprising a pair of opposing end walls, a first mold surface being stationary with respect to the pair of opposing end walls, and a second mold surface being movable toward the first mold surface such that a first end of the second mold surface is movable a larger travel distance toward the first mold surface than a second end during a molding process. Further, the pair of opposing end walls comprises a slider with an undercut mold surface that is movable in a direction transverse to a direction in which the second mold surface is movable toward the first mold surface.

Abstract: Various methods of making an interactive keyboard in which a plurality of mechanically-depressible keys are situated over a display device, each of the mechanically-depressible keys being configured to permit through-key viewing of images produced by the display device, is provided. One example method includes providing a mold which defines a mold cavity. The method further includes introducing keycap material into the mold cavity. In such an example, the keycap material and the mold interact to produce a molded keycap having a viewing portion with one or more optical layers that are at least partially see-through and configured to provide one or more optical effects in connection with light that is incident upon the one or more optical layers.

Abstract: A display and input system configured to receive tactile user input and provide dynamic display output is provided. The system includes a display device and a plurality of input locations situated over the display device. Each of the input locations is at least partially see-through to permit viewing of imagery generated by the display device, where each of the input locations includes an optical element spaced from an operative surface of the display device and configured to adjust viewer perception of image light emanating from the display device through input location. The display and input system may also be implemented to include mechanically-depressible keys providing keyboard-type input functionality.

Abstract: A keyboard for use with a computing device and a method of manufacturing a keyboard key are provided. One disclosed keyboard includes a plurality of keys, each key having a key cap including a perimeter wall and a void positioned within the perimeter wall and opening to a top of the key cap. Each key further includes a cushion having a top portion configured to be contacted by a digit of a user and a bottom portion configured to be fitted within the void in the key cap. The cushion being may be configured to absorb an impact force directed against the key during a keystroke.

Abstract: Embodiments related to the fabrication of a light guide are provided. One disclosed embodiment comprises extruding a thermoplastic polymer through a die to form an extrusion, machining the extrusion to one or more fixed dimensions, and maintaining a face of the extrusion in contact with a heated mold surface to soften or melt the face of the extrusion while applying pressure to the extrusion.

Abstract: Various embodiments are disclosed relating to fabrication of an optical wedge. For example, one embodiment provides a method for manufacturing an optical wedge comprising inserting a wedge blank into a vacuum molding tool and applying a vacuum to the vacuum molding tool to temporarily hold the wedge blank against a molding surface of the vacuum molding tool. The method further comprises removing a layer from a top surface of the wedge blank to expose a machined surface of the wedge blank, and casting a finish layer on the machined surface to form a finish layer of a finished optical wedge.

Abstract: Embodiments related to the fabrication of a light guide are provided. One disclosed embodiment comprises extruding a thermoplastic polymer through a die to form an extrusion, machining the extrusion to one or more fixed dimensions, and maintaining a face of the extrusion in contact with a heated mold surface to soften or melt the face of the extrusion while applying pressure to the extrusion.

Abstract: Injection molding of a part having a nonuniform thickness is provided. One disclosed embodiment of an injection molding device includes one or more side walls, a first mold surface intersecting the side walls and being stationary with respect to the side walls, and a second mold surface intersecting the side walls so as to define with the side walls and the first mold surface a cavity configured to receive a metered amount of injected molten thermoplastic material. The second mold surface is moveable toward the first mold surface in such a manner that a first end of the second mold surface moves a larger physical travel distance toward the first mold surface than does a second end of the second mold surface during a molding process.

Abstract: Injection molding of a part having a nonuniform thickness is provided. One disclosed embodiment of an injection molding device includes one or more side walls, a first mold surface intersecting the side walls and being stationary with respect to the side walls, and a second mold surface intersecting the side walls so as to define with the side walls and the first mold surface a cavity configured to receive a metered amount of injected molten thermoplastic material. The second mold surface is moveable toward the first mold surface in such a manner that a first end of the second mold surface moves a larger physical travel distance toward the first mold surface than does a second end of the second mold surface during a molding process.

Abstract: Injection molding of a part having a nonuniform thickness is provided. One disclosed embodiment of an injection molding device includes one or more side walls, a first mold surface intersecting the side walls and being stationary with respect to the side walls, and a second mold surface intersecting the side walls so as to define with the side walls and the first mold surface a cavity configured to receive a metered amount of injected molten thermoplastic material. The second mold surface is moveable toward the first mold surface in such a manner that a first end of the second mold surface moves a larger physical travel distance toward the first mold surface than does a second end of the second mold surface during a molding process.

Abstract: Embodiments are disclosed herein that are related to input devices with curved multi-touch surfaces. One disclosed embodiment comprises a touch-sensitive input device having a curved geometric feature comprising a touch sensor, the touch sensor comprising an array of sensor elements integrated into the curved geometric feature and being configured to detect a location of a touch made on a surface of the curved geometric feature.

Abstract: Embodiments are disclosed herein that are related to input devices with curved multi-touch surfaces. For example, in one disclosed embodiment, a method of making a multi-touch input device having a curved touch-sensitive surface comprises forming on a substrate an array of sensor elements defining a plurality of pixels of the multi-touch sensor, forming the substrate into a shape that conforms to a surface of the curved geometric feature of the body of the input device, and fixing the substrate to the curved geometric feature of the body of the input device.