A molded object, which is thermoformed by a thermoplastic wear-resistant molding membrane, has a plurality of concave-convex parts; the molded object comprises: a polycarbonate polyurethane (PU) layer; a thermoplastic polyurethane (PU) layer with ductility and elasticity, disposed on one surface of the polycarbonate PU layer; and an intermediate PU layer disposed between the polycarbonate PU layer and the thermoplastic PU layer; the polycarbonate PU layer is a surface layer of the molded object, the thermoplastic PU layer is an inner layer of the molded object; the concave-convex part comprises a plurality of upwardly protruding pressing parts, each of the pressing parts has a top wall and a peripheral wall extending downward from a periphery of the top wall; at least one character is disposed on the top wall of each of the pressing parts, and the character is formed by at least removing a material of the polycarbonate PU layer, so that the top wall forms a hollow part penetrating the polycarbonate PU layer.

Apparatuses, methods, and systems are disclosed for attaching structures. One system includes: a device having a first structure attached to a second structure; a first polymer coupled to the first structure, wherein the first polymer has a first temperature profile and a first shape; and a second polymer coupled to the second structure. The second polymer has a second temperature profile and a second shape. The second shape interlocks the first shape. The first polymer and the second polymer secure the first structure to the second structure in response to the first polymer and the second polymer being in a first temperature range. The first polymer and the second polymer release the first structure from the second structure in response to the first polymer and the second polymer being in a second temperature range different from the first temperature range.

A keycap forming method includes the following steps. Firstly, a stabilizer bar is fixed on a first male mold. Then, a keycap is formed through a second male mold and a female mold according to an injection molding process. Then, the second male mold and the female mold are separated from each other, so that the keycap is fixed on the female mold. Then, the first male mold and the female mold are stacked on each other, so that the stabilizer bar and the keycap are combined together. Then, the first male mold and the female mold are separated from each other. Consequently, the stabilizer bar is detached from the first male mold. By using the keycap forming method, it is not necessary to manually assemble the stabilizer bar with the keycap.

A process for forming a two layer plastic device with textures or drawings thereon and a structure formed by the structure are provided. An inner bottom layer has textures or drawings on the surface thereof which includes at least one enclosing space. A through hole is formed on the enclosing space so that the masking material can be filled into the space between the outer mold and the inner mold. Then the masking material enters into the enclosing space through the through hole. As a result, only one mold (the outer mold) is necessary for forming the masking layer, while in the prior art, two molds are needed. The whole process can be completed mechanically without any manual operation. A color of the masking layer may be different from that of the inner bottom layer so that the textures or drawings clearly exposes on the surface of the masking layer.

A method for manufacturing a base plate for a keyboard includes the steps of: a) providing a mold assembly including a female mold and a male mold, b) preparing a composite laminate which includes a carbon fiber layer and a thermoplastic resin layer, and which is formed with a plurality of positioning holes, c) disposing the composite laminate in the female mold, and combining the female and male molds, and d) injecting a plastic material to form positioning blocks which binds to the thermoplastic resin layer and integrates with the composite laminate to form the base plate.

Apparatuses, methods, and systems are disclosed for attaching structures. One system includes: a device having a first structure attached to a second structure; a first polymer coupled to the first structure, wherein the first polymer has a first temperature profile and a first shape; and a second polymer coupled to the second structure. The second polymer has a second temperature profile and a second shape. The second shape interlocks the first shape. The first polymer and the second polymer secure the first structure to the second structure in response to the first polymer and the second polymer being in a first temperature range. The first polymer and the second polymer release the first structure from the second structure in response to the first polymer and the second polymer being in a second temperature range different from the first temperature range.

A process for forming a two layer plastic device with textures or drawings thereon and a structure formed by the structure are provided. An inner bottom layer has textures or drawings on the surface thereof which includes at least one enclosing space. A through hole is formed on the enclosing space so that the masking material can be filled into the space between the outer mold and the inner mold. Then the masking material enters into the enclosing space through the through hole. As a result, only one mold (the outer mold) is necessary for forming the masking layer, while in the prior art, two molds are needed. The whole process can be completed mechanically without any manual operation. A color of the masking layer may be different from that of the inner bottom layer so that the textures or drawings clearly exposes on the surface of the masking layer.

A keycap forming method includes the following steps. Firstly, a stabilizer bar is fixed on a first male mold. Then, a keycap is formed through a second male mold and a female mold according to an injection molding process. Then, the second male mold and the female mold are separated from each other, so that the keycap is fixed on the female mold. Then, the first male mold and the female mold are stacked on each other, so that the stabilizer bar and the keycap are combined together. Then, the first male mold and the female mold are separated from each other. Consequently, the stabilizer bar is detached from the first male mold. By using the keycap forming method, it is not necessary to manually assemble the stabilizer bar with the keycap.

A keyboard membrane, which is a thin sheet molded object thermoformed by a thermoplastic wear-resistant molding membrane, comprising a plurality of concave-convex parts, the concave-convex part comprises a plurality of upwardly protruding pressing parts, each of the pressing parts has a top wall and a peripheral wall extending downward from a periphery of the top wall; the keyboard membrane is disposed on a key module with keys; each of the pressing parts is connected with one of the keys of the key module; a periphery of the keyboard membrane has a peripheral edge extending outward from the pressing part, and the peripheral edge wraps the key module to form a waterproof and dustproof keyboard.

Disclosed herein is an integrated embossing and injection molding tool that is used to overmold a frame on an embossed material. The embossed material and the frame may be used as a keyboard component of keyboard for a portable electronic device.