Multi-component button and a method of manufacturing it

• US 6,591,457 B1
• Filed: 06/08/2000
• Issued: 07/15/2003
• Est. Priority Date: 06/08/2000
• Status: Expired due to Fees

• Current Assignee: The Grigoleit Company
• Original Assignee: The Grigoleit Company
• Inventors: Howie, Robert K. Jr.
• Primary Examiner(s): Estremsky, Gary
• Assistant Examiner(s): WILLIAMS, MARK A
• Application Number:
  US09/590,409
• Time in Patent Office: 1,132 Days
• Field of Search: 164/41, 164/33, 16D/IG.18, 264/254, 264/275, 264/279, 264/279.1, 428/35.7, 428/195, 428/159, 428/161, 403/25, 362/26, 362/30, 362/28, 362/29, 362/100, 292/347
• US Class Current: 16/441
• CPC Class Codes: B29C 45/14467 Joining articles or parts of a single article B29C45/14377, B29C45/14385, B29C45/14581, B29C45/14614 and B29C45/006 take precedence
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29L 2031/466 Keypads, keytops
• CPC Class Codes: G05G 1/02 Controlling members for hand actuation by linear movement, e.g. push buttons
• CPC Class Codes: H01H 13/04 Cases; Covers
• CPC Class Codes: H01H 13/14 Operating parts, e.g. push-button
• CPC Class Codes: H01H 2011/0081 using double shot moulding, e.g. for forming elastomeric sealing elements on form stable casing
• CPC Class Codes: H01H 2209/0021 with metallic appearance, e.g. polymers with dispersed particles to produce a metallic appearance
• CPC Class Codes: H01H 2219/028 Printed information
• CPC Class Codes: H01H 2229/048 Insertion moulding

Abstract

A multi-component button and a method of making it. The button includes a plastic core having a top surface with a projection in the shape of an icon upstanding on the top surface. A thin piece of metal is seated on the top surface of the core and receives the icon. A plastic shell engages the outer edges of the thin piece of metal and forms side and end walls around the core. The method includes forming the core, positioning the metal piece on the top of the core and molding a plastic shell around the outer edges of the metal sheet and the side and end walls of the core.

Claims

1. A multi-component button including:

a plastic core having a top surface,

a projection in the shape of an icon upstanding on said top surface,

a thin piece of metal seated on said top surface of said core,

said thin piece of metal having outer edges,

a passage extending through said thin piece of metal,

said passage shaped to closely receive and allow said projection to extend through said thin piece of metal when said thin piece of metal is seated on said top surface of said core, and

a plastic shell engaging the outer edges of said thin piece of metal and having at least side and end walls surrounding said plastic core.

2. The multi-component button of claim 1 in which said top surface of said plastic core is convex and said thin piece of metal conforms to said top surface of said plastic core.

3. A method of making a multi-component button including the steps of:

forming a plastic core having a top surface and a projection in the shape of an icon upstanding on said top surface,

forming a thin piece of metal in substantially the same shape as said top surface of said plastic core,

forming a passage through said thin piece of metal with said passage having substantially the same shape as said projection,

seating said thin piece of metal on said top surface of said plastic core with said passage fitting over and receiving said projection, and

molding a plastic shell around at least some portions of said core and some portions of said thin sheet of metal to attach said thin sheet of metal to said top surface of said core.

4. The method of claim 3 in which said plastic core is formed with a convex top surface, said thin piece of metal is formed to be substantially flat and said thin sheet of metal is bent to conform to said convex top surface of said core before said plastic shell is molded around said core.