Electrical Switch Assembly

1. Field of the Invention

This invention relates to pushbutton key switch assemblies and more particularly to such assemblies using multi-spring actuators for each switch position.

2. Discussion of the Prior Art

Low cost, highly reliable key switch assemblies are required for many applications such as push button telephone keyboards and calculator keyboards. While many improvements have been made in key switch assemblies in recent years, such assemblies represent a significant cost or failure factor in many high volume products and further improvements are of great importance.

It is known to provide batch fabricated contact sets and switch actuators with independent spring biasing of key actuation and switch closure forces. However, the extreme precision, low cost and high reliability provided by switch contact assemblies in accordance with the present invention is not previously known.

For example, a single spring actuator arrangement is taught in U.S. Pat. No. 3,783,205 to Boulanger. The single spring of course fails to provide independent control over key actuation and contact closure forces, or precise control over the key position for switch closure notwithstanding normal tolerances in switch components. U.S. Pat. No. 3,780,237 to Seeger, Jr. et al, U.S. Pat. No. 3,856,998 to Sims, Jr. and U.S. Pat No. 3,993,884 to Kondur et al all teach dual spring key actuator arrangements. However, these arrangements do not provide the combination of precision, repeatability, and switch closure security that is attainable with a switch assembly in accordance with the present invention. For instance, only the patent to kondur et al teaches positioning of the follower, but assembly is quite complex with many latches, catches and washers and cannot be accomplished from a single side. None of these references teach the advantages of combining a dual spring actuator with a third spring comprised of a truncated cone contact or the contact configuration of this invention.

Disclosure of switch contact assemblies can be found in U.S. Pat. Nos. 3,383,487 to Weiner, 3,699,294 to Sudduth and 3,860,771 to Lynn et al. However, the combination of simplicity, cone spring switch contact assembly, high security circuit pattern and excellent actuator assembly taught by this application are not disclosed.

A highly reliable, yet low cost, key switch assembly in accordance with the invention includes a generally planar batch fabricated switch contact assembly and a switch actuator assembly. The switch contact assembly includes a plurality of switch positions arranged in rows and columns and includes a substrate that is folded about an apertured spacer to define opposed first and second contact sets at each switch position. The spacer has an aperture at each switch position through which the second contact set may be extended in response to a switch actuation force. Each first contact set includes interdigitated row and common conductors arranged as circularly and radially extending pairs. The row conductors for each row are connected together and all of the common conductors are connected together.

A planar actuator layer supports a second contact set including a protruding "bubble" at each switch position which is preferably configured as a cone shaped spring. Each second contact set includes a circularly extending ring and radially extending conductors disposed for switch closure engagement with radially extending and circularly extending respectively pairs of row and common conductors of a mating first contact set. Cone spring flexure, resilience and longevity is maintained even with metal conductors by providing at least three discontinuities in circumferentially extending portions of the second contact set within the cone flexure region and by avoiding a conductive center or hub interconnecting the radially extending conductors of the second contact set. However, the radially extending conductors for a contact set are interconnected peripherally of the flexure region and columns of second contact sets are interconnected. Thus, regardless of the angle variation of an actuator, switch closure results in multiple electrical interconnection of row, column and common conductors at an actuated switch position to assure a definite, secure and long life switch closure mechanism.

The switch actuator assembly includes a generally planar cover plate disposed adjacent the switch contact assembly with a key receiving and guiding aperture opposite each switch position. The plate apertures each extend along a central axis perpendicular to the switch contact assembly and receive an apertured key which may slide along the central axis between a first, nonactuated, limit and a second, actuated, limit. The apertured key receives in sliding, guiding relationship a follower, a follower spring and a cap for securing the follower and spring. The follower is secured at a fixed, nonactuated limit relative to the key and includes a post extending through the key for actuation engagement with a switch contact "bubble". A spherical configuration of the post about a center of wobble insures a good, distributed pressure engagement of the post with the contact set notwithstanding off center actuation of the key. A key biases the key toward a nonactuated first limit which permits precise, positive positioning of the post spherical end in spaced relation to the contact set cone spring.

The truncated cone shaped spring 46 serves to space the conductive contacts from each other, to provide a spring action which, in combination with the follower spring, establishes a selectable range of keystroke travel for closure and to provide an avalanche characteristic wherein more force is required to collapse the cone initially than to maintain the cone in a collapsed or actuated state. The cone spring and follower spring thus cooperate to yield a beneficial result that might be termed force-position hysteresis. The spring 46 may be formed in a die with the material, material thickness, die temperature, die pressure and die formation time chosen to provide a selected actuation force from a broad range to control factors such as key travel before closure.

Excellent human factors switching characteristics are attained by making the post spacing about half the key travel distance. The dual spring arrangement permits the key spring to provide a desired return force while the follower spring exerts a selected actuation force on a contact set cone spring. With nonactuated follower spring force slightly less than cone spring actuation force, but greater than maintenance force, an excellent tease free, force-distance hysteresis characteristic is attained in which a closed switch cannot be opened without at least some retreat of the actuating key toward the first nonactivated limit.

A better understanding of the invention may be had from a consideration of the following detailed description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a plan view of a keyboard in accordance with the invention;

FIG. 2 is a sectional side view taken along line 2--2 of FIG. 1;

FIG. 3 is a sectional plan view of a switch position of the switch assembly shown in FIG. 1 taken along line 3--3 of FIG. 2; and

FIG. 4 is a plan view of a printed circuit switch contact array in accordance with the invention.

Referring now to FIG. 1, a key switch assembly in accordance with the invention includes a cover plate 12 supporting and guiding an array of actuator keys 14, each located at a different switch position and arranged to provide four rows and three columns of pushbutton switches. A connector portion 16 of a folded switch contact substrate 18 extends from the switch assembly 10 to provide a convenient electrical connection to external circuitry.

Making further reference now to FIGS. 2 and 3, a typical switch position is shown as including a key actuator assembly 24 and a key contact assembly 26. The key actuator assembly 24 includes, in addition to actuator key 14, and a portion of cover plate 12, a follower 28, a cap 30 securing follower 28 within a central key aperture 32 within key 14, a helical coil follower spring 34 disposed in compression to force follower 28 downwardly relative to key 14, and a helical coil key spring 36 disposed in compression to force key 14 upward relative to key contact assembly 26. The key contact assembly 26 includes the flexible substrate 18 folded about a spacer 40 having a central aperture 42 extending therethrough at each switch position. The substrate 18 includes an upper planar layer 44 with upwardly extending truncated cone protrusions forming springs 46 defined as an integral part thereof. A lower planar layer portion 48 of substrate 18 is disposed in opposed, spaced apart, facing relationship to upper planar layer 44 and carries a first conductive switch closure contact circuit pattern 50 defining a first contact set 52 within the periphery of aperture 42. Similarly, upper planar layer 44 carries an upper conductive circuit pattern 54 having a second conductive switch closure contact circuit pattern 56 disposed in opposed, mating, switch closure relationship to the first contact set 52. Upon the application of an actuation force to cone spring 46, the cone spring 46 is forced downwardly to snap through center and cause upper contact set 56 to physically engage lower contact set 52 to provide electrical switch closure. Upon reduction of the actuation force below a switch closure maintenance force less than the actuation force, the cone spring 46 again snaps upwardly to return to its original unactuated condition as shown in FIG. 2.

The key 14 and follower 28 slide along a central axis 60 which extends perpendicular to the switch contact assembly 26. Cover plate 12 guidingly receives key 14 and includes a lower cylindrical portion 62 adjacent contact assembly 26, a flange 64 which extends inwardly from lower cylindrical portion 62 at a position spaced apart from contact assembly 26 and an upwardly extending flange 66 which is generally rectangular in cross section and provides additional guidance and support for key 14 as it slides along axis 60.

Actuator key 14 has a generally rectangular upper portion 70 which mates with flange 66, a generally cylindrical radially outward extending flange 72 just below upper portion 70 and a lower cylindrical portion 74 which extends from flange 72 to the bottom of the key. Flange 72 engages flange 64 of cover plate 12 to provide a first or upper limit of sliding key travel for actuator key 14. Key 14 also has a circumferentially extending protrusion 76 in the outer surface of cylindrical portion 74 and a central aperture 78 which receives a bushing 80 having defined therein the central key aperture 32. Bushing 80 has at an uppermost end thereof a convex conical shaped protrusion 84 which receives and guides follower spring 34. It will be appreciated that actuator key 14 may be fabricated as a single integral element without need for internal bushing 80.

Internal key aperture 32 receives in sliding, guiding relationship the follower 28 having an upper hollow cylindrical portion 90 and a downwardly extending solid cylindrical post 92. Post 92 extends downwardly through a central aperture 94 in retainer cap 30. The switch contact engaging end 96 of post 92 has a spherical surface shape defined about a center of wobble 98 of follower 28 and key 14. The actuator key 14 may not be pushed exactly along central axis 60 by an operator and because of required tolerance spaces between actuator key 14 and cover plate 12 and between follower 28 and actuator key 14, the follower 28 may wobble somewhat and engage the cone spring 46 other than perpendicularly along central axis 60. The curvilinear spherical surface 96 assures that notwithstanding this wobble, a smooth even pressure is distributed against cone spring 46 near the center thereof to assure secure switch closure contact.

The size and shape of post 92 may be selected to provide desired switch closure characteristics. Force-position hysteresis and a feeling of detent tend to be maximized by a flat end and a large diameter of post 92 which is approximately coextensive with the disk shaped top surface or truncation of a spring 46. These characteristics tend to be lessened by a rounded surface 96 and by a decreased diameter of post 96. A flat bottomed post 96 with a diameter about half the diameter of the flat disk shaped top of a cone spring 46 provides a good compromise between hysteresis and detent, wide area multi-point switch contact and switch reliability notwithstanding wobble during actuation.

Retainer cap 30 has a hollow cylindrical portion 100 which slidingly receives cylindrical portion 74 of key 14 and a flat disk-shaped portion 102 which forms the bottom of cap 30, engages the bottom of key 14, and engages a bottom of cylindrical portion 90 of follower 28 to constrain follower 28 within central key aperture 82 and define a downwardmost limit for sliding motion of follower 28 relative to key 14. Inwardly extending protrusions 104 are provided on the interior surface of cylindrical portion 100 to engage outwardly extending circumferential protrusion 76 and maintain retainer cap 30 in assembled position relative to key 14.

A back plate 106 supports the substrate 18 and is suitably attached to cover plate 12. Plate 106 assures a rigid back support against the relatively thin and flexible substrate 18.

Flange 72 engages flange 64 to position actuator key 14 at a first or upper limit in predetermined spaced relationship to contact assembly 26 when not actuated. In addition, retainer cap 30 serves in conjunction with compression follower spring 34 to position follower 28 at a fixed nonactuated position relative to key 14. The end 96 of post 92 may thus be precisely positioned at a preferred distance of about 50 mils above cone spring 46 notwithstanding normal tolerance variations in key spring 36 and follower spring 34. This 50 mil spacing of the end 96 represents slightly less than half of the total 125 mil travel distance available to actuatory key 14. In the rest condition, it is found desirable for the force on follower spring 34 to be slightly less than the approximately 100 grams required to depress cone spring 46 and somewhat greater than the 60 grams required to maintain cone spring 46 in an actuated condition after depression. A nominal standby force of 80 grams is thus selected for the unactuated compression force of follower spring 34. Thus, upon key actuation, key 14 travels a considerable distance before surface 96 engages cone spring 46 and must travel a short additional distance before the actuation force provided by follower spring 34 is sufficient to exceed 100 grams and depress cone spring 46. The spring constant of 3 lbs. per inch of follower spring 34 is selected to require an additional travel distance a little bit greater than the thickness of spacer 40 which might typically be a few mils. Therefore, as cone spring 46 snaps through center, the follower 92 can extend downwardly within key 14 to maintain a continuous actuation force against cone spring 46 greater than the 60 gram maintenance force even though the snap action of cone spring 46 may cause it to move faster than the motion of key 14. A single, low bounce continuous switch closure is thus attained and maintained until actuator key 14 retreats toward the nonactuated first limit.

As actuator key 14 is further depressed toward a second, actuated limit, in which cap 30 engages the top surface of top planar layer 44, follower spring 34 continues to depress somewhat with the actuation force being only slightly increased. As a result, even though an operator may exert a large force against actuator key 14, only the much smaller maximum force exerted by follower spring 34 is communicated against cone spring 46 as an actuation force. The engaging first and second sets of contacts 52, 56 are thus shielded from any excessive force that might cause rapid wear or damage to the contacts. At the same time, key spring 36 exerts an independent upward force against actuation key 14 as it extends in compression between flange 72 and upper planar layer surface 44 to provide a desired return force which may be substantially greater than the desired minimal actuation force actually exerted on cone spring 46. The operator human factors consideration may thus be defined independently of the quite different switch actuator considerations. A highly reliable switch with excellent operator "feel" thus results.

Referring now to FIG. 4, where substrate 18 is shown unfolded with upper planar surface 44 on the right and lower planar surface 50 on the left, it will be observed that a conductive pattern 110 defined on substrate 18 defines a conductive circuit pattern which connects a first column of second switch closure contact sets 56 to a terminal 112, a second column of second switch closure contact sets 56 to a terminal 114, and a third column of second switch closure contact sets 56 to a terminal 116. In similar manner, the first through fourth rows of first switch contact sets 52 are coupled respectively to terminals 118, 120, 122 and 124 respectively. The common conductor which is provided at each of the first contact sets 52 is coupled to a terminal 126.

Referring by way of example to the switch contact sets 52, 56 at row 4, column 3 and making further reference to FIG. 5, it will be observed that a radially outward circle 130 is defined approximately 2/3 by a row four conductor and 1/3 by the common conductor. The common conductor has a line 132 which extends radially inward from the outer circle 130 to the center and additional radially extending conductors 134, 136 which extend radially outward from the center with an included angle of approximately 120.degree. between line 132 and themselves. The fourth row conductor has three lines 138, 140 and 142 which extend radially inward from outer circle 130 toward the center in parallel closely spaced relationship to lines 132, 134 and 136 respectively without making actual contact with the common conductors. Within a contact region near the center of the outer circle 130, the row and common conductors also form four closely spaced concentric circular patterns with the common conductor defining a first solid circular pattern at the center, and a third circular pattern radially outward therefrom. The row conductor defines a second circular pattern between the first and third circular patterns and a fourth circular pattern radially outward of the third circular pattern. Thus, at each switch position the row and common conductors define two pairs of radially extending adjacent or interdigitated conductors and two pairs of circularly extending adjacent or interdigitated conductors.

At each second contact set 56 the column conductor defines an outer circle 144 which upon folding of substrate 18 aligns itself in opposed facing relationship to outer circle 130. These circles 130 and 144 extend about the periphery of an aperture 42 of spacer 40 to assure that within a switch position, the switch conductors as well as the substrate 18 are spaced apart by the thickness of spacer 40. Three lines 146, 148, 150 extend radially inward from outer circle 144 toward the center of circle 144 without actually reaching the center. Each of these lines further extends circumferentially at a radial distance within the radial extremities of shorter lines 134 and 136 to define three nontouching segments of a circle. The lines 146, 148 and 150 are angularly disposed so as to align themselves between the radially extending lines of the first switch contact set and assure their positioning in opposed relationship to the interdigitated pairs of circularly extending contacts of the first contact set. Similarly, the circularly extending portions of the second contact set are disposed to insure their engagement with the radially extending portions of the first contact set. Therefore, the multiple radial and circularly extending interdigitated pairs of the first contact set and the mating circularly and radially extending respectively conductors of the second contact set insure a multiple contact closure engagement upon depression of a cone spring 46 which insures that at least one set of contacts remains closed notwithstanding any wobble and hence deviation from center of the follower 28. An extremely reliable and secure multiple switch contact closure is thus attained in a switch contact assembly 26 which is relatively simple and inexpensive to manufacture.

The separate radially and circularly extending lines 146, 148 and 150 of the second contact set assure that the cone spring 46 retains a maximum flexibility and resiliency notwithstanding the printing of metal conductors thereon. The metal conductors do not have the resiliency of the planar layer 44 and cone spring 46 and thus tend to initiate spring return after actuation. However, it will be appreciated that in the event that the conductors are formed from a somewhat more flexible material, such as organic materials applied by silk screening processes, more conductive material can be used in each second contact set 56 and the entire portion of the inner surface of a cone spring radially inward of the circularly extending conductor portions can become a solid conductive disk.

While there has been shown and described a particular arrangement of a key switch assembly in accordance with the invention for the purpose of enabling a person of ordinary skill in the art to make and use the invention, it will be appreciated that the invention is not limited thereto. Accordingly, any modifications, variations or equivalent arrangements within the scope of the attached claims should be considered to be within the scope of the invention.