Membrane switch

• US 5,561,278 A
• Filed: 09/16/1994
• Issued: 10/01/1996
• Est. Priority Date: 09/16/1994
• Status: Expired due to Term

• Current Assignee: Nelson Name Plate Company
• Original Assignee: Phillip Rutten
• Inventors: Rutten, Phillip
• Primary Examiner(s): Brown, Brian W.
• Assistant Examiner(s): Friedhofer, Michael A.
• Application Number:
  US08/307,898
• Time in Patent Office: 746 Days
• Field of Search: 200/5 A, 200/512-517, 200/341
• US Class Current: 200/5.00A
• CPC Class Codes: H01H 13/702 with contacts carried by or formed from layers in a multilayer structure, e.g. membrane switches
• CPC Class Codes: H01H 13/80 characterised by the manner of cooperation of the contacts, e.g. with both contacts movable or with bounceless contacts
• CPC Class Codes: H01H 2201/008 Both contacts movable
• CPC Class Codes: H01H 2209/07 metallic
• CPC Class Codes: H01H 2215/002 Longer travel
• CPC Class Codes: H01H 2215/006 Only mechanical function
• CPC Class Codes: H01H 2215/036 Metallic disc
• CPC Class Codes: H01H 2217/03 Concave plane
• CPC Class Codes: H01H 2221/05 Force concentrator; Actuating dimple

Abstract

A membrane switch with multiple switch sites in which, at a given switch site, three concavo-convex structures are juxtaposed over a set of switch contacts so that when the key is pressed, the force applied causes the three structures to cooperate to complete an electrical circuit and close the switch. An operator easily can detect when a switch has been effectively closed because of the superior tactile response resulting from the concavo-convex components. Apertured spacers also are provided to allow the contacts to be brought into communication with each other and to provide a distance through which the actuating force must travel to further enhance tactile feedback to the user.

Claims

1. A tactile response switch assembly, comprising:

a plurality of superposed layers including a membrane layer having a concave outer surface and a convex inner surface, upon which a plurality of switch sites are defined;

a switch actuator layer;

a first switch contact layer;

a second switch contact layer adapted to be connected to associated circuitry;

at least one insulative layer disposed between said first switch contact layer and said second switch contact layer to prevent electrical shorting of any of said switch sites; and

a spacer layer disposed between said switch actuator layer and said first switch contact layer to provide a distance through which activation or deactivation of any of said switch sites can be sensed when an actuating force is applied thereto.

2. The switch assembly of claim 1, wherein said switch actuator is a structure approximating the shape of a dome having a concave surface and a convex surface, said switch actuator being aligned with said membrane layer so that said concave surface of said membrane layer contacts said convex surface of said dome when force is applied to any of said switch sites.

3. The switch assembly of claim 2, wherein said first switch contact layer comprises a boss corresponding to each of said switch sites, the boss being formed from an electrically conductive material, and having a concave surface and a convex surface, with said convex surface of said boss in alignment with said concave surface of said dome.

4. The switch assembly of claim 3, wherein said second switch contact layer comprises a substrate on which is disposed a pair of electrically conductive traces corresponding to each of said switch sites.

5. The switch assembly of claim 4, wherein said insulative layer disposed between said first switch contact layer and said second switch contact layer has openings to allow the each of said bosses and each of said pair of electrically conductive traces to be brought into communication when a force is applied to any of said switch sites.

6. The switch assembly of claim 5, wherein one of said spacer layers is superposed between said membrane layer and said switch actuator layer.

7. A multilayered membrane switch for an electrical circuit, the switch comprising:

a plurality of switching units, each said switching unit including a first switch contact and a second switch contact, said second switch contact aligned in a layer below said first switch contact, and a plurality of concavo-convex elements aligned in layers above said contacts, one of which said elements is an overlay covering said plurality of switching units having an outer surface that is convex and an inner surface that is concave, said concavo-convex elements cooperating to complete the electrical circuit between said first switch contact and said second switch contact when a mechanical force is applied to any said switching unit.

8. The membrane switch of claim 7, wherein said concavo-convex elements further include a dome having an upper surface that is convex and a lower surface that is concave, said overlay being aligned with said dome so that when mechanical force is applied, said convex surface of said overlay is brought into contact with said concave surface of said dome.

9. The membrane switch of claim 8, wherein said first switch contact is aligned in a layer below said dome so as to register with said dome when a force is applied, and said first switch contact has an upper surface that is convex and a lower surface that is concave.

10. An electro-mechanical interface for conveying electrical signals to associated circuitry, the interface comprising:

a plurality of switching components disposed in interconnected multiple layers, said switching components being capable of interaction when supplied by a pressure force, wherein said multiple layers including a resilient switch-actuating layer, a first contact-bearing switch layer, a second contact-bearing switch layer, and a covering layer upon which at least one switch site is circumscribed;

said resilient layer having at least one force-conveying element;

said first contact-bearing switch layer being spaced apart from and insulated from said second contact-bearing switch layer;

said second contact-bearing switch layer being in communication with the associated circuitry and having at least one switch contact; and

said covering layer having an interior surface and an exterior surface, said interior surface being concave and said exterior surface being convex.

11. A membrane switch for completing an electrical circuit with an improved tactile response, comprising:

a pair of electrically conductive switch contacts; and

a plurality of concavo-convex elements each having an upper surface that is concave and lower surface that is convex, said plurality of elements being in alignment with every other of said plurality of elements and with said pair of switch contacts, the uppermost of said elements comprising a membrane layer having a degree of convexity and a degree of concavity less than that of every other of said plurality of concavo-convex elements, said concavo-convex elements cooperating to complete the electrical circuit between said pair of contacts when a mechanical force is applied to said concavo-convex elements.

12. The switch assembly of claim 11 wherein said concavo-convex elements further include a dome.

13. The switch of claim 12, wherein one of said pair of electrically conductive switch contacts also is concavo-convex, having an upper surface that is convex and a lower surface that is concave.

14. The switch assembly of claim 13, wherein said membrane, said dome and said pair of electrically conductive switch contacts are spaced apart from each other by a spacer layer disposed between said dome and said pair of electrically conductive switch contacts and an insulative layer disposed between the first of said pair of electrically conductive switch contacts and the second of said pair of electrically conductive switch contacts.

15. A tactile-response switch assembly, having a plurality of superposed layers comprising:

a membrane layer having an inner surface which is concave and an outer surface which is convex, and at least one switch site being formed in said membrane layer;

a switch actuator layer disposed below said membrane layer, having a switch actuator corresponding to each of said switch sites, each said switch actuator having an inner surface which is more concave than, and an outer surface which is more convex than, said membrane layer, and which is designed to contact the portion of said membrane layer at each said switch site;

a spacer layer disposed between said membrane layer and said switch actuator layer, said spacer layer having at least one aperture through which each said portion of said membrane layer at each said switch site can be brought into contact with said outer surface of each said switch actuator;

an upper switch layer disposed below said switch actuator layer, having an upper switch corresponding to each said switch actuator and each said key site, each said upper switch being formed of an electrically-conductive material and having an inner surface which is more concave than, and an outer surface which is more convex than, said inner and outer surfaces of said membrane layer;

a lower switch layer disposed below said upper switch layer and having at least one lower switch electrical contact corresponding to each said upper switch, such that when each said upper switch is pressed into contact with each said lower switch contact an electrical circuit is completed;

an insulative layer disposed between said upper switch layer and said lower switch layer to prevent an electrical circuit from being completed in the absence of a force applied to each said upper switch; and

a power connector in communication with each said electrical contact on said lower switch layer.

16. The tactile-response switch assembly of claim 15, wherein a plunger is formed on the inner surface at each said switch site.

17. The tactile-response switch assembly of claim 15 wherein a second spacer layer is disposed below said lower switch layer.

18. A membrane switch assembly comprising a plurality of layers and having at least one switch for which an electrical circuit is completed by transferring a force through a series of three concavo-convex elements, the first of said elements comprising an membrane layer of the switch assembly, the second of said elements disposed in a switch-actuating layer of the switch assembly, and the third of said elements disposed in an upper switch contact layer of the switch assembly, each of said elements having an outer surface and inner surface:

said outer surface of said membrane layer is convex and said inner surface of said membrane layer is concave;

a key site is defined in said membrane layer for each switch;

said outer surface of said switch-actuating layer element is more convex than said outer surface of said membrane layer;

said outer surface of said upper switch contact layer element is more convex than said outer surface of said membrane layer, and said upper switch contact layer element is in alignment with said switch-actuating layer element and with a contact disposed in a lower switch layer, said lower switch layer adapted to be connected to a source of electrical power; and

an insulative layer disposed between said upper switch contact layer and said lower switch contact layer to prevent a short circuit when a switch actuating force is not being applied to said concavo-convex elements.