U.S. patent number 3,856,998 [Application Number 05/366,128] was granted by the patent office on 1974-12-24 for keyboard switch assembly with improved operating means.
This patent grant is currently assigned to Burroughs Corporation. Invention is credited to Dewey M. Sims, Jr..
United States Patent |
3,856,998 |
Sims, Jr. |
December 24, 1974 |
KEYBOARD SWITCH ASSEMBLY WITH IMPROVED OPERATING MEANS
Abstract
The disclosure relates generally to key assemblies employed in
electrical switch operating keyboard devices and more particularly
to the assembly of parts forming an individual depressible key of
such a keyboard. Each key assembly is composed of parts
cooperatively interfitting to provide both a low profile for the
keyboard as well as a bifurcated electrical contact provision.
Included in each key assembly is a pair of coiled springs of
different diameters which are coaxially and overlappingly related
to one another. The smaller diameter spring of the pair is a double
rate spring and as such is formed with two longitudinal sections of
different helical pitches for conveying forces employed to depress
the key to the switch associated with the assembly to effect
closure of the same, as well as for substantially reducing if not
eliminating a detrimental contact "bounce" encountered in the
operation of such assemblies. The force transmitting spring member
acts through a terminal member shaped to provide a teetering motion
in conjunction with the desired bifurcated action for assuring
closure of the contacts. The assembly is composed of parts formed
mainly of plastic material molded to shape and as such provides a
durable, light-weight, and low cost structure.
Inventors: |
Sims, Jr.; Dewey M. (Westland,
MI) |
Assignee: |
Burroughs Corporation (Detroit,
MI)
|
Family
ID: |
23441777 |
Appl.
No.: |
05/366,128 |
Filed: |
June 1, 1973 |
Current U.S.
Class: |
200/5A;
200/517 |
Current CPC
Class: |
H01H
13/80 (20130101); H01H 13/52 (20130101); H01H
13/705 (20130101); H01H 2201/002 (20130101); H01H
2221/062 (20130101); H01H 2235/03 (20130101); H01H
2203/054 (20130101); H01H 2235/018 (20130101); H01H
2233/074 (20130101); H01H 2235/004 (20130101); H01H
2221/026 (20130101); H01H 2235/022 (20130101); H01H
2201/004 (20130101) |
Current International
Class: |
H01H
13/70 (20060101); H01H 13/705 (20060101); H01H
13/52 (20060101); H01h 013/70 () |
Field of
Search: |
;200/1R,5R,5A,67A,159R,159A,159B,340 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Scott; James R.
Attorney, Agent or Firm: Uren; Edwin W. Parker; Ralzemond B.
Hall; Charles S.
Claims
What is claimed is:
1. A switch assembly including, in combination:
a. a relatively rigid member having one of a pair of electrical
contacts on a surface portion thereof;
b. a flexible diaphragm having the other one of said pair of
electrical contacts on a surface portion thereof in opposed
confronting relation to said first one of said pair of contacts,
said diaphragm normally supporting its contact of the pair of
contacts in spaced relationship to the other contact of the pair of
contacts but being deflectable in the direction of the relatively
rigid member to effect closure of the pair of contacts;
c. a member mounted for movement along a path toward and away from
the pair of contacts and disposed on the side of the flexible
diaphragm opposite to the rigid member;
d. means for yieldingly resisting movement of the movable member
toward the rigid member and for effecting engagement of the
contacts of said pair of contacts as a concluding result of such
movement, said means comprising a pair of coiled springs of
different diameters and arranged coaxially with respect to one
another with the smaller diameter spring being at least partially
enclosed within the larger diameter spring;
e. one of said pair of springs having one end seated upon a
relatively stationary support and the other end engaged with the
movable member in such a manner as to yieldingly resist movement
thereof toward the pair of contacts; and
f. the other of said pair of springs having one end effectively
bearing against the flexible diaphragm and having the other end
engaging the movable member in such manner as to yieldingly resist
movement of the movable member toward the pair of contacts with the
result that the force exerted by such movement of the movable
member is effectively transmitted by the last mentioned spring to
the diaphragm to deflect the same in the direction to effect
closure of the pair of contacts.
2. The switch arrangement defined in claim 1 wherein said other of
said pair of springs is a multi-rate spring having its coils set at
least at two different helical pitches.
3. The switch arrangement defined in claim 1 wherein said other of
said pair of springs is a double rate spring so designed as to have
the transistion from one spring rate to the other occur at the time
closure of said pair of electrical contacts is effected.
4. The switch arrangement defined in claim 1 wherein the larger
diameter coiled spring serves as said one of said pair of coiled
springs and the smaller diameter coiled spring serves as said other
of said pair of coiled springs.
5. The switch arrangement defined in claim 4 wherein the movable
member is in the form of a reciprocating plunger which is hollowed
interiorly to provide a chamber opening out of the plunger in the
direction of the diaphragm and shaped internally to partially
enclose and seat one end of the smaller diameter spring and shaped
externally to enter one end of the larger diameter spring and
provide a seat therefore.
6. The switch arrangement defined in claim 5 wherein conical
surfaces are presented to the respective inside diameters of the
smaller and larger coiled springs to prevent lateral deflection of
the springs as they are compressed.
7. The switch arrangement defined in claim 4 wherein said smaller
coiled spring acts upon the diaphragm through the intermediary of
an element having spaced apart projections engageable with
corresponding spaced areas of the diaphragm to deflect these areas
in the direction for closing said pair of contacts.
8. The switch arrangement defined in claim 7 wherein one of said
pair of contacts is split into at least two circuit parallel leads,
and wherein said spaced apart projections of said element
individually align with the circuit parallel leads for providing a
bifurcated action on the pair of contacts to close the same.
9. The switch arrangement defined in claim 8 wherein said element
has a limited universal tilting movement as closure of said pair of
contacts is being effected.
10. The switch arrangement defined in claim 7 wherein said element
is in the form of a plate-like member having the central portion
thereof deflectable out of its normal plane when said smaller
diameter coiled spring is transmitting the force of the movable
member toward the diaphragm.
11. In a keyboard-type switch construction in which laminates are
superposed in close proximity to one another, the combination:
a. a base panel having an electrically insulating surface divided
into a plurality of switching areas;
b. an electrical conducting switch contact element carried upon
said surface of the base panel within each of said switching
areas;
c. a flexible diaphragm overlying the said plurality of switching
areas of the base panel and normally supported in spaced relation
thereto, said diaphragm carrying an electrical conductive switch
contact element on the side thereof facing said base panel and
within each of said switching areas thereof;
d. a depressible switch operating member located on the side of the
diaphragm opposite to said base panel within each of said switching
areas thereof and supported for movement toward and away from the
base panel, each said member being effective upon depressive
movement to engage and depress an adjacent portion of said
diaphragm and thence to bring the switch contact element which is
carried thereby within the switching area of the depressed member
into engagement with the fixed contact element within the
corresponding switching area of the base panel; and
e. spring means opposing the depression of said member and
resisting each such movement with a relatively low spring rate
prior to engagement of said contact elements with one another and
with a second higher spring rate following engagement of the
contacts with one another.
12. The switch construction defined in claim 11 wherein each
conductive switch element carried by said flexible diaphragm is
divided into at least two parts each of which is acutely angled
into edgewise engagement with the corresponding contact element
carried by the base panel when the operating member is
depressed.
13. The switch construction defined in claim 11 wherein each
conductive switch element carried by said flexible diaphragm is
split into at least two circuit parallel leads each having a gap
therein, and wherein the leads terminate at the gap in a radius of
curvature and are capable when the operating member is depressed of
being acutely angled into point engagement with the corresponding
contact element carried by the base panel.
14. In a keyboard-type switch construction in which laminates are
superposed in close proximity to one another, the combination:
a. a supporting member having an electrically insulating surface
divided into a plurality of switching areas;
b. an electrical conducting switch contact element carried upon
said surface of the supporting member within each of said switching
areas;
c. a flexible diaphragm overlying the said plurality of switching
areas of the supporting member and normally supported in spaced
relation thereto, said diaphragm carrying an electrical conductive
switch element on the side thereof facing said supporting member
and within each of said switching areas thereof, each said switch
element having an edge portion thereof terminating centrally of its
switching area and being deflectible with the diaphragm to assume
an angle to the surface of the supporting member;
d. a switch actuator located on the side of the diaphragm opposite
to said supporting member within each of said switching areas
thereof and mounted for movement toward and away from the
supporting member, each such switch actuator being effective upon
movement toward the supporting member to engage and depress an
adjacent portion of said diaphragm and thence to move that switch
contact element which is carried by the diaphragm within the
switching area of the moving actuator at an angle toward and into
edgewise engagement with the corresponding contact element carried
by the supporting member; and
e. spring means associated with each switch actuator and yieldingly
opposing its movement toward the supporting member and being
operable to return its associated actuator and the adjacent
depressed portion of the diaphragm to normal inoperative
position.
15. The switch construction defined in claim 14 wherein each
conductive switch element carried by said flexible diaphragm is
divided into at least two parts each of which is acutely angled
into edgewise engagement with the corresponding contact element
carried by the base panel when the operating member is
depressed.
16. The switch construction defined in claim 14 wherein each
conductive switch element carried by said flexible diaphragm is
split into at least two circuit parallel leads each having a gap
therein, and wherein the leads terminate at the gap in a radius of
curvature and are capable when the operating member is depressed of
being acutely angled into point engagement with the corresponding
contact element carried by the base panel.
17. The switch construction defined in claim 14 wherein the spring
means includes a coiled spring in each of said switching areas and
effectively extending between each of said switch actuators and the
portion of the diaphragm within the switch area of the actuator,
said spring being a multi-rate spring operable to transfer from a
lower spring rate to a higher spring rate at approximately the time
the contact element carried by the diaphragm makes initial
engagement with the corresponding contact element carried by the
supporting member.
18. A switch assembly including, in combination:
a. a relatively rigid member having one of a pair of electrical
contacts on a surface portion thereof;
b. a flexible diaphragm having the other one of said pair of
electrical contacts on a surface portion thereof and in opposed
confronting relation to said first mentioned one of said pair of
contacts, said diaphragm normally supporting its contact of the
pair of contacts in spaced relationship to the other contact of the
pair of contacts but being deflectible in the direction of the
relatively rigid member to effect engagement of the pair of
contacts;
c. a switch actuating member mounted for movement along a path
toward and away from the pair of contacts and disposed on the side
of the flexible diaphragm opposite to the rigid member;
d. means for yieldingly resisting movement of the movable member
toward the rigid member and for effecting engagement of the
contacts of said pair of contacts in the course of such movement,
said means comprising at least one spring member arranged to
yieldingly oppose movement of the movable member toward the rigid
member;
e. one of said pair of contacts having at least two spaced apart
circuit parallel portions, and the other of said pair of contacts
having surface areas thereof confronting the circuit parallel
portions of the first contact; and
f. spaced apart projections individually aligning with the circuit
parallel portions and responding to movement of the movable member
toward the rigid member for first engaging and then deflecting
corresponding spaced apart areas of the diaphragm toward the rigid
member thereby to cause a bifurcated switch closing action to occur
between the pair of contacts.
19. In a keyboard-type switch construction in which laminates are
superposed in close proximity to one another, the combination:
a. a base panel having an electrically insulating surface divided
into a plurality of switching areas;
b. an electrical conducting switch contact element carried upon
said surface of the base panel within each of said switching
areas;
c. a flexible diaphragm overlying the said plurality of switching
areas of the base panel and normally supported in spaced relation
thereto, said diaphragm carrying an electrical conductive switch
contact element on the side thereof facing said base panel and
within each of said switching areas thereof;
d. a depressible switch operating member located on the side of the
diaphragm opposite to said base panel within each of said switching
areas thereof and supported for movement toward and away from the
base panel, each said member being effective upon depressive
movement to engage and deflect an adjacent portion of said
diaphragm and cause the switch contact element carried thereby
within the switching area of the depressed member to move into
engagement with the fixed contact element within the corresponding
switching area of the base panel;
e. spring means opposing the depression of each of said switch
operating members and for returning the same and the diaphragm to
normal undeflected state; and
f. each said switch contact element carried by said flexible
diaphragm having an electrically conductive extension terminating
approximately midway of its switching area and capable when the
adjacent portion of the diaphragm is deflected by the switch
operating member of being acutely angled into edgewise engagement
with the corresponding switch contact element carried by the base
panel.
20. The switch construction defined in claim 19 wherein each
conductive switch element carried by said flexible diaphragm is
divided into at least two circuit parallel leads each having a gap
therein.
21. The switch construction defined in claim 20 wherein each said
circuit parallel lead terminates at the gap in a radius of
curvature and is capable when the adjacent portion of the diaphragm
is deflected by the operating member of being acutely angled to
bring its curved terminating end into point engagement with the
corresponding switch contact element carried by the base panel.
22. In a keyboard-type switch construction in which laminates are
superposed in close proximity to one another, the combination:
a. a supporting member having an electrically insulating surface
divided into a plurality of switching areas;
b. an electrical conducting switch contact element carried upon
said surface of the supporting member within each of said switching
areas;
c. a flexible diaphragm overlying the said plurality of switching
areas of the supporting member and normally supported in spaced
relation thereto, said diaphragm carrying an electrically
conductive switch element on the side thereof facing said
supporting member and within each of said switching areas thereof,
each said switch element having an edge portion thereof terminating
within the border of its switching area and being deflectible with
the diaphragm to assume an acute angle to the surface of the
supporting member; and
d. a switch actuator located on the side of the diaphragm opposite
to said supporting member within each of said switching areas
thereof and mounted for movement toward and away from the
supporting member, each such switch actuator being effective upon
movement toward the supporting member to engage and deflect the
adjacent portion of said diaphragm and thereby cause the switch
contact element which is carried by the diaphragm within the
switching area of the moving actuator to move at an acute angle
toward and into edgewise engagement with the corresponding contact
element carried by the supporting member.
23. The switch construction defined in claim 22 wherein each
conductive switch element carried by said flexible diaphragm is
divided into at least two parts, each of which is acutely angled
into edgewise engagement with the corresponding contact element
carried by the base panel when the operating member is sufficiently
depressed to deflect the adjacent portion of the diaphragm.
24. The switch construction defined in claim 23 wherein each
conductive switch element carried by said flexible diaphragm is
split into at least two circuit parallel leads each having a gap
therein, and wherein the terminating end of each lead is
progressively reduced in width at the gap such that when the
operating member is depressed and deflects the adjacent portion of
the diaphragm the terminating ends of the leads are acutely angled
into point engagement with the corresponding contact element
carried by the base panel.
Description
BACKGROUND OF THE INVENTION
This invention is directed to that field of art pertaining to
switch actuating keyboards and more particularly to the structure
of the individual keys thereof for closing associated electrical
switches.
SUMMARY OF THE INVENTION
An important object of this invention is to provided an improved
key assembly for switch actuating keyboards which is designed for
reliable, long life usage.
Another important object of the invention is to provide a switch
actuating key structure which is designed in an improved manner to
eliminate "bouce" of the electrical contacts.
Another important object of the invention is to provide an improved
switch actuating key operated assembly which eliminates premature
electrical contact as well as helping in reducing the severity of
vibration transmissibility occurring at the switch.
A further important object of the invention is to provide an
improved bifurcated action for the individual keys of a
keyboard.
More specifically, the objects of the invention are effectively and
economically carried out with the cooperation of the parts forming
the key assembly in conjunction with certain diaphragms carrying
conductive elements thereon to form the electrical switch for the
actuatable parts of the key. Included in such a key mechanism are a
pair of coiled springs coaxially and overlappingly related to one
another and such that one coil spring acts to resist depression of
the key and the other acts to transmit the actuating forces for
closing the electrical contacts serving as the switch. For timing
the closure of the switch in the operation of the key assembly as
well as to improve the tactile feel thereof, the force transmitting
coil spring is especially designed so as to have two distinctive
spring rates as it is compressed. In addition, the force
transmitted by this coil spring is conveyed through an improved
bifurcated provision for insuring closure of the switch.
The above listed objects, advantages and other meritorious aspects
of the invention will be more fully explained in the following
detailed description. For more complete understanding of the
invention, reference may be had to the following detailed
description in conjunction with the accompanying drawing
sheets.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded perspective view of a fragmentary portion of
a keyboard showing the parts of one of the key assemblies in their
order of assembly;
FIG. 2 is an enlarged vertical sectional view through a key switch
assembly constructed in accordance with this invention showing the
parts of the assembly in its normal undepressed condition;
FIGS. 3 and 4 are vertical sectional views similar to that of FIG.
2 but of smaller scale and illustrating the parts of the assembly
in its raised and depressed conditions respectively;
FIG. 5 is an enlarged detail view of the double rate spring
employed as the force transmitting member for actuating the
switch;
FIG. 6 is a force deflection graph illustrating the action of the
double rate spring of FIG. 5;
FIG. 7 is an enlarged detail view of the under surface of the
switch actuating part;
FIG. 8 is an enlarged detail view of the upper surface of the
switch actuating part of FIG. 7;
FIG. 9 is an enlarged detail sectional view taken along line 9--9
of FIG. 7 and illustrating the action of one of the bifurcated
elements;
FIG. 10 is a sectional view similar to FIG. 9 but taken on line
10--10 of FIG. 7; and
FIG. 11 is an enlarged detail view of the conductor patterns
forming the contacts.
Referring to the drawing, a fragmentary portion of a keyboard
incorporating the present invention is generally shown in exploded
perspective condition in FIG. 1. In general, the top member 10 of
the keyboard may be formed of hardened plastic material molded so
as to provide a plurality of key stem guides 12 protruding
thereabove which may be arranged in crossing rows and columns in
accordance with conventional practice. At the bottom end of the
keyboard is a base member 14 which may either be a printed circuit
board formed of molded plastic material and bearing conductive
elements on its upper surface or be a metal plate overlaid by a
thin sheet of electrically insulating material bearing electrically
conductive elements or leads 16 on the upper surface thereof so as
to be insulated from the metal base. Interposed between the base
plate 14 and the top member 10 of the keyboard are the plurality of
key actuatable assemblies, one for each key of the keyboard, for
individually closing and opening a switch associated with the
conductive elements carried by the base member 14. In general, the
keyboard of the present invention is structured to include a number
of layers between these two members 10 and 14 which are shown in
FIG. 1 in their order of assembly.
With more specific reference to FIGS. 1 and 2, the layer
immediately above the base member 14 is a dielectric 18 serving as
a thin electrical separator between adjacent layers and having
cutouts or apertures 20 formed therein which are grouped together
in pairs with one for each key assembly as will be described in
more detail hereinafter. Immediately above the dielectric member 18
is a diaphragm 22 of insulating material carrying conductive leads
24 on its under surface which are likewise paired for each key
assembly as will be later described herein. Immediately
superimposing the diaphragm 22 is a cover member 26 which may be
formed of rubber material and serves as a thin deflectable paid as
also will be more fully described hereinafter. Over this pad, and
in slight spaced relation therefrom, is a thicker and more rigid
flexural member 28 formed of molded plastic material shaped at each
key position of the keyboard with an upwardly extending stud or
protrusion 30 which is preferably conically shaped as is
illustrated in FIGS. 1 and 2. Each cone 30 is centrally located
within a square area formed by a wall 32 molded at the time of the
fabrication of the member 28 but of greater thickness than the
normal thickness of the panel as better shown in FIG. 2. Between
each cone 30 and its wall 32, the member 28 is weakened by narrow
top and bottom opening slits 34 which enable the central conical
portion of the walled area to be deflected out of the plane of the
panel as later more fully described herein.
Slightly spaced above the member 28 is a thin metal plate 36 having
a soft cushioning layer 38, such as felt, bonded to the upper
surface thereof. The plate 36 and its felt lining 38 are apertured
as at 40 in alignment with each key of the keyboard and the
apertures are of such a size to admit the conical studs 30 as
evidenced in FIG. 2. Associated with each key of the keyboard are a
pair of coiled springs of different diameters and coaxially related
and positioned so that the smaller diameter spring 42 is at least
partly enclosed by the larger diameter spring 44 as shown in FIG.
2. The larger diameter coiled spring 44 of each key assembly has
its lower end seated upon the felt layer 38 bonded to the metal
plate 36. The smaller diameter coiled spring 42 of each key
assembly is of a size to enter its associated aperture 40 of the
metal plate 36 and encircle the conical protrusion 30 with which it
is associated for seating on the immediately surrounding flat base
of member 28 as shown in FIG. 2. The upper ends of these two coiled
springs 42 and 44 are seated in a movable member or plunger 46
which serves as a key stem and rises upwardly through its
associated guide 12 of the top member 10 of the keyboard and
projects thereabove in assembled condition as shown in FIG. 2.
Secured to the upper projecting end of the plunger 46 is a key top
or button 48 which is shaped to receive the upper end of the
plunger and to be releasably secured thereto.
With further reference to FIGS. 1 and 2, the plunger guide 12 of
each key assembly has a tubular upper section 50 slightly narrowing
in both its inner and outer diameters as the upper end thereof is
reached. This tubular portion of the guide 12 merges with a
square-shaped, box-like lower section 52 which is seated upon the
felt lined metal plate 36 in surrounding relation to the conical
protrusion 30 entering the bottom opening thereof. For interfit
with the guide 12, the plunger 46 is composed of an upper and lower
section of different lateral dimensions. As shown in FIG. 2, the
upper section 54 of the plunger slidingly bears against the inner
surface of the upper rim of the tapered tubular section 50 of the
guide, and the wider base section or collar 56 of the plunger is
received in the wider lower section 52 of the guide. The plunger's
wider section 56 is externally square-shaped as shown in FIG. 1 and
is dimensioned to have a sliding fit within the box-shaped lower
section 52 of the guide. Actually, only the corner portions of the
wider section 56 of the plunger are utilized for sliding contact
with the inner walls of the lower section 52 of the guide. This may
be accomplished in the manner illustrated herein by folding back
the bottom rim portion of the plunger through a reverse circular
bend as indicated at 58 in FIG. 2 and then forming the square
collar 56 by an opposite reverse bend to bring down the four right
angle corner portions 60 to the same level as the reverse bend 58
of the collar. The walls of the collar 60 are relatively thin as
compared with the reversely bent portion 56. Preferably, as
illustrated in FIG. 2, only the bottom edge of the corners of the
collar section 60 have a sliding fit with the inner wall surfaces
of the guide section 52. For this purpose, the corner portions 60
are slightly outwardly flared in the downward direction to bring
only the lower edges thereof into sliding engagement with the inner
wall of the guide section 52. In this manner only the extreme upper
and lower end portions of the plunger have a sliding engagement
with the guide, the maximum longitudinal separation of these
sliding contact surfaces providing widely separated bearings for
holding the plunger 12 from other than a straight line movement in
the direction of its axis. The deviation in lateral extent of the
upper and lower edges of the collar corners 60 may be in the order
of .0010 of an inch for this purpose.
The protruding end of the plunger has an interlocking relationship
with the key top 48 such that the latter may be releasably but
firmly snapped on and removed without difficulty. This is
accomplished by providing a cross shaped entrance 62 into the upper
end of the plunger 46 which is dimensioned to receive four
depending resilient prongs 64 integrally joined to the body portion
of the key top 48. The bases 66 of the grooves forming the cross
shaped entrance 62 slope slightly toward the axis of the plunger as
evident in FIG. 2 and each forms a shoulder 68 at its lower end.
The extremities of the prongs are each thickened radially outwardly
so as to be cammed inwardly by the sloping bases 66 until each
prong rides over its shoulder and thereafter expands into
interlocking engagement therewith as shown in FIG. 2. When force is
applied to remove the key top 48, the prongs are resiliently
contracted as they ride over the shoulders 68 and thereby free the
key top from the plunger.
As earlier mentioned herein, the upper ends of the two coiled
springs 42 and 44 are seated on the plunger. In the assembled
condition of the parts, the smaller diameter inner spring 42 has a
length such that when freely extended as shown in FIG. 2, it is
approximating twice that of the outer spring. However, in its
assembled condition, the outer spring 44 is under compression or
otherwise in freely extended condition its length would approximate
that of the inner spring 42. The upper end of the inner spring 42
overrides a downwardly depending cone 70 providing a tapered
conical surface for holding the upper end of the spring against
lateral bending movement when compressed in operation. The outer
coiled spring 44 surrounds the reversely bent portion 56 of the
plunger and enters a narrow space between this portion and the
depending square shaped collar 60 of the plunger. In this fashion
the upper ends of the two springs 42 and 44 are retained between
tapered conical surfaces and thus prevented from lateral bending or
snagging movement when either spring is compressed. Moreover, as
illustrated in FIGS. 2 and 5, the opposite ends of the two springs
42 and 44 are preferably closed and ground.
It will be noted that one of the coiled springs, namely, the inner
smaller diameter spring 42, has its convolutions at two different
helical pitches. Referring to FIGS. 1, 2 and 5, the upper end
section 72 of the coiled spring 42 in the illustrated embodiment of
the invention has a fine pitch as compared with the coarser or
wider pitch of the coils of the lower section 74 of the spring. The
result is that spring 42 has a low spring rate (see FIG. 6) which
assists in eliminating premature electrical contact while its high
spring rate insures electrical contact before the key top goes
beyond a desired limit. The combination of both rates in the same
spring allows the key top force to be relatively low at first
before a predetermined point in the plunger's movement is reached.
The two spring sections 72 and 74 of inner spring 42 initially act
as two independent springs in series, but as the inner spring is
compressed, it progresses from a low rate spring into a high rate
spring in a predetermined transistion zone B to D (theoretically it
could be point C) of FIG. 6. The resulting effective higher spring
rate helps eliminate contact bounce by reducing the severity of the
transmission of any vibration occuring between the inner spring 42
and the contact bearing diaphragm 22.
The force deflection graph of FIG. 6 illustrates the action of the
dual rate spring 42. Initially, the resistance to compression of
the total spring 42 is at a relatively low rate as evidenced by the
slope of the graph between A and B. As the finer pitch coils of
section 72 of the spring make abutting engagement with one another,
the spring rate changes to a higher rate as indicated by the
steeper slope of the graph between D and E. At approximately the
point D on the graph, all of the coils of spring section 72 are in
contact with one another thus terminating all resiliency in this
section of the spring. Thereafter, the coils of the spring section
74 are the only active ones remaining in the spring for resiliently
resisting downward movement of the plunger 46 and its key top 48.
The dual rate spring 42 should be chosen so that electrical contact
is made by the key assembly in the transistional area of the graph
between B and D and preferably nominal contact should be made at
the time point C is reached.
To gain the earlier mentioned bifurcated action, the underside of
the flexure member 28 opposite each conical protrusion 30 is
provided as best shown in FIG. 7 with a pair of depending pressure
applying elements 76--76 of similar half-moon shape. Such elements
are suspended from the underside of the flexure 28 in spaced
parallel relation to one another and on diametrically opposite
sides of the axis of the cone 30 as shown in FIG. 3. Each element
preferably exhibits an arcuate lower edge for engaging and
depressing the rubber cover 26 making a curved or rocking
chair-type contact therewith, and moreover these elements
preferably form an integral part of the flexure 28 as evidenced by
the cross hatching in FIG. 2. By such an arrangement and formation,
the two arcuate elements 76--76 collectively form a double radius
pressure applying structure incorporating a teetering ability
analogous to the legs of a rocking chair.
In addition, as best shown in FIG. 8, the upperside of the flexure
member 28 on two opposite sides of each cone 30 there is provided a
pair of similar narrow-shaped ledges of lands 78--78 located in a
plane intersecting the cone's axis and extending to a height
preferably flush with the upper surfaces of the thickened wall
portions 32 surrounding the cone section of the flexure 28. The two
lands 78--78 together form a seat for the lower end of the inner
coiled spring 42. They also form an axis about which each cone
section or square of the flexure 28 may rock when the pressures are
transmitted by the spring 42. This axis extends at 90.degree. or
right angles to the rocking axis of the arcuate elements 76--76 on
the underside of each cone section of the flexure 28. The result is
that each cone bearing square of the flexure 28 is capable of
rocking about either axis separately or both axes concurrently as
downward pressure is applied by the inner spring 42 in response to
the depression of its keyboard key. It is evident that each square
of the flexure is not only depressible in response to key actuation
but also is capable of rocking motion about either or both such
axes. Thus, the desired bifurcated action is achieved by converting
forces exerted by the spring 42 to two separated pressure applying
areas in response to each depression of the key while at the same
time enabling the bifurcated end of the double rate spring to
teeter or rock about two perpendicularly related axes for assuring
closure of the switch contacts.
The result of a key actuation is shown by comparing FIGS. 3 and 4
with one another. FIG. 3 shows the position of the parts similar to
that of FIG. 2 where the key top is raised to its maximum level and
the coiled spring 42 is under no compression. FIG. 4 shows the
position of the parts when the key top is fully depressed to its
maximum extent. It is noted in FIG. 4 that the cone 30 of the
flexure 28 has been depressed below its normal level shown in FIG.
3 which in turn causes the arcuate shaped elements 76--76 to
depress the rubber cover 26 and the diaphragm 22 downwardly
bringing the conductive leads 24 on the underside of diaphragm 22
into engagement with the conductive pads 16 on the base member 14
of the assembly. In so doing, the depending elements 76--76 are
brought into alignment with the pair of parallel leads 24 on the
underside of diaphragm 22 and depressing them through the pair of
oval apertures 20 of the dielectric 18 in alignment therewith and
thence bringing these leads into contact with the conductive pad 16
of the base member 14 which registers therewith. The intervening
portion 80 of the dielectric 18 which separates the oval holes 20
provides independent deflection zones into which the two parallel
leads 24 are introduced for engagement with the separated portion
of the pad 16 located in the position of the actuated key. In
effect, the intervening portion of the dielectric acts as a shim
which is straddled by the bifurcated structure 76--76 and about
which it may teeter or rock.
FIGS. 9, 10 and 11 illustrate the action of making contact between
the leads 24--24 of the flexible diaphragm 22 and the pads 16 of
the base member 14. The conductive patterns on the two laminates 22
and 14 may be that illustrated in FIG. 11 where in each key
position of the keyboard the base member 14 is provided with a
conductive pattern such as represented in the lower right hand
corner of FIG. 11 comprising the two conductive areas or pads
16--16 joined by conductive leads 82 to a peripheral conductor 84
which in turn can be connected to one or more adjacent conductive
patterns on the base member. Immediately superposing the conductive
pattern on base member 14 is the earlier mentioned dielectric sheet
18 having a pair of generally oval-shaped cutouts or apertures
20-20 in each key position which as shown in FIG. 11 will expose
the pads 16--16 therethrough.
Above the dielectric 18 sheet is the diaphragm 22 which may bear
the conductive pattern on the underside thereof illustrated in the
lower left corner of FIG. 11. The diaphragm is preferably a thin
elastomeric member which may be translucent rendering the pattern
on the underside thereof visible therethrough as indicated in FIGS.
1 and 11. For purposes hereinafter discussed, each lead 24 is shown
in FIGS. 1 and 11 as being interrupted or broken to form a gap 86
therein. These broken or split leads 24--24 are connected at their
outer ends to a peripheral conductor 88 which preferably registers
with and therefore overlies and bears upon the peripheral conductor
84 of the base member 14 through the intermediary of the insulating
sheet 18. Thus, during the depression of each switch assembly, the
registering peripheral conductors 84 and 88 provide a bearing zone
or frame surrounding the central area containing the pads 16 and
the broken leads 24.
An important feature of the switch formed by the overlying
conductive patterns is that provided by the division of each lead
24 into two aligned sections separated by the gap 86 and the
provision of a radius of curvature identified at 90 on the gap end
of each part of the divided lead. Referencing FIG. 9, it will be
apparent that when the bifurcated pressure elements 76--76 of each
switch assembly depress the laminates 22 and 26 through the holes
20--20 of the dielectric sheet as shown in FIGS. 9 and 10, they
will bow the gap portions of the leads 24--24. Moreover, because of
the bowing of the split sections of each lead 24, the initial
contact made by such lead with its pad 16 is a point of high
pressure which is later spread over more surface area of the lead
as the key assembly is further depressed. The curving of the ends
of the split parts of each lead 24 at the gap 86 assures that the
first contact with the pads 16 of the base member is a point on the
bottom right-angled edge of one of the extremities 90 of the
divided parts of each lead 24. Furthermore, following initial
contact the divided lead sections are progressively flattened by
further depression of the key assembly and in so doing the two gap
ends 90 of each lead move slightly toward one another in scrubbing
contact with the conductive pad 16.
In carrying out the aforesaid switch action, it is desirable
because of the limited amount of force for deflecting the laminates
22 and 26 to remove or etch away as much conductive material from
the pattern as possible leaving only enough of such material in the
least strained direction (which is the direction of the long axis
of each oval opening 20) for reliably performing the conductive
function of the pattern. The removal of such material will lower
the force needed to flex the diaphragm. By also dividing the
conductor leads 24--24 in the center of the oval opening, the
diaphragm will be further weakened thus removing the resistance to
bending moment of each conductor lead at the midpoint of its span.
It is preferred that pattern symmetry be employed in order to
produce consistent results. Lastly, the breaks or gaps 86 provided
by the division of the conductor leads 24--24 in the center of each
oval zone 20 and the radius of curvature applied to the ends 90 of
the leads terminating at the gap will make as high a pressure point
contact as possible with its associated conductive pad 16 by
bringing the acutely angled end 90 of each divided lead 24 into
point contact with the flat surface of the pad. The result is that
when the engagement between the contacts 16 and 24 first occur, the
high loading point 90 of each divided lead will first make a high
pressure point contact with the associated pad 16, and then
thereafter as further key pressure is applied the terminating ends
90 of the split leads 24 begin to flatten out and at the same time
move toward one another with a microscopic scrubbing action on the
flat surface of the conductive pad 16.
The electronic keyboard operation can be described as follows. It
is evident from the earlier description herein that when an
operator pushes on the key top the force travels through the key
top to the plunger. A small part of this force goes to the outer
compression spring 44 and the rest goes to the inner compression
spring 42. In a desired embodiment of the invention, the outer
spring keeps the key top in its most upward location with a preload
of about 40 grams. The inner spring has no load on it when the key
top is fully up but begins compressing as soon as the key top
starts to travel downward. The outer spring has a low rate of 45
grams per inch and thus adds little extra resistance as the key top
travels downward. In contrast, in a preferred embodiment of the
invention, the inner spring has a spring rate of 239 grams per inch
for the first .090 inches of travel and a rate of 1193 grams per
inch for the next .087 inches of key top travel.
The load on the outer spring 44 is transmitted to the spacer plate
36 and does not affect the diaphragm switch. But the load on the
inner spring 42 puts a load on the upper diaphragm or flexure 28
which in turn transmits most of this load equally to both of the
depending rocking element pads 76--76. Each pad 76 then produces a
relatively high pressure area on the rubber cover 26 and in turn on
the lower diaphragm 22. This load then causes the rubber cover and
the lower diaphragm to deflect through its associated pair of oval
holes 20 in the dielectric 18 until the conductive leads on the
underside of the lower diaphragm contact the conductive elements or
pads on the circuit board 14. As the load from the inner spring 42
continues to increase, the contact pressure increases accordingly.
The bifurcated action together with the teetering capability of the
cone section of the panel 28 about which the lower end of the
spring is seated will overcome any irregularities encountered in
making electrical contact between the conductive elements of the
assembly.
While a particular embodiment of the invention has been shown and
described, it will be understood, of course, that it is not desired
that the invention be limited thereto since modifications may be
made, and it is, therefore, contemplated by the appending claims to
cover any such modifications as fall within the true spirit and
scope of the invention.
* * * * *