ELECTRICAL SWITCH

• US 20080017491A1
• Filed: 12/01/2006
• Published: 01/24/2008
• Est. Priority Date: 12/05/2005
• Status: Active Grant

• Current Assignee: Omron Dualtec Automotive Electronics, Inc. (Omron Corporation)
• Original Assignee: Omron Dualtec Automotive Electronics, Inc. (Omron Corporation)
• Inventors: Rest, Darren, Azizi, Farzad, Larsen, Christopher
• Granted Patent: US 7,507,923 B2
• Time in Patent Office: Days
• US Class Current: 200/295
• CPC Class Codes: H01H 2215/006 Only mechanical function
• CPC Class Codes: H01H 2225/018 Consecutive operations
• CPC Class Codes: H01H 2229/034 Positioning of layers
• CPC Class Codes: H01H 2229/038 Folding of flexible printed circuit
• CPC Class Codes: H01H 23/003 with more than one electrically distinguishable condition in one or both positions
• CPC Class Codes: H01H 2300/01 Application power window

Abstract

A low profile switch assembly is provided having a base portion that supports a folded flexible circuit sealed about its edges, an overlying deformable elastomeric portion, and a pair of window knobs. The base portion has a pair of integrally formed, upwardly extending posts that pivotally support the window knobs and encourage alignment of the flexible circuit and the overlying elastomeric pad. A series of domes are formed in the elastomeric pad, pairs of which are operated sequentially by the window knob acting on a lever bridging the pairs of domes. The domes, when collapsed, compress portions of the flexible circuit to bridge opposing traces within the folded circuit to actuate respective switches. The arrangement of the components provides a low profile device that inhibits contamination and uses fewer parts.

Claims

1. A switch assembly comprising a base portion having at least one integrally formed post extending upwardly therefrom, the post for pivotally supporting an actuation button, the base portion supporting a flexible circuit portion interposed between the base portion and an elastomeric portion, the elastomeric portion having at least one collapsible dome formed therein, wherein the button interacts with the at least one dome upon pivotal movement thereof to collapse the dome and compress and operate the flexible circuit portion.

2. A switch assembly according to claim 1 wherein the flexible circuit portion comprises a unitary flexible circuit board folded over itself along an edge.

3. A switch assembly according to claim 2 wherein the flexible circuit portion comprises a pair of opposing contacts for each dome that are engaged upon compression of the flexible circuit portion to close a switch.

4. A switch assembly according to claim 3 wherein the flexible circuit portion comprises an intermediate layer between an upper portion and lower portion of the unitary flexible circuit board, the intermediate layer maintaining a separation between the opposing contacts prior to the dome compressing the flexible circuit portion.

5. A switch assembly according to claim 4 wherein the intermediate layer comprises an aperture aligned with each pair of opposing contacts.

6. A switch assembly according to claim 2 wherein the unitary flexible circuit portion is sealed about its periphery.

7. A switch assembly according to claim 1 wherein the flexible circuit portion is shaped such that it surrounds the at least one post and is substantially flat on the base portion.

8. A switch assembly according to claim 1 wherein the flexible circuit portion comprises one or more apertures for receiving corresponding nubs on the elastomeric portion that are in turn received by corresponding apertures in the base portion.

9. A switch assembly according to claim 1 comprising a first dome and a second dome bridged by a first lever, the first lever being operated on by the actuation button at a point along its length offset from center such that the first dome engages the flexible circuit portion before the second dome engages the flexible circuit portion to provide a sequential operation of the first and second domes.

10. A switch assembly according to claim 9 wherein the first dome comprises a first downward protrusion that extends towards the flexible circuit portion and the second dome comprises a second downward protrusion that extends towards the flexible circuit portion, the first protrusion being closer to the flexible circuit portion than the second protrusion.

11. A switch assembly according to claim 9 wherein the first and second domes comprise nubs for securing the first lever thereto by inserting the nubs into corresponding apertures on the first lever.

12. A switch assembly according to claim 9 comprising a third dome and a fourth dome bridged by a second lever, the second lever being operated on by the actuation button at a point along its length offset from center such that the third dome engages the flexible circuit portion before the fourth dome engages the flexible circuit portion to provide a sequential operation of the third and fourth domes;

wherein the first lever is operated on upon movement of the actuation button in a first direction and the second lever is operated on upon movement of the actuation button in a second direction.

13. A switch assembly according to claim 12 where the post extends between the first and second domes and the third and fourth domes.

14. A switch assembly according to claim 1 wherein the elastomeric portion includes an aperture for permitting passage of each of the at least one post therethrough.

15. A switch assembly according to claim 1 wherein the elastomeric portion includes a downwardly extending skirt covering an edge of the base portion to completely cover the flexible circuit portion.

16. A switch assembly according to claim 6 wherein the elastomeric portion includes a downwardly extending skirt covering an edge of the base portion to completely cover the flexible circuit portion.

17. A switch assembly according to claim 1 wherein the elastomeric portion comprises an aperture for receiving an upwardly extending protrusion on the base portion to align the elastomeric portion with the base portion and flexible circuit portion.

18. A switch assembly according to claim 12 a first post extending between the first and second domes and the third and fourth domes, the first post, first dome, second dome, third dome and fourth dome defining a first switching unit, the base portion comprising a second post extending between fifth, sixth, seventh and eighth domes to form a second switching unit.

19. A switch assembly according to claim 18 wherein the flexible circuit portion comprises a unitary flexible circuit board folded over itself along an edge, the flexible circuit portion comprising a pair of opposing contacts for each dome that are engaged upon compression of the flexible circuit portion to close a switch;

and an intermediate layer between an upper portion and lower portion of the unitary flexible circuit board, the intermediate layer maintaining a separation between the opposing contacts prior to the dome compressing the flexible circuit portion;

wherein the intermediate layer comprises an aperture aligned with each pair of opposing contacts and the unitary flexible circuit portion is sealed about its periphery and wherein the elastomeric portion includes a downwardly extending skirt covering an edge of the base portion to completely cover the flexible circuit portion.

20. A method for assembling a switch comprising:

providing a base portion having at least one integrally formed post extending upwardly therefrom, the post for pivotally supporting an actuation button;

arranging a flexible circuit portion over the base portion such that it lies substantially flat thereon;

arranging an elastomeric portion over the flexible circuit portion, the elastomeric portion having at least one collapsible dome formed therein; and

pivotally attaching the actuation button to the post, wherein upon pivotal movement of the actuation button, the actuation button interacts with the at least one dome to collapse the dome and compress and operate the flexible circuit portion.

21. A method according to claim 20 wherein prior to arranging the flexible circuit portion the method comprises folding a unitary flexible circuit board over itself, sealing the flexible circuit board along an edge.

22. A method according to claim 20 wherein arranging the elastomeric portion comprises extending a skirt of the elastomeric portion over an edge of the base portion.