U.S. patent number 3,886,012 [Application Number 05/387,909] was granted by the patent office on 1975-05-27 for method of assembly of keyboard switch by ultrasonics.
This patent grant is currently assigned to Bowmar Instrument Corporation. Invention is credited to Laurie F. Slater.
United States Patent |
3,886,012 |
Slater |
May 27, 1975 |
Method of assembly of keyboard switch by ultrasonics
Abstract
A method of assembling a keyboard of the type used in electronic
calculators in which a first Mylar sheet having openings therein
for receiving switch elements is selectively ultrasonically bonded
to an underlying printed circuit board, the switch elements are
placed in the openings in the first sheet, and a second Mylar cover
sheet is selectively ultrasonically bonded to the underlying first
sheet.
Inventors: |
Slater; Laurie F. (Fort Wayne,
IN) |
Assignee: |
Bowmar Instrument Corporation
(N/A)
|
Family
ID: |
23531807 |
Appl.
No.: |
05/387,909 |
Filed: |
August 13, 1973 |
Current U.S.
Class: |
156/73.1;
156/289; 156/298; 156/300; 156/324.4; 156/580.2; 200/5E; 264/69;
156/249; 156/290; 156/313; 156/580; 200/5A; 200/5R; 228/110.1 |
Current CPC
Class: |
B29C
66/847 (20130101); B29C 66/1122 (20130101); B29C
65/08 (20130101); B29C 65/4815 (20130101); H01H
13/7006 (20130101); B29C 66/8322 (20130101); B29C
66/53461 (20130101); B29C 66/45 (20130101); B29C
66/81431 (20130101); B29C 66/7392 (20130101); B29C
66/74 (20130101); B29C 66/73921 (20130101); B29C
66/71 (20130101); B29L 2031/466 (20130101); Y10T
156/1093 (20150115); B29C 66/742 (20130101); B29L
2031/3425 (20130101); Y10T 156/109 (20150115); B29C
66/71 (20130101); B29K 2067/003 (20130101); B29C
66/71 (20130101); B29K 2067/00 (20130101) |
Current International
Class: |
B29C
65/08 (20060101); B29C 65/00 (20060101); H01H
13/70 (20060101); B32g 031/20 () |
Field of
Search: |
;200/5R,5A,5E
;156/73,580,309,289,290 ;29/470.3 ;161/406,DIG.7 ;264/69 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Whitby; Edward G.
Claims
What is claimed is:
1. The method of assembling a keyboard comprising the steps of:
a. providing an insulative, planar board having opposite surfaces,
one of said surfaces having at least one switch contact
thereon,
b. providing a first sheet of insulating material having opposite
surfaces respectively coated with ultrasonically actuatable
adhesive material, said first sheet having an opening therein
adapted to receive a switch element,
c. placing one surface of said first sheet on said one surface of
said board with said contact exposed to said opening,
d. placing a second sheet of material which will not bond to said
adhesive material on the other surface of said first sheet thereby
forming a first sandwich comprising said board and said first and
second sheets,
e. placing said first sandwich in ultrasonic welding apparatus and
energizing the same thereby to activate said adhesive material on
said one surface of said first sheet to bond the same to said one
surface of said board,
f. removing said first sandwich from said apparatus and removing
said second sheet from said first sheet,
g. placing a switch element in said opening in cooperative
relationship with said contact,
h. placing a third sheet of insulating material on said other
surface of said first sheet over said switch element thereby
forming a second sandwich comprising said board and said first and
third sheets,
i. placing said second sandwich in said apparatus and energizing
the same thereby to actuate said adhesive material on said other
surface of said first sheet to bond the same to said third sheet,
and
j. removing the thus bonded second sandwich from said
apparatus.
2. The method of claim 1 wherein said apparatus includes a horn
having a surface selectively movable into engagement with said
second and third sheets respectively, said horn surface having an
opening therein of generally the same size as said first sheet
opening, said placing steps (e) and (i) including orienting said
first and second sandwiches, respectively, so that said first sheet
opening is in registry with said horn surface opening.
3. The method of claim 2 wherein there are a plurality of said
first sheet openings arranged in a predetermined pattern, a
corresponding plurality of contacts and switch elements, and a
corresponding plurality of horn openings arranged in the same
pattern, said horn openings being respectively in registry with
said first sheet openings in said placing steps (e) and (i).
4. The method of claim 3 wherein said adhesive material is a
heat-activated, thermoplastic polyester film.
5. The method of claim 4 wherein said sheets of insulating material
are polyethylene terephthalate.
6. The method of claim 5 wherein said second sheet is wax
paper.
7. The method of claim 1 wherein said apparatus produces mechanical
vibrations in said horn in the region of 20kHz.
8. The method of claim 2 wherein said horn is moved into engagement
with said first and second sandwiches, respectively, during said
placing steps (e) and (i), and approximately 50 pounds per square
inch pressure is applied thereby to the respective sandwich.
9. The method of claim 1 wherein said appratus is energized for
approximately 11/2 seconds during said placing step (e), and for
approximately 6/10 second during said placing step (i).
10. In a method of assembling a keyboard, the steps comprising:
a. providing an insulative, planar board having opposite surfaces,
one of said surfaces having at least one switch contact
thereon,
b. providing a planar sheet having opposite surfaces, at least one
of said surfaces being coated with ultrasonically actuatable
adhesive material, said sheet having an opening therein,
c. placing said one surface of said sheet on said one surface of
said board with said contact exposed to said opening thereby
forming a sandwich comprising said board and sheet,
d. placing said sandwich in ultrasonic welding apparatus including
a horn having a surface selectively movable into engagement with
the other surface of said sheet, said horn surface having an
opening therein in registry with said sheet opening,
e. energizing said apparatus thereby to actuate said adhesive
material thereby to bond said sheet to said board, and
f. removing the thus-bonded sandwich.
11. The method of claim 10 wherein there are a plurality of said
sheet openings arranged in a predetermined pattern and a
corresponding plurality of horn openings arranged in the same
pattern and respectively in registry in said placing step (d).
12. The method of claim 11 wherein each of said horn openings is
generally the same size as the respective sheet opening.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a method of assemblying a
keyboard of the type used in electronic calculator apparatus.
2. Description of the Prior Art
U.S. Pat. No. 3,796,843 granted Mar. 12, 1974 to Gilbert H. Durkee,
Per G. Wareburg and Allen C. Yoder, assigned to the assignee of the
present application, discloses a keyboard switch assembly in which
a first sheet of insulating material having switch
element-retaining openings therein covers one side of a printed
circuit board having conductors thereon with terminal portions
exposed to the first sheet openings. Switch elements are positioned
in the first sheet openings in cooperative relationship with the
terminal portions and a second sheet of insulating material covers
the first sheet and the switch elements. Other keyboard switch
assemblies are shown for example in U.S. Pat. Nos. 3,643,041 and
3,684,842, German Pats. Nos. 486,212 and 180,6241, and IBM
Technical Disclosure Bulletin No. 12, Volume 7, May, 1965, Page
1168.
It has been conventional practice in such prior keyboard switch
assemblies to retain the printed circuit board and several sheets
of insulating material in assembled relation by the use of pressure
sensitive adhesive which requires the initial application of
protective cover sheets over the tacky adhesive and the subsequent
removal of such cover sheets, and permits dust and other foreign
particles to adhere to the tacky adhesive following removal of the
cover sheets but prior to final assembly.
Ultrasonic techniques have been employed for bonding or welding one
plastic article to another and for bonding plastic to metal.
Ultrasonic plastic welding apparatus is commercially available from
Branson Sonic Power Company (formerly Branson Instruments, Inc.)
and various forms of such apparatus together with various methods
employed thereby are disclosed in United States Patents assigned to
that compay, referring particularly to U.S. Pat. Nos. 3,284,257 and
3,480,492. In addition, U.S. Pat. No. 2,633,894 broadly discloses
the use of wax paper as a heat insulator in ultrasonic welding, the
U.S. Pat. No. 3,022,814 discloses the use of a thermoplastic layer
between two bodies for bonding the same ultrasonically.
SUMMARY OF THE INVENTION
The invention, in its broader aspects, provides a method of
assembling a keyboard including the steps of providing an
insulative, planar board having opposite surfaces, one of the
surfaces having at least one switch contact thereon, and providing
a planar sheet having opposite surfaces, at least one of the
surfaces being coated with ultrasonically-actuatable adhesive
material, the sheet having an opening therein. The adhesive-coated
surface of the sheet is placed on the one surface of the insulative
board with the contact exposed to the opening thereby forming a
sandwich comprising the board and the sheet. The sandwich is placed
in ultrasonic welding apparatus which includes a horn having a
surface selectively movable into engagement with the other surface
of the sheet, the horn surface having an opening therein in
registry with the sheet opening. The apparatus is then energized to
activate the adhesive material thereby to bond the sheet to the
board and the thus bonded sandwich is then removed from the
apparatus.
In the preferred embodiment of the invention, the sheet of
insulating material has both of its surfaces coated with
ultrasonically-actuatable adhesive material, another sheet of
material which will not bond to the adhesive material being placed
on the other surface of the insulative sheet prior to placing the
sandwich in the welding apparatus. Upon removal of the sandwich
from the apparatus, the other sheet is removed, a switch element is
placed in the opening in the insulative sheet in cooperative
relationship with at least one contact on the insulative board, and
another sheet of insulating material is placed on the other surface
of the first sheet over the switch element thereby forming a second
sandwich. The second sandwich is then placed in the apparatus which
is energized to activate the adhesive material on the other surface
of the first insulator sheet therby to bond the same to the second
insulative sheet, the resulting completely bonded sandwich being
then removed from the apparatus.
It is accordingly an object of the invention to provide an improved
method of assembling a keyboard.
Another object of the invention is to provide an improved method of
assembling a keyboard employing ultrasonic techniques.
A further object of the invention is to provide an improved method
of selectively, ultrasonically bondint the components of a
keyboard.
The above-mentioned and other features and objects of this
invention and the manner of attaining them will become more
apparent and the invention itself will be best understood by
reference to the following description of an embodiment of the
invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view, partly broken away, showing a keyboard switch
assembly including a keyboard which may be assembled by the method
of the invention;
FIG. 2 is a cross-sectional view taken along the line 2--2 of FIG.
1;
FIG. 3 is a fragmentary, exploded perspective view showing the
assembly of the first sandwich in accordance with the method of the
invention;
FIG. 4 is a side view showing the ultrasonic welding appartus
employed in performing the method of the invention, and further
showing bonding of the first sandwich;
FIG. 5 is a bottom plan view of the horn employed in the apparatus
of FIG. 4 as viewed generally along the line 5--5 of FIG. 4;
FIG. 6 is a fragmentary, exploded perspective view showing the
assembly of the second sandwich in accordance with the method of
the invention; and
FIG. 7 is a fragmentary view showing bonding of the second
sandwich.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, there is shown a keyboard switch
assembly of the type more fully shown and described in the
aforesaid U.S. Pat. No. 3,796,843. The illustrated keyboard switch
assembly, generally indicated at 10, comprises a keyboard
sub-assembly 11 and a cover member and push-button sub-assembly 21.
Keyboard sub-assembly 11 comprises single-sided printed circuit
board 12, snap-acting dome switch members 14, and switch member
retaining sheet 16 formed of suitable insulative material. Cover
and push-button sub-assembly 21 comprises cover member 20 and push
buttons 22. Switch members 14 and insulative sheets 16, 18 are
sandwiched between printed circuit board 12 and cover member 20 and
the keyboard switch assembly 10 is held in assembled relation by
rivets 24. The illustrative keyboard switch assembly 10 is intended
for use in an electronic calculator.
While keyboard switch assembly 10 includes a plurality of switching
sub-assemblies 28 each comprising one push-button 22, one
snap-acting dome switch member 14, and associated switch terminals
and conductors on upper surface 26 of printed circuit board 12,
each of the switching sub-assemblies are similar and functionally
identical and thus description of one such sub-assembly 28 will
suffice.
Printed circuit board 12 comprises a sheet of rigid plastic
material having one surface 26 copper clad, the conductors and
terminals on surface 26 being formed by photo-engraving techniques
as is well known to those skilled in the art. Each switching
subassembly 28 comprises three switch terminals 30 on surface 26
disposed in an equilateral triangle, and a center switch terminal
32 on surface 26 disposed in the center of the triangle formed by
outer terminals 30. Terminals 30, 32 are connected by conductors
34, 36 on upper surface 26 of board 12 as more fully described in
the aforesaid U.S. Pat. No. 3,796,843.
Snap-acting dome switch members 14 have a generally triangular
configuration with apexes which are arcuately curved about the
center, the apexes defining straight sides therebetween.
Projections, or dimples 38 are formed downwardly from the apexes
and a center projection or dimple 40 is formed projecting into the
interior of the dome. Snap-acting dome switch members 14 are
disposed over and facing upper surface 26 of board 12, conductors
34, 36, and center terminals 32, outer projections 38, respectively
engaging outer terminals 30 and thus spacing the periphery of
switch members 14 above the raised conductors and terminals. Center
projections 40 are respectively in registry with and spaced from
center terminals 32 in the normal positions of switch members 14.
Application of a downward force on a switch member 14 in response
to manual actuation of a respective push-button 22 will deflect the
switch member from its normal position to a non-over center
position in which its center projection 40 engages the respective
center contact 32 thereby electrically connecting the center
contact to the respective outer contacts 30 to complete the desired
electrical circuit.
Retaining sheet 16 is formed of a sheet of relatively thin flexible
insulating material, such as polyethylene terephthalate (Mylar) and
has openings 42 therein which respectively receive and locate
snap-acting dome switch members 14, openings 42 generally
conforming to the configuration of switch members 14 with cut-out
portions 44 respectively aligned with projections 38 which
respectively expose portions of outer terminals 30. Cover sheet 18
is formed of an imperforate sheet of relatively thin, flexible
insulative material, such as Mylar, and covers retaining sheets 16
and switch members 14. Cover members 20 covers sheet 18 and has
openings 46 therein which receive push-buttons 22. Application of
manual finger pressure on a particular push-button 22 results in
the application of force through cover sheet 18 on a respective
snap-acting dome switch member 14 thereby actuating the switch
member to its non-over center deflected position to perform the
desired switching function. Upon release of manual finger pressure
on push-button 22, the respective switch member 14 returns to its
normal position thus opening the circuit previously established and
returning the respective push-button 22 it is normal, inactive
position.
Referring now to FIG. 3, in accordance with the method of the
invention, opposite surfaces 48, 50 of retaining sheet 16 are
coated with a thin layer of an ultrasonically-actuatable adhesive
material. A heat activated, thermoplastic polyester film adhesive
sold by USM Corporation, Girder Chemical Division, identified as
Bostik 10-302 has been found to be suitable. The adhesive material
described in the aforesaid U.S. Pat. No. 3,480,492 is also
suitable. Adhesive-coated surface 50 of sheet 16 is placed on
surface 26 of circuit board 12 covering conductors 34, 36 with
center contacts 32 respectively exposed to openings 42 and outer
contacts 30 respectively exposed to cut-out portions 44. A
relatively thin, flexible sheet 52 of material which will not bond
to the adhesive material is then placed on adhesive-coated surface
48 of a sheet 16 thus forming a first sandwich 54. Wax paper has
been found to be a suitable material for sheet 52.
Referring now to FIGS. 4 and 5, first sandwich 54 is then placed in
ultrasonic welding apparatus 56 with bottom surface 58 of circuit
board 12 engaging bed 60 of the apparatus. Apparatus 56 includes
horn 62 which may be manually selectively raised and lowered by
level 64 so that its flat bottom surface 66 may be moved into
engagement with the upper surface of sheet 52 of sandwich 54, as
indicated in dashed lines in FIG. 4. A Branson Ultrasonic Welder,
Model 4120 which generates mechanical vibratory energy in horn 62
in the range of 20kHz has been used in perfoming the method of the
invention.
In accordance with an important aspect of the invention, bottom
surface 66 of horn 62 has a plurality of shallow openings 68 formed
therein arranged in the same pattern as openings 42 in sheet 16,
each opening 68 in horn 62 having generally the same diameter as
the corresponding opening 42 in sheet 16. Sandwich 54 is placed on
bed 60 of welding apparatus 56 so that openings 42 in sheet 16 are
respectively in registry with openings 68 in horn 62. Openings 68
in working surface 66 of horn 62 serve to concentrate the
ultrasonic energy in the areas of sheet 16 where bonding is
desired, i.e., in the areas intermediate and surrounding openings
42. In the case of the specific keyboard sub-assembly 11 shown in
FIG. 1, openings 68 having a depth of one-sixteenth inch were found
to be suitable.
Upon placing sandwich 54 on bed 60 of ultrasonic welding apparatus
56 and properly orienting the same, which may be accomplished by a
suitable fixture, horn 62 is lowered by lever 64 so that bottom
surface 66 engages sandwich 54 with sufficient pressure to maintain
the sandwich tightly compacted, approximately 50 pounds per square
inch pressure having been found to be suitable. Apparatus 56 is
then energized for a time sufficient ultrasonically to actuate the
adhesive on bottom surface 50 of sheet 16 so as to bond sheet 16 to
upper surface 26 of circuit board 12, approximately 11/2 seconds
having been found to be suitable. Energization of apparatus 56 may
be under the control of a suitable timer.
Horn 62 of apparatus 56 is then raised to the upper position shown
in solid lines in FIG. 4, sandwich 54 is removed from apparatus 56,
and sheet 52 is removed thus leaving circuit board 12 with sheet 16
bonded thereto.
Referring now to FIG. 6, switch elements 14 are then inserted in
openings 42 of sheet 16 and cover sheet 18 is placed on
adhesive-coated upper surface 50 of sheet 16 covering the same and
switch elements 14 thus forming a second sandwich 70.
Referring now additionally to FIG. 7, second sandwich 70 is placed
in welding apparatus 56 with bottom surface 58 of circuit board 12
engaging bed 62, openings 42 in sheet 16 again being respectively
positioned in registry with openings 68 in bottom surface 66 of
horn 62. Horn 62 is then lowered into engagement with the upper
surface of sheet 18 and sufficient pressure, such as about fifty
pounds per square inch, is applied tightly to compact sandwich 70.
Welding apparatus 56 is then again energized for a length of time
sufficient ultrasonically to activate adhesive on upper surface 48
of sheet 16 thereby to bond the same to cover sheet 18,
approximately 6/10th second having been found to be suitable. Horn
62 is then raised to its upper position and the thus bonded
keyboard sub-assembly 11 removed from apparatus 56.
It will readily be seen that the selective ultrasonic bonding
method of the invention facilitates the handling of the several
components of the keyboard since the ultrasonically bondable
adhesive material is not tacky. Further, the need initially to
apply and subsequentially to peel-off protective cover sheets is
eliminated and there is no tendency for dust or other foreign
material to collect on the adhesive. Further, the tendency of
pressure-sensitive adhesive material to migrate or spread upon the
application of pressure is eliminated. Finally, the invention
provides a relatively fast, uniform and inexpensive method of
assembling a keyboard in production.
While there have been described above the principles of this
invention in connection with specific apparatus, it is to be
clearly understood that this description is made only by way of
example and not as a limitation to the scope of the invention.
* * * * *