US4402131A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Electrical switch assembly and method of manufacture
Assignee: Miraco Inc
•
Filing: 1981-11-04
•
Granted: 1983-09-06
•
Expires: 2001-11-04
Abstract
Abstract The present invention provides low cost electrical switch assemblies and methods for manufacturing same. The switch assembly comprises an array of resiliently flexible metallic conductors arranged in predetermined circuit pathways on a dielectric carrier panel. A plurality of apertures or cavities are provided at predetermined locations in the carrier panel. The switch contacts comprise a pair of generally L-shaped fingers which are integral extensions of the flexible conductors. The fingers extend from opposite edge surfaces of the carrier panel defining an associated aperture or cavity, to pass one another over or within their associated aperture or cavity, with the free ends of the fingers terminating adjacent one another. The free ends of the L-shaped fingers extend in part above or below the plane of the carrier panel, and are positioned in spaced relationship to one another so that the conductors they connect are normally open, but are sufficiently close to one another so that slight deflection of the fingers from their normal orientation moves the free ends in contact with each other to thereby close the switch. Alternatively, the free ends of the L-shaped fingers are positioned in contact with one another so that slight deflection of the fingers from their normal orientation breaks their contact. The metallic conductors and integral switch contacts may be formed by photoimaging and either chemical milling or additive techniques such as plating up or solder doming, and/or mechanical milling and/or precision die stamping techniques.
Inventors
- 👤 Joseph A. Roberts
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 00:01
CPC Classifications
H; H01; H01H; H01H13/00; H01H13/70; H01H13/78; H01H13/785; H01H1/00; H01H1/12; H01H1/36; H01H1/40; H01H1/403; H01H13/02; H01H13/12; H01H13/702; H01H2201/00; H01H2201/022; H01H2201/032; H01H2203/00; H01H2203/008; H01H2209/00; H01H2209/004; H01H2211/00; H01H2211/026; H01H2211/028; H01H2225/00; H01H2225/012; H01H2229/00; H01H2229/008; H01H2229/014; H01H2229/016; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49105; Y10T29/49117; Y10T29/49124; Y10T29/49155; Y10T29/49156
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
254 words
A method of fabricating an electrical switch assembly comprising a dielectric substrate having at least one cavity formed in one face of said substrate, and one or more electrically conductive circuits formed of resiliently flexible conductive material fixed in part to said dielectric substrate, each of said electrically conductive circuits having an array of switch means, each said switch means comprising a pair of contact members overlying said cavity, said pair of contact members comprising (a) integral extensions of such said conductive circuits and including (b) a pair of generally L-shaped fingers (1) disposed inwardly for a distance and (2) cantilevered from the edge of their associated cavity, said L-shaped fingers occupying the same plane adjacent the edge of their associated cavity, extending beyond the geometric center of said associated cavity, and extending, in part, above or below the plane of said one face; said method comprising the steps of: (a) providing a resiliently flexible electrically conductive sheet; (b) removing material from areas of said electrically conductive sheet while leaving a pattern of conductors and said contact members but continuous to one another; (c) severing the continuous contact members to form said L-shaped fingers; (d) permanently deforming said L-shaped fingers at least in part; (e) providing a dielectric substrate having cavities at predetermined locations in one surface thereof; and (f) fixedly positioning said pattern of conductors and L-shaped fingers resulting from step (d) relative to said one surface of the dielectric panel, with said L-shaped fingers positioned at least in part overlying said cavities.
Claim 2
Independent Claim
254 words
A method of fabricating an electrical switch assembly comprising a dielectric substrate having at least one cavity formed in one face of said substrate, and one or more electrically conductive circuits formed of resiliently flexible conductive material fixed in part to said dielectric substrate, each of said electrically conductive circuits having an array of switch means, each said switch means comprising a pair of contact members overlying said cavity, said pair of contact members comprising (a) integral extensions of such said conductive circuits and including (b) a pair of generally L-shaped fingers (1) disposed inwardly for a distance and (2) cantilevered from the edge of their associated cavity, said L-shaped fingers occupying the same plane adjacent the edge of their associated cavity, extending beyond the geometric center of said associated cavity, and extending, in part, above or below the plane of said one face; said method comprising the steps of: (a) providing a resiliently flexible electrically conductive sheet; (b) removing material from areas of said electrically conductive sheet while leaving a pattern of conductors and said contact members but continuous to one another; (c) severing the continuous contact members to form said L-shaped fingers; (d) permanently deforming said L-shaped fingers at least in part; (e) providing a dielectric substrate having cavities at predetermined locations in one surface thereof; and (f) fixedly positioning said pattern of conductors and L-shaped fingers resulting from step (d) relative to said one surface of the dielectric panel, with said L-shaped fingers positioned at least in part overlying said cavities.
Claim 3
Dependent Claim
22 words
A method according to claim 1, wherein said material is removed from selected areas of said electrically conductive sheet by chemical milling.
Claim 4
Dependent Claim
23 words
A method according to claim 1, wherein said material is removed from selective areas of said electrically conductive sheet by precision die stamping.
Claim 5
Independent Claim
22 words
A method according to any one of claims 1, 2 or 3, wherein said L-shaped fingers are permanently deformed by heat forming.
Claim 6
Dependent Claim
47 words
A method according to claim 1, wherein said electrically conductive sheet comprises a laminate of a metallic foil and a polymeric substrate material underlying said metallic foil, and including the step of permanently deforming said L-shaped fingers by heat forming portions of said substrate underlying said fingers.
Claim 7
Dependent Claim
31 words
A method according to claim 1, wherein said electrically conductive sheet comprises unsupported metallic sheet, and including the step of permanently deforming said L-shaped fingers by forming the metal under pressure.
Claim 8
Independent Claim
32 words
A method according to any one of claims 1, 5 or 6, and wherein said severing step (c) and said deforming step (d) are accomplished in a single stamping and forming operation.
Claim 9
Dependent Claim
22 words
A method according to claim 1, including the step of covering the structure resulting from step (f) with a flexible dielectric overlay.
Claim 10
Independent Claim
262 words
A method of fabricating an electrical switch assembly comprising a carrier substrate having at least one cavity formed in one face of said substrate, and one or more electrically conductive circuits formed of resiliently flexible conductive material fixed in part to said carrier substrate, each of said electrically conductive circuits having an array of switch means, each said switch means comprising a pair of contact members overlying said cavity, said pair of contact members comprising (a) integral extensions of such said conductive circuits and including (b) a pair of generally L-shaped fingers (1) disposed inwardly for a distance and (2) cantilevered from the edge of their associated cavity, said L-shaped fingers occupying the same plane adjacent the edge of their associated cavity, extending beyond the geometric center of said associated cavity, and extending, in part, above or below the plane of said one face; said method comprising the steps of: (a) providing a resiliently flexible circuit panel having an electrically conductive pattern in the form of said electrically conductive circuit and said contact members but continuous to one another; (b) severing the continuous contact members to form said L-shaped fingers; (c) depositing electrically conductive material onto selected areas of said L-shaped fingers so as to produce raised areas thereon; (d) providing a dielectrical panel having cavities at predetermined locations in one surface thereof; and (e) fixedly positioning the pattern of conductors and L-shaped fingers resulting from step (c) onto said one surface of said dielectric panel, with said raised areas of said L-shaped fingers positioned at least in part overlying said cavities.
Claim 11
Independent Claim
262 words
A method of fabricating an electrical switch assembly comprising a carrier substrate having at least one cavity formed in one face of said substrate, and one or more electrically conductive circuits formed of resiliently flexible conductive material fixed in part to said carrier substrate, each of said electrically conductive circuits having an array of switch means, each said switch means comprising a pair of contact members overlying said cavity, said pair of contact members comprising (a) integral extensions of such said conductive circuits and including (b) a pair of generally L-shaped fingers (1) disposed inwardly for a distance and (2) cantilevered from the edge of their associated cavity, said L-shaped fingers occupying the same plane adjacent the edge of their associated cavity, extending beyond the geometric center of said associated cavity, and extending, in part, above or below the plane of said one face; said method comprising the steps of: (a) providing a resiliently flexible circuit panel having an electrically conductive pattern in the form of said electrically conductive circuit and said contact members but continuous to one another; (b) severing the continuous contact members to form said L-shaped fingers; (c) depositing electrically conductive material onto selected areas of said L-shaped fingers so as to produce raised areas thereon; (d) providing a dielectrical panel having cavities at predetermined locations in one surface thereof; and (e) fixedly positioning the pattern of conductors and L-shaped fingers resulting from step (c) onto said one surface of said dielectric panel, with said raised areas of said L-shaped fingers positioned at least in part overlying said cavities.
Claim 12
Dependent Claim
15 words
A method according to claim 9 wherein said raised areas comprise metal deposited by plating-up.
Claim 13
Dependent Claim
16 words
A method according to claim 9 wherein said raised areas comprise metal deposited by solder doming.
Claim 14
Dependent Claim
23 words
A method according to claim 9 and including the step of covering the structure resulting from step (e) with a flexible dielectric overlay.
Claim 15
Dependent Claim
16 words
A method according to claim 9 wherein said electrically conductive pattern is formed by additive techniques.
Claim 16
Dependent Claim
22 words
A method according to claim 13, wherein said material is removed from areas of said electrically conductive sheet by precision die stamping.
Claim 17
Dependent Claim
48 words
A method according to claim 13, wherein said electrically conductive sheet comprises a laminate of a metallic foil and a polymeric substrate material underlying said metallic foil, and including the step of permanently deforming said L-shaped fingers by heat forming portions of said polymeric substrate underlying said fingers.
Claim 18
Dependent Claim
31 words
A method according to claim 13, wherein said electrically conductive sheet comprises unsupported metallic sheet, and including the step of permanently deforming said L-shaped fingers by forming the metal under pressure.
Claim 19
Dependent Claim
22 words
A method according to claim 13, including the step of covering the structure resulting from step (f) with a flexible dielectric overlay.
Claim 20
Independent Claim
31 words
A method according to any one of claims 13 or 15, and wherein said severing step (c) and said deforming step (d) are accomplished in a single stamping and forming operation.
Claim 21
Independent Claim
254 words
A method of fabricating an electrical switch assembly comprising a dielectric substrate having at least one cavity formed in one face of said substrate, and one or more electrically conductive circuits formed of resiliently flexible conductive material fixed in part to said dielectric substrate, each of said electrically conductive circuits having an array of switch means, each of said switch means comprising a pair of contact members overlying said cavity, said pair of contact members comprising (a) integral extensions of said conductive circuits and including (b) a pair of generally L-shaped fingers (1) disposed inwardly for a distance and (2) cantilevered from the edge of their associated cavity, said L-shaped fingers occupying the same plane adjacent the edge of their associated cavity, extending beyond the geometric center of said associated cavity, and extending, in part, above or below the plane of said one face; said method comprising the steps of: (a) providing a resiliently flexible electrically conductive sheet; (b) removing material from areas of said electrically conductive sheet while leaving a pattern of the conductors and said contact members but continuous to one another; (c) severing the continuous contact members to form said L-shaped fingers; (d) permanently deforming said L-shaped fingers at least in part; (e) providing dielectric substrate having cavities at predetermined locations in one surface thereof; and (f) fixedly positioning said pattern of conductors and L-shaped fingers resulting from step (d) relative to said one surface of said dielectric substrate, with said L-shaped fingers positioned at least in part within said cavities.
Claim 22
Independent Claim
254 words
A method of fabricating an electrical switch assembly comprising a dielectric substrate having at least one cavity formed in one face of said substrate, and one or more electrically conductive circuits formed of resiliently flexible conductive material fixed in part to said dielectric substrate, each of said electrically conductive circuits having an array of switch means, each of said switch means comprising a pair of contact members overlying said cavity, said pair of contact members comprising (a) integral extensions of said conductive circuits and including (b) a pair of generally L-shaped fingers (1) disposed inwardly for a distance and (2) cantilevered from the edge of their associated cavity, said L-shaped fingers occupying the same plane adjacent the edge of their associated cavity, extending beyond the geometric center of said associated cavity, and extending, in part, above or below the plane of said one face; said method comprising the steps of: (a) providing a resiliently flexible electrically conductive sheet; (b) removing material from areas of said electrically conductive sheet while leaving a pattern of the conductors and said contact members but continuous to one another; (c) severing the continuous contact members to form said L-shaped fingers; (d) permanently deforming said L-shaped fingers at least in part; (e) providing dielectric substrate having cavities at predetermined locations in one surface thereof; and (f) fixedly positioning said pattern of conductors and L-shaped fingers resulting from step (d) relative to said one surface of said dielectric substrate, with said L-shaped fingers positioned at least in part within said cavities.
Claim 23
Dependent Claim
21 words
A method according to claim 19, wherein said material is removed from areas of said electrically conductive sheet by chemical milling.
Claim 24
Independent Claim
22 words
A method according to any one of claims 13, 19 or 20, wherein said L-shaped fingers are permanently deformed by heat forming.
Claim 25
Dependent Claim
25 words
A method according to claim 21, wherein said severing step (c) and said deforming step (d) are accomplished in a single stamping and forming operation.
Claim 26
Independent Claim
263 words
A method of fabricating an electrical switch assembly comprising a carrier substrate having at least one cavity formed in one face of said substrate, and one or more electrically conductive circuits formed of resiliently flexible conductive material fixed in part to said carrier substrate, each of said electrically conductive circuits having an array of switch means, each of said switch means comprising a pair of contact members overlying said cavity, said pair of contact members comprising (a) integral extensions of such said conductive circuits and including (b) a pair of generally L-shaped fingers (1) disposed inwardly for a distance and (2) cantilevered from the edge of their associated cavity, said L-shaped fingers occupying the same plane adjacent the edge of their associated cavity, extending beyond the geometric center of said associated cavity, and extending, in part, above or below the plane of said one face; said method comprising the steps of: (a) providing a resiliently flexible circuit panel having an electrically conductive pattern in the form of said electrically conductive circuit and said contact members but continuous to one another; (b) severing the continuous contact members to form said L-shaped fingers; (c) depositing electrically conductive material onto selected areas of said L-shaped fingers so as to produce raised areas thereon; (d) providing a dielectrical panel having cavities at predetermined locations in one surface thereof; and (e) fixedly positioning the pattern of conductors and L-shaped fingers resulting from step (c) onto said one surface of said dielectric panel, with said raised areas of said L-shaped fingers positioned at least in part within said cavities.
Claim 27
Independent Claim
263 words
A method of fabricating an electrical switch assembly comprising a carrier substrate having at least one cavity formed in one face of said substrate, and one or more electrically conductive circuits formed of resiliently flexible conductive material fixed in part to said carrier substrate, each of said electrically conductive circuits having an array of switch means, each of said switch means comprising a pair of contact members overlying said cavity, said pair of contact members comprising (a) integral extensions of such said conductive circuits and including (b) a pair of generally L-shaped fingers (1) disposed inwardly for a distance and (2) cantilevered from the edge of their associated cavity, said L-shaped fingers occupying the same plane adjacent the edge of their associated cavity, extending beyond the geometric center of said associated cavity, and extending, in part, above or below the plane of said one face; said method comprising the steps of: (a) providing a resiliently flexible circuit panel having an electrically conductive pattern in the form of said electrically conductive circuit and said contact members but continuous to one another; (b) severing the continuous contact members to form said L-shaped fingers; (c) depositing electrically conductive material onto selected areas of said L-shaped fingers so as to produce raised areas thereon; (d) providing a dielectrical panel having cavities at predetermined locations in one surface thereof; and (e) fixedly positioning the pattern of conductors and L-shaped fingers resulting from step (c) onto said one surface of said dielectric panel, with said raised areas of said L-shaped fingers positioned at least in part within said cavities.
Claim 28
Dependent Claim
15 words
A method according to claim 23, wherein said raised areas are formed by plating-up metal.
Claim 29
Dependent Claim
15 words
A method according to claim 23, wherein said raised areas are formed by solder doming.
Claim 30
Dependent Claim
23 words
A method according to claim 25, and including the step of covering the structure resulting from step (e) with a flexible dielectric overlay.
Claim 31
Dependent Claim
15 words
A method according to claim 23, wherein said conductive pattern is formed by additive techniques.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-09-05 | 1987-03-07 | 1987-09-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-09-05 | 1991-03-07 | 1991-09-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-09-05 | 1995-03-07 | 1995-09-06 | $7700.00 | Window Closed / Lapsed |