GB2386339A - Mechanical contact apparatus and a method of production - Google Patents

Mechanical contact apparatus and a method of production Download PDF

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Publication number
GB2386339A
GB2386339A GB0212081A GB0212081A GB2386339A GB 2386339 A GB2386339 A GB 2386339A GB 0212081 A GB0212081 A GB 0212081A GB 0212081 A GB0212081 A GB 0212081A GB 2386339 A GB2386339 A GB 2386339A
Authority
GB
United Kingdom
Prior art keywords
silicone rubber
mould
mechanical contact
layers
edges
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB0212081A
Other versions
GB0212081D0 (en
Inventor
Andrew Paul Switky
Philip Stob
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Eleksen Ltd
Original Assignee
Eleksen Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Eleksen Ltd filed Critical Eleksen Ltd
Publication of GB0212081D0 publication Critical patent/GB0212081D0/en
Publication of GB2386339A publication Critical patent/GB2386339A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F3/00—Input arrangements for transferring data to be processed into a form capable of being handled by the computer; Output arrangements for transferring data from processing unit to output unit, e.g. interface arrangements
    • G06F3/01—Input arrangements or combined input and output arrangements for interaction between user and computer
    • G06F3/02—Input arrangements using manually operated switches, e.g. using keyboards or dials
    • G06F3/0202—Constructional details or processes of manufacture of the input device
    • G06F3/0221—Arrangements for reducing keyboard size for transport or storage, e.g. foldable keyboards, keyboards with collapsible keys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H13/00—Switches having rectilinearly-movable operating part or parts adapted for pushing or pulling in one direction only, e.g. push-button switch
    • H01H13/70—Switches having rectilinearly-movable operating part or parts adapted for pushing or pulling in one direction only, e.g. push-button switch having a plurality of operating members associated with different sets of contacts, e.g. keyboard
    • H01H13/702—Switches having rectilinearly-movable operating part or parts adapted for pushing or pulling in one direction only, e.g. push-button switch having a plurality of operating members associated with different sets of contacts, e.g. keyboard with contacts carried by or formed from layers in a multilayer structure, e.g. membrane switches
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2713/00—Use of textile products or fabrics for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/46—Knobs or handles, push-buttons, grips
    • B29L2031/466—Keypads, keytops
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2203/00—Form of contacts
    • H01H2203/008—Wires
    • H01H2203/0085—Layered switches integrated into garment, clothes or textile
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2203/00—Form of contacts
    • H01H2203/008—Wires
    • H01H2203/01—Woven wire screen
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2209/00—Layers
    • H01H2209/002—Materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2223/00—Casings
    • H01H2223/046—Casings convertible
    • H01H2223/052—Casings convertible reductible in size, e.g. for transportation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2229/00—Manufacturing
    • H01H2229/044—Injection moulding
    • H01H2229/048—Insertion moulding

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Theoretical Computer Science (AREA)
  • Human Computer Interaction (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Push-Button Switches (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

Apparatus for responding to a mechanical contact applied thereto is described and preferably takes the form of a keyboard. The apparatus is substantially flat, flexible and foldable and is constructed from many component layers wherein a least one of the component layers is a textile fabric. A moulded outer edge is provided for constraining unfinished edges of these layers. The edge may be moulded from an elastomeric material such as silicone rubber, polyurethane and other thermoplastics. The moulded edge is formed by locating the unfinished edges of an assembly of layers in a mould cavity 402 in which the elastomeric material may preferably be injected to encapsulate the unfinished edges. The edges of the mould apply compression to the textile fabric.

Description

l Mechanical Contact Apparatus and a Method of Production The present
invention relates to a method of producing apparatus arranged to respond to mechanical contact applied thereto.
A position detector using foldable fabric is described in international patent publication WO 00/72239, the contents of which is incorporated herein by reference. A position detector is also described in co-pending United States patent application 09/744,155 and again the contents of this application are incorporated herein by reference.
to A problem with using fabric layers to produce a detector, or any other similar device, is that the edges of the fabric are prone to fraying and as such measures must be taken to finish off the edges of the device. Conventionally, fabric materials are finished off by a process of hemming and sewing in order to produce a clean edge. Alternatively, it is also known to use gluing s techniques. Both of these known techniques require sophisticated operations to be performed such that mass production procedures become complicated and therefore expensive.
According to an aspect of the present invention, there is provided a method of producing apparatus arranged to respond to mechanical contact 20 applied thereto, comprising the steps of: assembling a substantially flat flexible and foldable mechanical contact detector from a plurality of component layers, wherein at least one of said component layers is a textile fabric and, said assembled detector has unfinished edges; locating said unfinished edges of said assembled detector in a mould, wherein edges of z said mould apply compression to said textile fabric; and applying liquid material to said mould so as to encapsulate said unfinished edges.
The invention will now be described by way of example only with reference to the corresponding drawings, of which: Figure 1 shows procedures for producing an apparatus arranged to respond to mechanical contact; Figure 2 details the step of assembling a contact detector.; Figure 3 details the step of applying outer layers; Figure 4 details the moulding of an edge for the detector; Figure 5 details the cross section identified in Figure 4; Figure 6 shows a finished example of the apparatus; Figure 1 Procedures for producing an apparatus arranged to respond to mechanical contact are shown in Figure 1. At step 101 a flexible contact detector is assembled from a plurality of fabric layers. In a preferred embodiment, the nature of the detector is substantially as described in the aforesaid international patent publication WO Ou/72239 assigned to the present Assignee. However, other configurations of detector could benefit from the present invention. For example, the invention could be used with a flexible circuit type detector.
go After the flexible detector has been assembled at step 101, outer layers are applied at step 102. These outer layers each consist of a fabric layer having a silicone rubber layer cured thereon. The presence of the silicone rubber ensures that the detector is water resistant. In addition if the contact detector is being used to provide basis for a flexible keyboard, for z example, indentations identifying the location of specific keys may be moulded into one of the silicone rubber layers.
At step 103 unfinished edges of the detector assembly are located into a mould. Thereafter, at step 104 pressure is applied to the mould in order to provide a seal around its edges. In particular, the fabric layer or layers are placed into compression.
a, At step 105 liquid silicone rubber is applied into the mould and at step 106 the silicone rubber is cured so as to present a solid elastomer forming the outer edge. Consequently, the unfinished edges of the detector are encapsulated within the silicone rubber, which presents a tidy finished edge to the apparatus. Furthermore, the procedure achieves a high level of 10 repeatability, making it suitable for scaling-up for mass production. Silicone rubber has particular benefits for this application but other elastomeric materials could be used, such as polyurethane, TPE and other thermoplastics etc. 5 Figure 2 Step 101 for the assembly of the flexible contact detector is detailed in Figure 2. The detector assembly consists of a first outer conducting layer 201 and a second outer conducting layer 202. Sandwiched between said outer conducting layer 201, 202 are a first insulating layer 203, a central conducting go layer 204 and a second insulating layer 205. In use, a potential gradient is created across outer layer 201. Contact results in a voltage being detectable at layer 202. Furthermore, a determination of current allow the extent of the contact to be determined. False triggering of the device is inhibited because folding may result in contact being created between layer 201 and layer 204 as or between 204 and layer 202. However, it is difficult for folding to create contact between layer 201 and 202 such that a false triggering event is
unlikely to occur.
Figure 3 Step 102, for the application of the silicone rubber coated outer layers to the detector, are illustrated in Figure 3. In this example, the fabric contact detector forms a basis for a manually operable keyboard of the type that may interface to a hand held computing platform, such as that described in international patent application WO 01/75572, equivalent to United States patent application number O9/98O, 236, both of which are incorporated herein 0 by reference. Alternatively, the keyboard may be interfaced to a mobile telephone as described in co- pending British patent application (P141).
Similarly, keyboards of this type may be interfaced into any device requiring manual data input.
An alternative embodiment to using a fabric keyboard is described in international patent publication WO 01/75572, the contents of which is incorporated herein by reference. A similar disclosure is also included in co
pending United States patent application number 09/980,236, the contents of which is also included herein by reference. In the alternative embodiment, the keyboard is a membrane keyboard having an uppermost layer of silicone 20 rubber. This silicone rubber layer is laminated on its upper surface with a durable fabric layer onto which graphical icons and alpha numerics are printed. Alternatively, the uppermost layer is laminated with a durable flexible plastic film, such as a film of polyester or polyvinylchloride, onto which the graphics etc have been printed.
25 The alternative membrane keyboard includes a first electrically
conductive membrane film and a second electrically conductive membrane film. In addition, a spacing membrane layer is positioned between the first electrically conductive membrane layer and the second electrically conductive membrane layer.
5 The first electrically conductive membrane layer is a film of MYLAR (polyethylene terephthalate. Electrodes are printed onto the underside of the film thereby forming a conductivity channel for the first electrically conductive membrane. The electrodes are connected to an interface circuit that supplies voltages to these electrodes via conductive tracks. Each electrode is to specifically aligned so as to correspond with a key registration device on the outermost layer.
The second electrically conductive membrane layer is also composed of a MYLAR membrane having electrodes printed thereon. Each of the electrodes printed onto the upper surface layer is aligned with a corresponding electrode on the co-operating layer and a corresponding key registration device on the outermost layer.
A separator layer is provided in the form of a non-conductive membrane sheet of MYLAR with holes located to coincide with the positions of the co-operating electrodes. The separator layer prevents electrical contact go occurring between the electrodes of the layers unless a mechanical interaction has occurred by the pressing of a specific key. Alternatively, the membrane layers may be made of alternative plastics materials.
The layers illustrated in Figure 2 are brought together to provide an assembled flexible contact detector 301. This assembled contact detector
has unfinished edges 302 requiring a finishing operation to be performed. An upper surface layer 303 consists of an outer fabric layer supported by a silicone rubber layer, wherein the silicone rubber is sealed to the fabric layer during a curing process. During the curing process, pressure is applied to bring the layers together and to introduce three dimensional key positions 304 into the composite upper surface layer.
A lower surface layer 304 provides a base for the material. In order to ensure that the whole of the device is water resistant, in this embodiment the lower surface layer also has silicone rubber on its upper surface which to becomes cured by the use of heat to form a bond with the upper surface 303.
Consequently, the upper surface layer composite 303, the central flexible contact detector 301 and the lower surface layer composite 304 are brought together to produce an operational apparatus with unfinished edges.
Figure 4 The operational apparatus with unfinished edges is located into a mould as identified at step 103 and as detailed in Figure 4.
The mould consists of two portions, namely a lower portion 401 and a cooperating upper portion. Mould 401 defines a channel 402 into which so silicone rubber is received during the moulding process.
In the plan view of the mould shown in Figure 4, three unfinished operational apparatus (keyboards in this example) are receivable in the mould. In the example shown in Figure 4, a first keyboard 404 has been received within the mould, a second keyboard 405 has been received within the mould and a third keyboard is about to be introduced. An outer contact region 406 contacts with a co-operating region of the upper portion so as to
form a seal. Inner raised region 407 co-operates with a similar region on the upper portion and presses firmly against the operational assembly. I n particular, inner region 407 applies compressive force to the fabric layers.
After three keyboards have been introduced into the lower portion of 5 the mould, the upper portion of the mould is lowered into position and a pre determined force is applied to the two portions so as to achieve a seal at portion 406. The spacing above the "pinch" portion 407 should ensure that the keyboards are held firmly so as to prevent the seepage of liquid silicone rubber but should not be too small such that the operational apparatus is o compressed too tightly so as to ensure no damage is caused to the detector layers. It should be appreciated that the inclusion of three devices within the mould is merely an example. More devices could be included in each mould or, alternatively, a continuous process could be developed.
5 In an alternative mould construction, an elastomeric gasket is included within portion 407 to facilitate the correct level of compression, even when different thickness layers are used.
Figure 5 20 A cross section on line v-v is shown in Figure 5. In the lower mould portion 401 keyboard 405 is supported by raised portion 407. This co operates with a similar raised portion 501 in upper mould portion 502. Liquid silicone rubber is received within void 503, defined by region 402 of the lower mould portion 401 in combination with portion 504 of the upper mould portion 25 502.
The silicone rubber injected into void 503 is selected so as to be compatible with silicone rubbers used for the production of the keyboard 505.
Preferably, the silicone rubber selected vulcanises at room temperature and the curing process is facilitated by heating the upper and lower mould 5 portions 502, 401 and by raising them to an operating temperature of, typically, between fifty and one hundred and fifty degrees centigrade. After being injected into void 503, the silicone rubber is left to cure for approximately two minutes, "hereafter the upper mould portion 502 is raised and the cured articles are removed, thereby allowing the process to be o repeated. Figure 6 After the cured articles have been removed from the mould, edges of the article are trimmed as identified at step 107.
The finished keyboard is shown in Figure 6 in which an operational area 601 is surrounded by a moulded bead 602 produced by the process previously described.
In an alternative embodiment, the tools may be provided with a "tear seal" feature so as to facilitate the trimming of the external edge.

Claims (14)

Claims:
1. A method of producing apparatus arranged to respond to mechanical contact applied thereto, comprising the steps of: 5 assembling a substantially flat flexible and foldable mechanical contact detector from a plurality of component layers, wherein at least one of said component layers is a textile fabric, wherein said assembled detector has unfinished edges locating said unfinished edges of said assembled detector in a mould, 10 wherein edges of said mould apply compression to said textile fabric; and applying liquid material to said mould so as to encapsulate said unfinished edges.
2. A method according to claim 1, wherein said applied liquid 15 material sets to form a solid elastomeric material.
3. A method according to claim 2, wherein said elastomeric material is silicone rubber.
20
4. A method according to claim 3, wherein said silicone rubber is room temperature vulcanising silicone rubber.
5. A method according to claim 2, wherein heat is applied to said mould to encourage the solidification
6. A method according to any of claims 1 to 5, wherein said apparatus is a keyboard configured to respond to mechanical contact.
7. A method according to claim 6, wherein said keyboard is 5 flexible.
8. A method according to claim 7, wherein said flexible keyboard is constructed predominantly from fabric.
10
9. Apparatus arranged to respond to a mechanical contact applied thereto, said apparatus comprising substantially flat flexible and foldable mechanical contact detection means, constructed from a plurality of component layers wherein at least one of said component layers is a textile fabric; and 15 a moulded outer edge wherein unfinished edges of said layers are constrained within said moulded edge.
10. Apparatus according to claim 9, wherein said edge is mouided from an elastomeric material.
11. Apparatus according to claim 10, wherein said elastomeric material is silicone rubber.
12. Apparatus according to claim 11, wherein said silicone rubber as is room temperature vulcanising silicone rubber.
13. apparatus substantially as herein described with reference to the accompanying drawings.
14. A method of producing apparatus arranged to respond to mechanical contact applied thereto, substantially as herein described with reference to the accompanying drawings.
GB0212081A 2002-03-11 2002-05-27 Mechanical contact apparatus and a method of production Withdrawn GB2386339A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US36335702P 2002-03-11 2002-03-11

Publications (2)

Publication Number Publication Date
GB0212081D0 GB0212081D0 (en) 2002-07-03
GB2386339A true GB2386339A (en) 2003-09-17

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Family Applications (1)

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GB0212081A Withdrawn GB2386339A (en) 2002-03-11 2002-05-27 Mechanical contact apparatus and a method of production

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1667182A1 (en) * 2004-12-01 2006-06-07 IEE INTERNATIONAL ELECTRONICS & ENGINEERING S.A. Foil-type switching element with enhanced carrier foil
US7554051B2 (en) 2004-03-18 2009-06-30 Peratech Limited Sensor assembly
US8585606B2 (en) 2010-09-23 2013-11-19 QinetiQ North America, Inc. Physiological status monitoring system
EP2677515A3 (en) * 2012-06-21 2014-03-12 Shenzhen Zhongkaixin Technology Co., Ltd Detachable and foldable integrated organ and process for manufacturing keyboard thereof
US9028404B2 (en) 2010-07-28 2015-05-12 Foster-Miller, Inc. Physiological status monitoring system
US9211085B2 (en) 2010-05-03 2015-12-15 Foster-Miller, Inc. Respiration sensing system
EP3213172A4 (en) * 2014-10-30 2018-06-20 Microsoft Technology Licensing, LLC Foldable input device

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4386989A (en) * 1980-01-28 1983-06-07 Societe Nationale Industrielle Et Aerospatiale Method for producing a bendable and twistable element and such an element produced thereby
EP0145812A2 (en) * 1982-12-30 1985-06-26 Orreus Limited Treating cloth material
DE3712882A1 (en) * 1987-04-15 1988-11-03 Schaeffler Teppichboden Gmbh Trim moulding and method for the production thereof
EP0629481A1 (en) * 1993-06-18 1994-12-21 Facchinetti, Annamaria Mould for moulding plastic elements on thin flexible material and elements moulded thereby
WO2000072239A1 (en) * 1999-05-20 2000-11-30 Electrotextiles Company Limited Detector constructed from fabric

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4386989A (en) * 1980-01-28 1983-06-07 Societe Nationale Industrielle Et Aerospatiale Method for producing a bendable and twistable element and such an element produced thereby
EP0145812A2 (en) * 1982-12-30 1985-06-26 Orreus Limited Treating cloth material
DE3712882A1 (en) * 1987-04-15 1988-11-03 Schaeffler Teppichboden Gmbh Trim moulding and method for the production thereof
EP0629481A1 (en) * 1993-06-18 1994-12-21 Facchinetti, Annamaria Mould for moulding plastic elements on thin flexible material and elements moulded thereby
WO2000072239A1 (en) * 1999-05-20 2000-11-30 Electrotextiles Company Limited Detector constructed from fabric

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7554051B2 (en) 2004-03-18 2009-06-30 Peratech Limited Sensor assembly
EP1667182A1 (en) * 2004-12-01 2006-06-07 IEE INTERNATIONAL ELECTRONICS & ENGINEERING S.A. Foil-type switching element with enhanced carrier foil
WO2006058880A1 (en) * 2004-12-01 2006-06-08 Iee International Electronics & Engineering S.A. Foil-type switching element with enhanced carrier foil
US9211085B2 (en) 2010-05-03 2015-12-15 Foster-Miller, Inc. Respiration sensing system
US9028404B2 (en) 2010-07-28 2015-05-12 Foster-Miller, Inc. Physiological status monitoring system
US8585606B2 (en) 2010-09-23 2013-11-19 QinetiQ North America, Inc. Physiological status monitoring system
EP2677515A3 (en) * 2012-06-21 2014-03-12 Shenzhen Zhongkaixin Technology Co., Ltd Detachable and foldable integrated organ and process for manufacturing keyboard thereof
EP3213172A4 (en) * 2014-10-30 2018-06-20 Microsoft Technology Licensing, LLC Foldable input device

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Publication number Publication date
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