US3886012A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of assembly of keyboard switch by ultrasonics
Assignee: Mercury Systems Inc
•
Filing: 1973-08-13
•
Granted: 1975-05-27
•
Expires: 1993-08-13
Abstract
Abstract A method of assembling a keyboard of the type used in electronic calculators in which a first Mylar sheet having openings therein for receiving switch elements is selectively ultrasonically bonded to an underlying printed circuit board, the switch elements are placed in the openings in the first sheet, and a second Mylar cover sheet is selectively ultrasonically bonded to the underlying first sheet.
Inventors
- 👤 Laurie F Slater
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 04:02
CPC Classifications
B; B29; B29C; B29C66/00; B29C66/70; B29C66/74; B29C65/00; B29C65/02; B29C65/08; B29C65/48; B29C65/4805; B29C65/481; B29C65/4815; B29C66/01; B29C66/05; B29C66/10; B29C66/11; B29C66/112; B29C66/1122; B29C66/40; B29C66/41; B29C66/45; B29C66/50; B29C66/51; B29C66/53; B29C66/534; B29C66/5346; B29C66/53461; B29C66/73; B29C66/739; B29C66/7392; B29C66/73921; B29C66/80; B29C66/81; B29C66/814; B29C66/8141; B29C66/81431; B29C66/83; B29C66/832; B29C66/8322; B29C66/84; B29C66/847; H; H01; H01H; H01H13/00; H01H13/70; H01H13/7006; B29C66/71; B29C66/742; B29L; B29L2031/00; B29L2031/34; B29L2031/3425; B29L2031/46; B29L2031/466; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1089; Y10T156/109; Y10T156/1092; Y10T156/1093
Claims Analysis
Total Claims: 14
Claim 1
Independent Claim
268 words
THE METHOD OF ASSEMBLING A KEYBOARD COMPRISING THE STEPS OF: A. PROVIDING AN INSULATIVE, PLANAR BOARD HAVING OPPOSITE SURFACES, ONE OF SAID SURFACE HAVING AT LEAST ONE SWITCH CONTACT THEREON, B. PROVIDING A FIRST SHEET OF INSULATING MATERIAL HAVING OPPOSITE SURFACES RESPECTIVELY COATED WITH ULTRASONICALLY ACTUATABLE ADHESIVE MATERIAL, SAID FIRST SHEET HAVING AN OPENING THEREIN ADAPTED TO RECEIVE A SWITCH ELEMENT, C. PLACING ONE SURFACE OF SAID FIRST SHEET ON SAID ONE SURFACE OF SAID BOARD WITH SAID CONTACT EXPOSED TO SAID OPENING, D. PLACING A SECOND SHEET OF MATERIAL WHICH WILL NOT BOND TO SAID ADHESIVE MATERIAL ON THE OTHER SURFACE OF SAID FIRST SHEET THEREBY FORMING A FIRST SANDWICH COMPRISING SAID BOARD AND SAID FIRST AND SECOND SHEETS, E. PLACING SAID FIRST SANDWICH IN ULTRASONIC WELDING APPARATUS AND ENERGIZING THE SAME THEREBY TO ACITVATIVE SAID ADHESIVE MATERIAL ON SAID ONE SURFACE OF SAID FIRSST SHEET TO BOND THE SAME TO SAID ONE SURFACE OF SAID BOARD, F. REMOVING SAID RIRST SANDWICH FROM SAID APPARATUS AND REMOVING SAID SECOND SHEET FROM SAID FIRST SHEET, G. PLACING A SWITCH ELEMENT IN SAID OOPENING IN COOPERATIVE RELATIONSHIP WITH AID CONTACT, H. PLACING A THIRD SHEET OF INSULATING MATERIAL ON SAID OTHER SURFACE OF AID FIRST SHEET OVER SAID SWITCH ELEMENT THEREBY FORMING A SECOND SANDWICH COMPRISING SAID BOARD AND SAID FIRST AND THIRD SHEETS, I. PLACING SAID SECOND SANDWICH IN SAID APPARATUS AND ENERGIZING THE SAME THEREBY TO ACTUATE SAID ADHESIVE MATERIAL ON SAID OTHER SURFACE OF SAID FIRST SHEET TO BOND THE SAME TO SAID THIRD SHEET, AND J. REMOVING THE THUS BONDED SECOND SANDWICH FROM SAID APARATUS.
Claim 2
Independent Claim
268 words
THE METHOD OF ASSEMBLING A KEYBOARD COMPRISING THE STEPS OF: A. PROVIDING AN INSULATIVE, PLANAR BOARD HAVING OPPOSITE SURFACES, ONE OF SAID SURFACE HAVING AT LEAST ONE SWITCH CONTACT THEREON, B. PROVIDING A FIRST SHEET OF INSULATING MATERIAL HAVING OPPOSITE SURFACES RESPECTIVELY COATED WITH ULTRASONICALLY ACTUATABLE ADHESIVE MATERIAL, SAID FIRST SHEET HAVING AN OPENING THEREIN ADAPTED TO RECEIVE A SWITCH ELEMENT, C. PLACING ONE SURFACE OF SAID FIRST SHEET ON SAID ONE SURFACE OF SAID BOARD WITH SAID CONTACT EXPOSED TO SAID OPENING, D. PLACING A SECOND SHEET OF MATERIAL WHICH WILL NOT BOND TO SAID ADHESIVE MATERIAL ON THE OTHER SURFACE OF SAID FIRST SHEET THEREBY FORMING A FIRST SANDWICH COMPRISING SAID BOARD AND SAID FIRST AND SECOND SHEETS, E. PLACING SAID FIRST SANDWICH IN ULTRASONIC WELDING APPARATUS AND ENERGIZING THE SAME THEREBY TO ACITVATIVE SAID ADHESIVE MATERIAL ON SAID ONE SURFACE OF SAID FIRSST SHEET TO BOND THE SAME TO SAID ONE SURFACE OF SAID BOARD, F. REMOVING SAID RIRST SANDWICH FROM SAID APPARATUS AND REMOVING SAID SECOND SHEET FROM SAID FIRST SHEET, G. PLACING A SWITCH ELEMENT IN SAID OOPENING IN COOPERATIVE RELATIONSHIP WITH AID CONTACT, H. PLACING A THIRD SHEET OF INSULATING MATERIAL ON SAID OTHER SURFACE OF AID FIRST SHEET OVER SAID SWITCH ELEMENT THEREBY FORMING A SECOND SANDWICH COMPRISING SAID BOARD AND SAID FIRST AND THIRD SHEETS, I. PLACING SAID SECOND SANDWICH IN SAID APPARATUS AND ENERGIZING THE SAME THEREBY TO ACTUATE SAID ADHESIVE MATERIAL ON SAID OTHER SURFACE OF SAID FIRST SHEET TO BOND THE SAME TO SAID THIRD SHEET, AND J. REMOVING THE THUS BONDED SECOND SANDWICH FROM SAID APARATUS.
Claim 3
Dependent Claim
70 words
The method of claim 1 wherein said apparatus includes a horn having a surface selectively movable into engagement with said second and third sheets respectively, said horn surface having an opening therein of generally the same size as said first sheet opening, said placing steps (e) and (i) including orienting said first and second sandwiches, respectively, so that said first sheet opening is in registry with said horn surface opening.
Claim 4
Dependent Claim
59 words
The method of claim 2 wherein there are a plurality of said first sheet openings arranged in a predetermined pattern, a corresponding plurality of contacts and switch elements, and a corresponding plurality of horn openings arranged in the same pattern, said horn openings being respectively in registry with said first sheet openings in said placing steps (e) and (i).
Claim 5
Dependent Claim
15 words
The method of claim 3 wherein said adhesive material is a heat-activated, thermoplastic polyester film.
Claim 6
Dependent Claim
14 words
The method of claim 4 wherein said sheets of insulating material are polyethylene terephthalate.
Claim 7
Dependent Claim
12 words
The method of claim 5 wherein said second sheet is wax paper.
Claim 8
Dependent Claim
19 words
The method of claim 1 wherein said apparatus produces mechanical vibrations in said horn in the region of 20kHz.
Claim 9
Dependent Claim
41 words
The method of claim 2 wherein said horn is moved into engagement with said first and second sandwiches, respectively, during said placing steps (e) and (i), and approximately 50 pounds per square incH pressure is applied thereby to the respective sandwich.
Claim 10
Dependent Claim
30 words
The method of claim 1 wherein said appratus is energized for approximately 1 1/2 seconds during said placing step (e), and for approximately 6/10 second during said placing step (i).
Claim 11
Dependent Claim
150 words
In a method of assembling a keyboard, the steps comprising: a. providing an insulative, planar board having opposite surfaces, one of said surfaces having at least one switch contact thereon, b. providing a planar sheet having opposite surfaces, at least one of said surfaces being coated with ultrasonically actuatable adhesive material, said sheet having an opening therein, c. placing said one surface of said sheet on said one surface of said board with said contact exposed to said opening thereby forming a sandwich comprising said board and sheet, d. placing said sandwich in ultrasonic welding apparatus including a horn having a surface selectively movable into engagement with the other surface of said sheet, said horn surface having an opening therein in registry with said sheet opening, e. energizing said apparatus thereby to actuate said adhesive material thereby to bond said sheet to said board, and f. removing the thus-bonded sandwich.
Claim 12
Dependent Claim
150 words
In a method of assembling a keyboard, the steps comprising: a. providing an insulative, planar board having opposite surfaces, one of said surfaces having at least one switch contact thereon, b. providing a planar sheet having opposite surfaces, at least one of said surfaces being coated with ultrasonically actuatable adhesive material, said sheet having an opening therein, c. placing said one surface of said sheet on said one surface of said board with said contact exposed to said opening thereby forming a sandwich comprising said board and sheet, d. placing said sandwich in ultrasonic welding apparatus including a horn having a surface selectively movable into engagement with the other surface of said sheet, said horn surface having an opening therein in registry with said sheet opening, e. energizing said apparatus thereby to actuate said adhesive material thereby to bond said sheet to said board, and f. removing the thus-bonded sandwich.
Claim 13
Dependent Claim
40 words
The method of claim 10 wherein there are a plurality of said sheet openings arranged in a predetermined pattern and a corresponding plurality of horn openings arranged in the same pattern and respectively in registry in said placing step (d).
Claim 14
Dependent Claim
21 words
The method of claim 11 wherein each of said horn openings is generally the same size as the respective sheet opening.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-05-26 | 1978-11-25 | 1979-05-27 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-05-26 | 1982-11-25 | 1983-05-27 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-05-26 | 1986-11-25 | 1987-05-27 | $7700.00 | Window Closed / Lapsed |