U.S. patent number 3,773,997 [Application Number 05/207,142] was granted by the patent office on 1973-11-20 for key assembly diaphragm switch actuator with overtravel and feel mechanisms.
This patent grant is currently assigned to Datanetics Corporation. Invention is credited to Pat. E. Evans, Meryl E. Miller, Michael Muller.
United States Patent |
3,773,997 |
Evans , et al. |
November 20, 1973 |
**Please see images for:
( Certificate of Correction ) ** |
KEY ASSEMBLY DIAPHRAGM SWITCH ACTUATOR WITH OVERTRAVEL AND FEEL
MECHANISMS
Abstract
A key assembly for actuating a diaphragm switch, and including a
housing, a keystem movably mounted on the housing, and a switch
actuator coupled to the keystem through a lost-motion connection
arranged so a relatively large stroke of the keystem is required to
effect a small actuator motion needed to operate the switch. A coil
spring biases the keystem away from the housing to an extended
position in which the switch is not actuated, and a second coil
spring urges the actuator away from the keystem. The lost-motion
connection between the keystem and actuator provides positive
retraction of the actuator during the return stroke of the keystem.
A leaf spring on the keystem rides a cam surface or ramp on the
housing, and the ramp is shaped to modify the effect of the coil
springs such that the keystem tends to toggle past the point of
switch actuation to prevent switch jitter and to provide a tactile
signal that actuation has occurred.
Inventors: |
Evans; Pat. E. (Costa Mesa,
CA), Miller; Meryl E. (Palos Verdes Peninsula, CA),
Muller; Michael (Newport Beach, CA) |
Assignee: |
Datanetics Corporation
(Fountain Valley, CA)
|
Family
ID: |
22769369 |
Appl.
No.: |
05/207,142 |
Filed: |
December 13, 1971 |
Current U.S.
Class: |
200/517;
200/330 |
Current CPC
Class: |
H01H
13/705 (20130101); B41J 5/12 (20130101); B41J
5/16 (20130101); H01H 2221/026 (20130101); H01H
2221/044 (20130101); H01H 2215/028 (20130101); H01H
2215/034 (20130101); H01H 2227/028 (20130101); H01H
2229/018 (20130101); H01H 2227/032 (20130101); H01H
2233/058 (20130101); H01H 2229/044 (20130101); H01H
2233/096 (20130101); H01H 2233/02 (20130101); H01H
2233/086 (20130101); H01H 2235/018 (20130101); H01H
1/2008 (20130101); H01H 2003/028 (20130101) |
Current International
Class: |
B41J
5/00 (20060101); B41J 5/16 (20060101); B41J
5/12 (20060101); H01H 13/70 (20060101); H01H
13/705 (20060101); H01h 013/50 (); H01h 003/48 ();
H01h 013/36 () |
Field of
Search: |
;200/153V,159B,159R,172A,153T,159A,172R,77,160 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
IBM Technical Disclosure, Vol. 13, No. 11, April 1971, "Key For
Elastic Diaphragm Switch Keyboards," Fazzio et al. .
IBM Technical Disclosure, Vol. 14, No. 6, Nov. 1971, "Snap-Action
Elastic-Diaphragm Switch Mechanism," Harris..
|
Primary Examiner: Schaefer; Robert K.
Assistant Examiner: Vanderhye; Robert A.
Claims
What is claimed is:
1. A key assembly for actuating a device, comprising:
a housing;
a keystem mounted on the housing to be movable through a stroke
between a normally extended position and a depressed position, the
keystem having a pair of elongated channels therein, each channel
having a lower end defining a stop shoulder;
an actuator mounted on the housing to be movable through a stroke
between a normally retracted position and an extended position, the
actuator having a pair of arms extending therefrom over opposite
sides of the keystem, each arm having an inwardly extending portion
fitting into a respective channel to form a lost-motion connection
which captively retains the actuator on the keystem;
first resilient means disposed between the keystem and actuator for
urging the actuator away from the keystem; and
second resilient means disposed between the housing and keystem for
urging the keystem toward the normally extended position;
the keystem and first resilient means being operative to move the
actuator toward the extended position when the keystem is moved
toward the depressed position, the arm portions being movable in
the keystem channels to permit the keystem stroke to exceed the
actuator stroke, the arm portions abutting the channel stop
shoulders to drive the actuator to the retracted position when the
keystem is returned to the normally extended position.
2. The assembly defined in claim 1 in which the actuator and
keystem are non-rotatively mounted on the housing.
3. The assembly defined in claim 2 and further comprising a third
resilient means arranged between the keystem and housing to be
operative during an intermediate portion of the keystem stroke to
impose on the keystem a force resisting keystem motion followed by
an opposite force aiding further keystem motion as the keystem is
moved through the intermediate stroke portion toward the depressed
position.
4. A key assembly for actuating a diaphragm switch, comprising:
a hollow housing having a lower end adapted for mounting on the
switch;
a keystem slidably mounted in and extending from an upper end of
the housing, the keystem being movable between a normally extended
position and a depressed position;
a first spring disposed between the keystem and housing for urging
the keystem toward the extended position, the first spring exerting
an increasing restoring force opposing an actuating force exerted
on the keystem to move the keystem from the normally extended
position toward the depressed position;
a resilient means interposed between the keystem and housing for
modifying the total force opposing the actuating force by first
increasing the total force and then decreasing the total force as
the keystem is moved through an intermediate portion of full
downstroke travel toward the depressed position;
an actuator slidably mounted in the housing and having a lower end
movable into operative contact with the switch when the housing is
mounted on the switch, the actuator having a coupling means
extending therefrom in captive engagement with the keystem, the
coupling means providing a lost-motion connection which forces the
actuator away from the switch into a retracted position when the
keystem is in the normally extended position while permitting
limited downstroke motion of the keystem toward the depressed
position without requiring equal motion of the actuator; and
a second spring disposed between the keystem and actuator to urge
the keystem and actuator apart, the second spring providing a
resilient connection between the keystem and actuator such that an
increasing restoring force exerted by the second spring during the
keystem downstroke is effective to urge the actuator away from the
keystem into actuating contact with the switch, the second spring
permitting overtravel movement of the keystem beyond a position
adequate to obtain switch actuation, while maintaining a restoring
force against the actuator to hold the switch in an actuated
position during overtravel movement and until the keystem is
permitted to move back toward the extended position.
5. The assembly defined in claim 4 in which the keystem and
actuator are non-rotatively mounted in the housing whereby rotation
is prevented as the keystem and actuator are moved linearly with
respect to the housing.
6. The assembly defined in claim 5 in which the housing defines a
stop surface abutting the actuator in the retracted position to
prevent further motion of the actuator toward the upper end of the
housing, and to limit upward travel of the keystem with respect to
the housing.
7. The assembly defined in claim 4 in which the housing defines a
channel extending in the direction of keystem travel, the channel
having a projection intermediate its ends extending toward the
keystem, and in which the resilient means includes a resilient arm
on the keystem and having a follower which fits in and rides along
the channel as the keystem is moved in the housing, the follower
riding over the channel projection to deflect and then release the
resilient arm as the keystem is moved through the intermediate
position.
8. The assembly defined in claim 7 in which the keystem has a pair
of side surfaces defining channels which are elongated in the
direction of keystem motion, each channel having a stop shoulder at
a lower end thereof, and in which said coupling means comprises a
pair of arms secured to and extending from the actuator over the
side surfaces of the keystem, the arms having inwardly extended
ends slidably fitted into the channels and abutting the stop
shoulders to limit separation of the keystem and actuator.
9. The assembly defined in claim 8 in which the actuator and arms
are integrally formed from a material having sufficient resiliency
that the arms may be spread apart to slide over the keystem and
then resume a normal spacing with the inwardly extending ends of
the arms captively engaged in the keystem channels.
10. The assembly defined in claim 4 in which the keystem includes a
cap post, the post having projections extending therefrom, and
further comprising a cap having a socket and formed of a plastic
material which will cold flow, the post making a force fit in the
socket, the cap being formed of a softer material than a material
forming the keystem post whereby the cap will cold flow around the
post projections to form detent sockets receiving the projections
and retaining the cap on the post.
11. A key assembly comprising:
a diaphragm switch having an actuating surface which is movable to
effect switch actuation;
a hollow housing having an undersurface disposed adjacent the
switch actuating surface;
a clamping means securing the switch and housing together;
a keystem slidably mounted in and extending from an upper end of
the housing, the keystem being movable toward and away from the
switch actuating surface between a depressed position and a
normally extended position, the keystem having a pair of side
surfaces defining channels which are elongated in the direction of
keystem motion, each channel having a stop shoulder at a lower end
thereof;
a first coil spring disposed between the keystem and housing for
urging the keystem toward the extended position;
an actuator slidably mounted in the housing between the keystem and
switch actuating surface, the actuator having a pair of arms
secured to and extending therefrom over the keystem side surfaces
in captive engagement of the keystem, the arms having inwardly
extending ends slidably fitted in the keystem channels and abutting
the stop shoulders to limit separation of the keystem and actuator,
the arms thereby forming a lost-motion connection which pulls the
actuator in a direction away from the switch actuating surface into
a retracted position when the keystem is in the normally extended
position while permitting limited downstroke keystem motion toward
the depressed position without requiring equal motion of the
actuator; and
a second spring disposed between the keystem and actuator to urge
the keystem and actuator apart, the second spring providing a
resilient connection between the keystem and actuator such that an
increasing restoring force exerted by the second spring during a
keystem downstroke toward the depressed position is effective to
urge the actuator away from the keystem against the switch
actuating surface to effect switch actuation, the second spring
permitting overtravel movement of the keystem beyond a position
adequate to obtain switch operation, while maintaining a restoring
force against the actuator to hold the switch in an actuated
position during overtravel movement and until the keystem is
permitted to move back toward the extended position.
12. The assembly defined in claim 11 in which the actuator and arms
are integrally formed from a material having sufficient resiliency
that the arms may be spread apart to slide over the keystem and
then resume a normal spacing with the inwardly extending ends of
the arms captively engaged in the keystem channels.
13. The assembly defined in claim 12 in which the keystem and
actuator are non-rotatively mounted in the housing, and in which
the housing defines a sto surface abutting the actuator in the
retracted position to prevent further motion of the actuator toward
the upper end of the housing, and to limit upward travel of the
keystem with respect to the housing.
14. The assembly defined in claim 13 in which the housing defines a
channel extending in the direction of keystem travel, the channel
having a projection intermediate its ends and extending toward the
keystem, and in which the keystem includes an integrally formed
spring arm having a follower which fits in and rides along the
channel as the keystem is moved in the housing, the follower riding
over the channel projection to deflect and then release the spring
arm as the keystem is moved through an intermediate downstroke
position to effect switch operation.
Description
BACKGROUND OF THE INVENTION
Key assemblies are used in manual actuation of electrical switches
or other devices in a variety of communications and data-entry
applications. Many key assemblies are normally grouped together to
form a keyboard for printing or entering alphanumeric characters
and other symbols. Familiar examples of keyboards are found in
typewriters, teletypes, calculators, and computer data-entry
terminals.
The switch or other device operated by a key assembly typically has
a short actuation stroke, but a relatively long finger stroke is
normally desired for the key to prevent inadvertent actuation when
the operator's fingers rest on the keys. One function of a key
assembly is thus to provide a lost motion or overtravel connection
between the finger and switch. The key also identifies the
character or symbol associated with the switch. These functions are
performed by a variety of known key assemblies, but these prior-art
devices are typically deficient in providing reliability and a
satisfactory tactile "feel," in preventing switch jitter, and in
permitting simple manufacturing and assembly procedures.
Conventional key assemblies use one or more return springs which
urge the key into an extended or non-actuated position. The
restoring force of these springs and the device being actuated, and
any frictional drag on the key and device, constitute the force
which the operator must overbalance to actuate the key. This force
gives the key a characteristic "feel," and the key assembly must be
designed to provide an easy and comfortable action fo the operator,
while still maintaining a crisp return action when the operator's
finger is removed.
The key assembly of this invention uses a combination of spring
elements to meet these requirements, and also to provide two
additional operating features. The springs are selected such that
the key restoring force has a discontinuity at the point of device
actuation during the downward key stroke. This discontinuity is
sensed by the operator through the fingers, and provides
unconscious assurance that the key stroke or displacement has been
adequate for actuation. The discontinuity also tends to urge the
key away from the exact point of actuation to prevent hovering at
this stroke position which could cause switch jitter and unintended
multiple actuation. The key assembly is further designed for quick
and simple assembly, and is made from relatively inexpensive molded
plastic parts.
Another important feature of the invention is a coupling
arrangement between keystem and actuator which insures positive
retraction or lifting of the actuator during the return stroke of
the keystem. The actuator is drawn into a predetermined retracted
position where no force is exerted on the device to be actuated,
thereby substantially eliminating the risk of undesired actuation
due to vibration or shock. Binding or irregular motion due to side
loads applied during actuation is minimized by providing relatively
long bearing or guide surfaces which support the keystem and
actuator.
SUMMARY OF THE INVENTION
The key assembly of this invention includes a housing adapted for
mounting on or adjacent to a device to be actuated such as a
diaphragm switch. A keystem is slidably mounted on the housing to
be movable through a stroke between a normally extended position
and a depressed position. A resilient means such as a coil spring
is positioned between the housing and keystem to urge the keystem
toward the extended positon. An actuator is mounted on the housing
to be movable between a retracted position and an actuating
position in which the actuator contacts the device to effect
actuation such as a switch closure.
A coupling means forms a lost-motion connection between the keystem
and actuator, permitting a relatively large keystem stroke to
produce a smaller movement of the actuator. The coupling means
provides a positive connection of the keystem and actuator as the
keystem approaches the normally extended position to insure that
the actuator is retracted away from the device after actuation. The
keystem and actuator are preferably non-rotatively mounted on the
housing, and a second resilient means such as a coil spring is
disposed between the keystem and actuator.
In one form, the keystem includes a means cooperating with the
housing for providing a discontinuity in a
force-versus-displacement characteristic of the key assembly during
the actuation stroke. The second resilient means is selected to
match the characteristics of the device being actuated such that
device actuation is effected at a stroke position where the
discontinuity occurs. A cap is fitted on the keystem, and is made
of a soft material which forms detent sockets receiving projections
on the keystem.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional elevation of a key assembly according to
the invention, the assembly being mounted on a diaphragm
switch;
FIG. 1A is a sectional elevation of a diaphragm switch;
FIG. 2 is a sectional elevation of a housing used in the key
assembly;
FIG. 3 is a top view of the housing on line 3--3 of FIG. 2;
FIG. 4 is a bottom view of the housing oriented as shown in FIG.
1;
FIG. 5 is a side elevation, partly broken away, of a keystem;
FIG. 6 is a front elevation of the keystem, partly broken away, on
line 6--6 of FIG. 5;
FIG. 7 is a top view of the keystem on line 7--7 of FIG. 5;
FIG. 8 is a bottom view of the keystem on line 8--8 of FIG. 5;
FIG. 9 is an elevation of an actuator;
FIG. 10 is a sectional view of the actuator on line 10--10 of FIG.
9;
FIG. 11 is a top view of the actuator on line 11--11 of FIG. 9;
FIG. 12 is a bottom view of a cap on line 12--12 of FIG. 1; and
FIg. 13 is a graph showing a force-versus-displacement
characteristic of the key assembly during an actuation stroke.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A key assembly 10 according to the invention is shown in FIG. 1
mounted on an upper chassis plate 11 having a circular opening 12
therethrough. A diaphragm switch assembly 13 is positioned beneath
key assembly 10, and the switch assembly is sandwiched between
upper chassis plate 11 and a lower chassis plate 14. A clamping
plate 15 holds the key assembly against the upper chassis plate.
The upper and lower chassis plates, clamping plate and switch
assembly are secured together as a sandwich by screws (not shown)
or any other convenient fastening means.
A number of different styles of diaphragm switches (see, for
example, U.S. Pat. No. 3,594,684) are commercially available, and a
typical style is shown in FIG. 1A. This switch includes a rigid
baseplate such as a circuit board 18 having a metalized portion on
its upper surface forming a first electrical contact 19. A second
electrical contact 20 is formed on the undersurface of a thin
flexible plastic sheet 21 disposed above circuit board 18. An
insulator sheet 22 (shown exaggerated in thickness) having an
opening 23 therethrough is sandwiched between the circuit board and
insulating sheet with opening 23 in alignment with the first and
second contacts. A flexible protective cover sheet 24 rests on the
upper surface of sheet 21 to complete the assembly.
When pressure is applied to cover sheet 24 as indicated by arrow
25, sheets 21 and 24 deflect resiliently to move second contact 20
downwardly to make an electrical connection with first contact 19.
When the pressure is removed, the elasticity of sheets 21 and 24
restores the switch to the position shown in FIG. 1A to separate
the contacts and open the switch. Other styles of diaphragm
switches and similar devices are useful with key assembly 10, and
the switch shown in FIG. 1A is simply an example of one suitable
version.
Key assembly 10 includes an integrally molded keystem guide or
housing 30 (FIGS. 1-4). The housing has a circular base 31, and a
circular recess 32 is formed in the undersurface of the base.
Recess 32 provides a clearance space above the upper surface of
switch assembly 13 (FIG. 1) to avoid stresses which could occur in
cover sheet 24 if the entire undersurface of the base rested on the
cover sheet. A clamping flange 33 extends radially from the top of
base 31, and one corner 34 of the flange is beveled to key the
housing to clamping plate 15 which has a mating shape to index the
key assembly in a desired position.
An intermediate portion 36 of the housing extends upwardly from the
top of the clamping flange, and tapers to an inwardly extending
shoulder 37. An upper portion 38 of the housing extends upwardly
from intermediate portion 36 above shoulder 37. The upper portion
is shaped as a truncated cone with flattened sides 39 (FIG. 3).
The interior of the housing is hollow, and defines a lower chamber
41 of rectangular cross section, and a smaller upper chamber 42
also of rectangular cross section. Two opposed sidewalls 43 extend
along the length of upper chamber 42, and two further sidewalls 44
extend through both the upper and lower chambers. A pair of
spaced-apart ribs 45 extend inwardly from each of sidewalls 44 in
lower chamber 41 to form a smooth extension of sidewalls 43 into
the lower chamber. Each rib terminates short of the bottom of
housing 30 to form a shoulder or stop 46.
A channel 48 is formed in each sidewall 44, and extends the length
of the housing from the top of upper portion 38 to the lower end of
sidewall 44 at the top of circular recess 32. The upper part of
each channel 48 is slightly tapered as best seen in FIG. 2. One of
channels 48 is interrupted between its ends by a detent or
projection 49 (FIGS. 1 and 2) which extends outwardly in the
channel toward the center of the hollow interior of the housing to
a tip 50 which is flush with the plane of sidewall 44. The bottom
surface of this channel curves smoothly inwardly toward tip 50 both
above and below the tip as shown in FIG. 1 to form a cam surface or
ramp.
An integrally molded keystem 53 (FIGS. 5-8) has a circular flange
54 with an inwardly stepped undersurface forming a spring-retaining
shoulder 55. Extending upwardly from the top of flange 54 is a
cruciform post 56 having sidewalls 57. A button or projection 58 is
formed on each face of each of the sidewalls.
A stem 59 of generally rectangular cross section extends downwardly
from circular flange 54 of the keystem. A channel 60 is formed
along the length of each of the opposed narrower side faces of stem
59, and a shallower channel 61 is formed along the length of the
opposed wider faces of the stem. These channels form outwardly
extending guide ribs 62 at each of the four corners of the
stem.
A spring-retaining post or lug 63 extends downwardly from the
bottom of stem 59. An actuator guide channel 64 extends centrally
along the lower portion of each of the wider side surfaces of stem
59. The bottom of each channel 64 defines a horizontal shelf or
shoulder 65 extending perpendicularly to the longitudinal axis of
the stem. A leaf spring 66 is integrally formed with the upper part
of the stem, and extends downwardly within one of channels 60 to
terminate in a laterally extending button or follower 67. The
follower normally projects beyond the plane of the ajdacent side
face of stem 59, but associated channel 60 is sufficiently deep
that leaf spring 66 may be deflected inwardly until the tip of
follower 67 is flush with the side of the stem. A notch 68 in
flange 54 above spring 66 provides clearance for mold tooling
during manufacture of the stem.
An integrally molded actuator 72 (FIGS. 9-11) has a base 73 with a
pair of retainer arms 74 extending upwardly therefrom. An inwardly
extending projection 75 is formed at the upper end of each retainer
arm. A pair of spring-retaining lugs 76 are formed on the upper
surface of base 73 between arms 74. A pair of sidewalls 77 extend
upwardly from opposite ends of base 73, and the outer faces of the
sidewalls form guiding and bearing surfaces for the actuator when
it is installed in the housing as explained below. A downwardly
extending dimple or button 78 is formed on the undersurface of base
73.
A cap 82 for key assembly 10 is shown in FIGS. 1 and 12, and
includes an inner core 83 and an outer jacket 84. The cap is made
by a known "double-shot" molding process in which the inner core is
first formed with an alphanumeric character 85 (only a portion of
which is shown in cross section in FIG. 1) projecting upwardly from
the upper surface thereof. The outer jacket is formed around the
core in the second stage of the molding process, and the material
forming the jacket flows around the alphanumeric character so the
cap has a smooth upper surface. A central boss 86 is integrally
formed within core 83, and is supported by stiffening ribs 87. A
cruciform socket 88 is formed in boss 86, and the socket is
dimensioned to make a snug press fit over post 56 of keystem
53.
All the components described thus far are preferably injection
molded from commercially available plastic materials. ABS plastics
are suitable for housing 30 and cap 82. Actuator 72 is preferably
formed from a polysulfone plastic. Stem 59 is molded from a plastic
which is harder than the material forming cap 82, and an acetal
resin such as sold under the trademark "Delrin" is
satisfactory.
To assemble key assembly 10, a main return spring 90 (FIG. 1) is
first slipped over stem 59 of keystem 53 to seat against shoulder
55. Keystem 53 is then fitted into housing 30 with stem 59
extending downwardly into the hollow interior of the housing as
shown in FIG. 1. The stem is oriented so follower 67 of leaf spring
66 on the keystem fits into that channel 48 which includes
projection 49. The bottom of return spring 90 seats against
shoulder 37 (not visible in FIG. 1, but shown in FIGS. 2 and 3) of
the housing, and the spring acts to urge the keystem upwardly out
of the housing.
An actuator overtravel spring 91 (FIGS. 1 and 6) is fitted between
retainer arms 74 of actuator 72. The actuator spring seats around
lugs 76 (which restrain any lateral movement of the spring) against
the upper surface of base 73. The upper end of the spring
temporarily seats against the undersurfaces of projections 75 at
the top of the retainer arms.
With keystem 53 held fully depressed in housing 30 against the
restoring force of return spring 90, actuator 72 and spring 91 are
next inserted through the undersurface of the housing into lower
chamber 41. As the actuator is pressed upwardly into the housing,
the chamfered upper surfaces of projections 75 on the actuator
retainer arms contact the bottom of stem 59, and the actuator
material is sufficiently resilient that the retainer arms bend
outwardly away from each other to slide upwardly over the lower end
of the stem. As this upward motion is continued, projections 75 on
the retainer arms slide home into actuator guide channels 64. The
resilient retainer arms then snap inwardly to their normal position
to seat projections 75 within channels 64, preventing withdrawal of
the actuator from the housing.
Actuator spring 91 seats on the undersurface of stem 59 and fits
around retaining lug 63 which restrains lateral movement of the
upper end of the spring. The actuator spring is a compression
spring which urges the actuator downwardly away from the stem
toward a position in which projections 75 on the retainer arms seat
against shoulders 65 in guide channels 64.
An alternative assembly procedure is to install overtravel spring
in actuator 72 as described above, and then to insert the actuator
into housing 30. The housing is next placed on a flat surface to
hold the actuator in place, or a retaining tool or fixture may be
used for this purpose. Return spring 90 is then installed over the
top of the housing, and stem 59 of keystem 53 is fitted into the
housing and forced into captive engagement with the actuator.
The key assembly is completed by forcing post 56 of keystem 53 into
socket 88 of cap 82. The cap and keystem are forced together until
the undersurface of boss 86 of the cap fits against the top of
flange 54 on the keystem as shown in FIG. 1. There are no clearance
channels in socket 88 of the cap for projections 58 on post 56 of
the keystem, and these parts accordingly must be forced
together.
The plastic material forming the cap is relatively soft compared to
the keystem material, and the cap material will cold flow in a
relatively short time to form permanent sockets which receive
projections 58 on the keystem post. The sockets or depressions
remain even if the cap is temporarily removed from the keystem, and
they form with the post projections a series of detents which
retain the cap on the keystem. The cap detent sockets are thus
formed automatically during assembly of the components by virtue of
the selection of a relatively softer material for the cap, and a
significant tooling complication of molding the sockets during cap
fabrication is thus eliminated.
An important feature of the invention is the speed and simplicity
with which the several components can be assembled. Both springs
used in the assembly are cylindrical rather than conical, and thus
cannot be installed upsidedown. Conical springs also have the
disadvantage of tending to tangle with each other when stored in
bulk, and this problem is substantially reduced with cylindrical
springs. When the actuator and keystem axe pressed together to seat
projection 75 in channel 64, the keystem and actuator capture each
other to prevent disassembly of the components, and no snap rings
or other separate retainers are needed to complete the
assembly.
The actuator serves as a retainer which limits upward travel of the
keystem away from the housing. The upper surface of base 73 of the
actuator abuts stops 46 (FIG. 1) on the undersurface of ribs 45 of
the housing to limit upward motion of the actuator within the
housing. Projections 75 of the actuator retainer arms in turn seat
against shoulders 65 of the actuator guide channels 64, and thus
limit upward travel of the keystem with respect to the housing. The
components of the key assembly are shown in this fully extended
position in FIG. 1, with main return spring 90 urging the keystem
to its uppermost position with projections 75 seated against
shoulders 65, and the top of the actuator base seated against stops
46. In an alternative arrangement, the housing and actuator can be
dimensioned such that the "roof" surfaces (marked 41 in FIG. 4) of
lower chamber 41 serve as shoulders or stops which abut the tops of
retainer arms 74 when the actuator is fully retracted.
Keystem 53 makes a slip fit within the housing, and guide ribs 62
on stem 59 ride smoothly on the sidewalls of upper chamber 42, and
on the sidewall extensions formed by ribs 45. Close lateral
guidance is thus provided for the keystem over its full range of
travel, and side loads on the cap do not result in any misalignment
or binding of the key action. Similarly, actuator 72 makes a slip
fit in lower chamber 41 with base 73 and sidewalls 77 sliding
against and being guided by sidewalls 43 and 44 of the housing.
The keystem and actuator are thus closely guided over their full
ranges of travel by the inner surfaces of the housing, and binding
or irregular motion of these components due to cap side loads is
avoided. The rectangular configuration of the actuator also
prevents rotation of this part within the housing. This is
desirable from the standpoint of quality control as any burrs or
defects in the molded parts which might cause binding will be
revealed immediately by operational testing after assembly. If
rotation was permitted, a burr might be in a non-binding position
during inspection, and not cause faulty operation until the
actuator eventually rotated to a position in which binding
occurred.
The coupling of keystem 53 and actuator 72 arising from the
engagement of retainer-arm projections 75 in guide channels 64 is a
lost-motion connection which is desired when the key assembly is
used to actuate a short-travel device such as a diaphragm switch.
In this style of switch, a very slight depression of switch cover
sheet 24 (FIG. 1A), typically in the range of 0.007 inch, is
sufficient to deflect movable contact 20 against stationary contact
19. On the other hand, keyboard operators normally prefer a key
action with a relatively long stroke (typically in the range of 0.1
to 0.2 inch) to actuate the switch. The keystem must thus have a
considerable range of overtravel with respect to the movement of
the actuator, and the lost-motion connection or coupling of these
components satisfies this requirement.
In use, key assembly 10 is mounted on a diaphragm switch as shown
in FIG. 1. To actuate the switch, cap 82 is depressed by the
operator to drive keystem 53 downwardly in housing 30. This motion
of the keystem compresses actuator spring 91, urging the actuator
92 downwardly on the upper surface of the diaphragm switch against
the natural restoring force of the switch. As the downstroke of the
cap and keystem continues, the downward force on the actuator
eventually overcomes the restoring force of the diaphragm switch
and contact 20 moves against contact 19 to close the switch.
As the keystem moves downwardly during the actuation stroke,
follower 67 on leaf spring 66 rides downwardly in channel 48 into
contact with projection 49. During continued downward movement of
the keystem, leaf spring 66 is deflected inwardly until follower 67
rides over tip 50 on projection 49. The leaf-spring follower
thereafter rides "downhill" on the lower part of projection 49. An
additional force on the cap is thus required to deflect the leaf
spring as the follower rides over projection 49, and a
discontinuity in the force-versus-displacement characteristic of
the switch is introduced in the mid-travel range of the key
stroke.
This discontinuity is illustrated in FIG. 13 which is a graph
showing total downstroke restoring force of the key assembly (which
force must be overcome by the operator's finger to effect keystem
motion) on the ordinate, and displacement of the cap and keystem on
the abcissa. During the initial part of the downstroke, the
restoring force increases essentially linearly, but a distinct
increase in spring rate occurs as leaf-spring follower 67 contacts
and rides up projection 49. When the follower passes over tip 50 of
projection 49, the curve changes slope, reflecting the release of
energy stored in the leaf spring as the follower rides "downhill"
on the projection. As the downstroke continues, follower 67 passes
below projection 49, and the force again increases in a relatively
linear manner.
Actuator spring 91 is chosen to match the characteristics of
diaphragm switch 13 such that switch closure is effected just as
follower 67 passes over tip 50 of projection 49. When the switch is
actuated, the operator thus senses a distinct change in the "feel"
of the key, and recognizes subconsciously that an adequate key
stroke has been made. Some overtravel range of the keystem is
provided beyond the point of actuation, and the keystem bottoms
when projections 75 on the actuator reach the top of guide channels
64.
In addition to providing a tactile sense of switch actuation, the
leaf spring and follower have the further advantage of urging the
keystem away from the exact position in which actuation occurs.
This is desirable to prevent switch jitter which could occur if the
operator's finger is rested on the cap to depress the keystem
partially toward an actuated position. That is, the discontinuity
in the force-versus-displacement characteristic of the key assembly
tends to make it difficult to hold the keystem at the exact point
of switch actuation, and the possiblity of undesired multiple
switch closures is minimized.
Although the tactile sensing of switch actuation is normally
desired, this feature may not be wanted in some applications for
the key assembly. In these cases, keystem 53 is simply rotated
180.degree. from the position shown in FIG. 1 before being inserted
in housing 30 during assembly. In this position, follower 67 on
leaf spring 66 rides in an empty channel 48 which does not have a
projection 49. The force discontinuity shown in FIG. 13 is thus
eliminated, but only a single keystem need be maintained in
inventory for either style of key assembly.
When the key downstroke is completed, the operator's finger is
lifted from the cap, and the cap and keystem are driven upwardly by
main return spring 90. Closure of the diaphragm switch is
terminated when the restoring force of the switch itself overcomes
the decreasing force exerted on the actuator by spring 91 during
the upstroke of the key. An important feature of the invention is
that the actuator is positively retracted into housing 30 during
the final portion of the return stroke of the cap and keystem. This
occurs because projections 75 on retainer arms 74 of the actuator
bottom on shoulders 65 of the keystem before the return stroke is
completed, and the actuator is lifted by the keystem and return
spring 90 to a fully retracted position with the top of base 73
seated against stops 46 as shown in FIG. 1.
If desired, stops 46 may be positioned such that button 78 (which
bears against the diaphragm switch during switch actuation) on the
actuator is lifted away from the top of the diaphragm switch at the
end of the return stroke. This positioning of the parts is
desirable when the key assembly is used in conditions of vibration
and shock which might result in inadvertent switch closure if the
actuator rested against the top of the diaphragm switch at the end
of the key return stroke.
In a typical configuration, the components of the key assembly are
selected to provide an actuation stroke of about 0.11 inch, and a
total stroke of about 0.17 inch. Return spring 90 is selected to
provide a total key actuating force of about 3 ounces at the point
of switch closure. As mentioned above, actuator spring 91 is
selected to have a restoring force equal to the switch restoring
force at contact closure when the keystem is in a downstroke
position placing follower 67 on tip 50.
Inadvertent disassembly of the key assembly is virtually eliminated
because snap rings or other separate fasteners susceptible to
unintended disengagement are not used. The assembly can be easily
dismantled, however, for inspection or other purposes. The housing
is removed from the diaphragm switch or other device to provide
clearance below lower chamber 41, and the cap and keystem are fully
depressed to drive actuator 72 partly out of the bottom of the
housing. In this position, retainer arms 74 are accessible and can
be urged apart to release projections 75 from captive engagement in
guide channels 64. The actuator is thereby released from the
keystem, and all components of the assembly can be separated and
inspected.
In a typical application, a number of keystem assemblies are
arrayed together in a framework to form a multiple-character
keyboard. It may sometimes be desirable to provide extra diaphragm
switches in the array to permit future addition of new symbols or
characters which expand the capability of the keyboard. In such
cases, the housing, actuator and overtravel spring are installed on
the frame over the inactive diaphragm switch, and installation of
the keystem is deferred. When the switch is to be activated, a
keystem, cap and return spring are simply plugged into the housing
to make automatic captive engagement with the actuator, and the new
key assembly is ready for use.
There has been described a key assembly particularly suitable for
devices having a short actuation stroke such as a diaphragm switch.
The key assembly is made of inexpensive molded parts which are
easily and rapidly assembled without use of separate fasteners or
adhesives. Close lateral guidance for the moving parts of the key
assembly is provided by the housing, and positive retraction of the
non-rotating actuator assures reliable operation.
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