EP1878033B1 - Electrically conducting contact and method for production thereof - Google Patents

Electrically conducting contact and method for production thereof Download PDF

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Publication number
EP1878033B1
EP1878033B1 EP06721946.9A EP06721946A EP1878033B1 EP 1878033 B1 EP1878033 B1 EP 1878033B1 EP 06721946 A EP06721946 A EP 06721946A EP 1878033 B1 EP1878033 B1 EP 1878033B1
Authority
EP
European Patent Office
Prior art keywords
metal
keypad
contact
pill
sponge
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.)
Active
Application number
EP06721946.9A
Other languages
German (de)
French (fr)
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EP1878033A1 (en
Inventor
Christoph Keist
Klaus Hoffmann
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.)
Abatek International AG
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Abatek International AG
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Filing date
Publication date
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Publication of EP1878033A1 publication Critical patent/EP1878033A1/en
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Publication of EP1878033B1 publication Critical patent/EP1878033B1/en
Active legal-status Critical Current
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Classifications

    • 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
    • H01H13/78—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 characterised by the contacts or the contact sites
    • H01H13/785—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 characterised by the contacts or the contact sites characterised by the material of the contacts, e.g. conductive polymers
    • 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
    • H01H13/78—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 characterised by the contacts or the contact sites
    • H01H13/79—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 characterised by the contacts or the contact sites characterised by the form of the contacts, e.g. interspersed fingers or helical networks
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2201/00—Contacts
    • H01H2201/022—Material
    • H01H2201/03—Composite
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2201/00—Contacts
    • H01H2201/022—Material
    • H01H2201/032—Conductive polymer; Rubber
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2203/00—Form of contacts
    • H01H2203/008—Wires
    • 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
    • H01H2203/00—Form of contacts
    • H01H2203/036—Form of contacts to solve particular problems
    • H01H2203/038—Form of contacts to solve particular problems to be bridged by a dome shaped contact
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2215/00—Tactile feedback
    • H01H2215/004—Collapsible dome or bubble
    • H01H2215/006—Only mechanical function
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2221/00—Actuators
    • H01H2221/036—Return force
    • H01H2221/042—Foam
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2239/00—Miscellaneous
    • H01H2239/004—High frequency adaptation or shielding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49105—Switch making

Definitions

  • the present invention relates to a contact element for the intermittent contacting of printed conductors on a printed circuit board, in particular for flexible safety mats or input devices. Furthermore, it relates to a method for the production of flexible safety mats or input devices and uses of such contact elements.
  • Silicone control mats are increasingly used in the automotive sector, such. for switching e.g. Mirror adjusters, window regulators, etc.
  • a flexible mat for example made of silicone over a circuit board is arranged.
  • tracks are arranged, which have interruptions at the points to be actuated.
  • contact elements are arranged on the underside of the flexible mat of silicone and bridging these interruptions, spaced from the circuit board. These contact elements are typically referred to as contact pills. If the flexible mat is pressed down in the right area, contacting takes place.
  • Silicone material is made conductive with carbon or other electrically conductive particles, pressed into plates and punched out and then vulcanized together with the switching mat in the compression tool.
  • a copper sheet is laminated on one side with a silicone layer, on the other with nickel and gold coated. From the sheet then pills are punched, which are vulcanized together with the switching mat in the compression tool.
  • the invention is therefore based on the object to provide an improved flexible switching mat with a contact element for the intermittent contacting of printed conductors on a printed circuit board or a similar carrier with interrupted conductor tracks available. This particular for use for flexible safety mats or input devices, such. B. for the automotive sector.
  • the core of the invention is thus to use a metal sponge, which on the one hand by the existing contiguous network of metal has a well-defined conductivity respectively a well-defined ohmic resistance when the interconnects are bridged. It also has a Metal sponge inherently on a certain flexibility and elastic deformability, which can always ensure a good contact especially with repeated actuation and, for example, oblique actuation. Dirt particles can also be absorbed by the flexibility.
  • the metal sponge is a metal sponge which has a substantially contiguous metallic-based network in order to be able to reliably assume the abovementioned functionality.
  • the metal sponge preferably has a substantially coherent network of cavities (in English so-called metal sponge ) .
  • so-called metal foams in English so-called metallic foams ) in which the cavities do not form a substantially completely coherent network, but rather are in the form of pores.
  • metal sponge is understood to mean that it is a coherent network on a metallic basis, which has cavities in the form of a substantially contiguous network.
  • the cavities of the metal sponge are at least substantially completely filled with an elastomeric material.
  • This design is surprisingly characterized by excellent functionality.
  • the arranged in the cavities elastomeric and thus elastic material causes the thus substantially completely filled metal sponge as a whole receives permanently elastic properties. While an "empty" metal sponge resp. Metal foam especially under heavy mechanical load, if the cavities are not filled with elastic material, and may also be irreversibly deformed, this is no longer possible in such a filled metal sponge due to the arranged in the cavities elastic material. It also prevents the metallic network breaking under load and thus affecting the conductivity. On the other hand, due to the network of metallic material, the conductivity is reliable and always consistent. In this way, a contact element can be made available in an astonishingly simple manufacturing process, which can take over its function excellent long-term even with intensive repeated and even rough use.
  • the contact element is connected in the form of a contact pillar with the switching mat or with an element of the switching mat, wherein the switching mat respectively the element of the switching mat consists of an elastomeric material, and this elastomeric material, the cavities of the metal sponge substantially completely penetrates.
  • the elastomeric material may be a material selected from: silicone elastomer, liquid silicone rubber, liquid silicone rubber, thermoplastic elastomer or rubber. In other words, those materials are used which are typically already used in the field of safety mats.
  • a very simple construction which is characterized by a simple, reliable production process and low production costs, is possible if it is the material of the switching mat in the elastomeric, arranged in the cavities material and to some extent material of the switching mat at least partially penetrates into the contact pellet , The material of the switching mat then penetrates the contact pill at least partially, which on the one hand leads to the contact pill being firmly connected to the switching mat, and on the other hand leads to the contact pill receiving the above-discussed lasting elastic properties.
  • the contact element is in the form of a contact pill whose cavities are at least partially, preferably in at least one surface area, filled with an electrically conductive elastomeric material, wherein it preferably with graphite or metal particles such as z.
  • an electrically conductive elastomeric material preferably with graphite or metal particles such as z.
  • nickel particles offset elastomeric material particularly preferably with graphite or metal particles such as nickel particles offset elastomeric silicone.
  • An increase in the conductivity can also be achieved by the contact element being in the form of a contact pill, and the contact pill on the surface facing the strip conductors is provided with an additional metallic coating, in particular of gold or chromium.
  • contact pill In connection with the term contact pill it must be specified that these may be circular, to some extent circular cylindrical elements, but that they may also be oval, hexagonal, square, rectangular or any other basic shapes. Typically, the contact pill is a circular contact element.
  • the material of the metal sponge is preferably a metal selected from the group: nickel, chromium, gold, aluminum, copper or alloys or mixtures formed therefrom. Also foams or sponges, which are stratified of different metals, are possible.
  • Such sponges can be produced for example in a deposition process (CVD, chemical vapor deposition), wherein a plastic foam is coated with metal and then the plastic is removed, so that a contiguous metal sponge with coherent cavities formed.
  • metal foams resp.
  • Metal sponges with an average pore size in the range of 100-1000 ⁇ m, preferably in the range of 550-700 ⁇ m, particularly preferably in the range of 600-650 ⁇ m.
  • the contact element is preferably in the form of a contact pill with a thickness in the range of 0.5-3 mm, preferably in the range of 0.5-0.9 mm.
  • the metal sponge advantageously has a density in the range of 200-800 g / m 2 , particularly preferably in the range of 300-500 g / m 2 , based on a material thickness of 1.6 mm.
  • the present invention relates to a method for producing a switching mat or an element of a switching mat (eg, silicone dome), as described above.
  • the method is characterized in that such a contact element is inserted into a compression tool, an injection molding tool or a transfer molding tool, preferably at recesses provided for the contacts, then an elastomer mixture is inserted or supplied and / or injected, and when closed Tool pressure and temperature can be adjusted in the tool so that the elastomer is low viscosity and at least partially penetrates into the metal sponge.
  • Pressure and temperature in the tool are preferably set such that the Elastomer substantially completely penetrates into the metal sponge of the contact element in the form of a contact pill.
  • the contact element can be presented in the form of a contact pill, which are produced from a metal sponge plate in a stamping process or a cutting process, in which preferably a partial compression of the metal sponge is effected.
  • the contact pill and / or the metal sponge plate can be filled before or after the stamping process at least partially with an electrically conductive or non-conductive elastomeric material or coated by a squeegee, pressure or spray method, or with an additional metallic coating, in particular of gold or chromium be provided. If the metal sponge plate is already filled with an elastomeric material, such a contact element can then also be glued or otherwise connected to the corresponding points of a switching mat (for example, from below onto a silicone dome).
  • the present invention relates to the use of a safety mats or in elements resp.
  • Components for safety mats or input devices such as keyboards, or input devices especially from the automotive sector such as windows, mirrors, and / or for direct connection of motors.
  • the latter is possible since the contact elements according to the invention can reliably switch comparatively high currents.
  • a metal foam or metal sponge may be used as a flexible contact sheet in elastomer such as e.g. embedded in silicone. So as a flexible touchpad.
  • the present invention is to be understood in particular in connection with safety mats, as initially generally referred to the hand FIGS. 1 and 2 be explained should.
  • FIG. 1 shows a section through the switching area of a switching mat.
  • a circuit board 1 printed conductors 2, 3 are provided. These traces are interrupted at a defined location, and at this point should be made possible by a manual input (pressing iS a keyboard) from above a contact, that is a bridging of the two tracks 2, 3.
  • a switching mat which consists in this specific case of a plastic cap 4, below which are arranged in each case in the switching areas flexible elements, for example made of silicone.
  • These flexible elements consist of a silicone dome 5, which is connected to the top with the plastic cap 4. Laterally next to the interruption of the printed conductors, this dome 5 is supported on the printed circuit board via a membrane 5a with the switching mat base 6.
  • the dome 5, the diaphragm 5a and the base 6 are integrally made of a flexible material. Such an element is also called a silicone button.
  • a contact pill 7 is attached.
  • the plastic cap 4 is pressed from above, for example, with a finger down, takes place after reaching a threshold force Einknichen the membrane 5a, and the contact pill 7 is printed on the circuit board 1 respectively to the two from the left respectively from the right conductor tracks 2, 3rd pressed down. Since the contact pill is a conductive element, for example a carbon pill or a gold pill, the conductors 2 and 3 are thus connected to one another and a circuit is effected. After releasing the silicone dome speeds due to the elasticity of the material in the membrane 5a back to its original, in FIG. 1 shown position, which causes the connection is interrupted again, since the contact pill is removed upward from the contact area.
  • FIG. 2a shows a plan view of such a switching element, which consists of a diaphragm 17, which, as in FIG. 2b ), has circular recesses. Grab through these recesses from below two buttons 18 through. It is possible that a plastic cap 4 is glued or laid over the keys.
  • the switching mat consists in this case of two actual switching elements, as in the Figures 2c 2e) in a perspective view, and in FIG. 2f), a section along the dotted line in FIG Figure 2c ) can be seen.
  • FIG. 2d Below this switching mat 4 is in Figure 2d ) shown arranged on which two separate conductor paths are arranged, which in each case underneath the keys 18 via Maisier Anlagene 20, that is in these areas 20, the conductors are interrupted and should be bridged by the contact pills 7 of the switching mat, if the switching mat is operated accordingly.
  • the switching mat is made of a flexible elastic material such as silicone rubber and consists of one piece Dom 5, a diaphragm 5a and the base 6, wherein between the base and the dome, a free-standing cavity is formed, in which from below the contact pills 7 are attached.
  • a flexible elastic material such as silicone rubber
  • the aim of the present invention is, so to speak, to find a solution which combines the advantages of the two technologies mentioned above of the carbon pill and the gold pill and at the same time eliminates their disadvantages. That The softness of the carbon pill (dirt is trapped, low in price) should be combined with the electrical properties of the gold pill (very low contact resistance, independent of actuation force).
  • a metal sponge as the material for the contact pill 7, preferably a nickel-metal sponge having a porosity of, for example, 100 PPI (pores per inch) and a density of, for example, 400 gr / m 2 at a thickness of typically 1.6 mm used. This is schematically in FIG. 3a ).
  • the sponge pills are placed in the compression tool on the recesses provided for the contacts, then an elastomer mixture is inserted or injected respectively. fed, and the tool closed. Due to the pressure (typically 150kg / cm 2 ) and the temperature in the tool (typically 170 ° C), the elastomer becomes low in viscosity and at least partially infiltrates the metal sponge. At the same time, the metal sponge is compressed by the pressure in the compression tool and forms a fairly homogeneous surface, partly interspersed with elastomer, on the lower side. This surface now serves as a contact element, the sponge as a "net” not only leads to the surface, but over the whole pill.
  • Such metal sponge pills have approximately the electrical properties of the gold pills, without being susceptible to dirt, and are cheap to manufacture.
  • the metal sponge pill is a metal sponge-punched or cut-out pill, which is otherwise unmodified. This situation is in FIG. 3b ).
  • This electrically conductive metal sponge or foam is vulcanized in the tool with insulating silicone or otherwise applied to the keypad, eg by gluing, clamping, etc.
  • the metal sponge pill is already at least partially with elastomeric material, which may be non-conductive or additionally electrically conductive prior to its attachment to the keypad or their integration into the switching mat.
  • the metal foam is completely or partially filled with an electrically conductive or non-conductive material. This can be for example with graphite or metal dust offset silicone.
  • Such a completely filled with metal sponge pill is in Figure 3c ) shown schematically. From these plates, the pills are then made.
  • the metal sponge pill is additionally coated for better conductivity at least on the side facing the contacts, that is to say the printed conductors.
  • the metal sponge is coated with electrically conductive material on one or both sides.
  • the coating can For example, be carried out with a doctor blade or spray method. Such a coating 10 is shown schematically in FIG 3d figure ).
  • the metal sponge pill is refined.
  • the metal sponge can be coated on one, both sides or throughout additionally with gold or another high-grade layer in order to increase the conductivity and to reduce the burnup.
  • the metal foam pill is gilded by steaming or electroplating etc. for example. This can be done on all variants on one or both sides.
  • the punched pills may be coated in a drum. Such an embodiment in combination with a coating 10 is shown schematically in FIG FIG. 3e ).
  • conductive metal foams and metal sponges are preferred.
  • Such metal sponges are made, for example, of nickel, nickel coated e.g. with chromium or gold, aluminum, copper, etc. Different pore sizes can be used, typically 400 ⁇ m.
  • FIG. 4 A possible method for producing such contact pills 7 from a metal sponge plate 14 is shown in FIG. 4 shown.
  • the punching tool 12 has at its tip a tapered on the outside taper, which leads to the actual cutting edge.
  • the metal sponge plate 14 is placed on a soft pad 15, and the punch 12 is inserted punched with retracted punch 13 into the metal sponge plate 14.
  • the punching tool 12, 13 is moved and, as in FIG. 4d ), the punched product 16, respectively the contact pill, with the ejector 13 removed from the punching tool 12 and collected, for example, in a container or even inserted into a mold.
  • FIG. 5 In addition, another possibility of using such a metal sponge or a metal foam is shown.
  • a flexible mat 21 made of an elastomer in the concrete case of silicone, two conductors 2 and 3 made of metal foam or metal sponge are embedded in such a way and penetrated by the elastomer or silicone, respectively, that they are guided over one another in one area. Between the two conductors, a cavity 22 is present in this area.
  • the conductors are connected at the points 24 with appropriate electronics or circuits, and is now in a schematically shown key area 23 from above (or equally from below) exerted a pressure on this mat 21, so contact the two conductors 2, 3rd due to the flexibility of the mat 21 and thus provide a key function.
  • Such a mat can in turn be produced by presenting the conductors, for example, as unfilled metal foams or metal sponges in a mold, and then the elastomer to form the structure according to FIG FIG. 5 is supplied.
  • Electrically conductive or non-conductive elastomers can be applied in processes such as doctor blade, spray, screen printing, pad printing, etc.
  • Dow Corning 3631 liquid silicone may be used as a base material for coating or as a flexible filler.
  • conductive particles e.g. Nickel-coated carbon particles can be used by Inco Special Products.
  • Xyshield Type XY800 Nickel Plated Graphite from Laird Technologies can be used as a paste for a coating (base material + particles ready mixed.
  • HTV silicone possibly with color pigments; e.g. Type B6670, 30-80 Shore A, 70 Shore A preferred, to be used by Dow Corning. .
  • Materials such as gold, chromium, etc. can be applied in processes such as sputtering, vapor deposition, electroplating, etc.
  • HTV silicone elastomer is used for mats, but the present invention can also be implemented with liquid silicone liquid silicone rubber (LSR), thermoplastic elastomers (TPE) or rubber of any kind.
  • LSR liquid silicone liquid silicone rubber
  • TPE thermoplastic elastomers

Description

TECHNISCHES GEBIETTECHNICAL AREA

Die vorliegende Erfindung betrifft ein Kontaktelement zur intermittierenden Kontaktierung von Leiterbahnen auf einer Leiterplatte, insbesondere für flexible Schaltmatten oder Eingabegeräte. Weiterhin betrifft sie ein Verfahren zur Herstellung von flexiblen Schaltmatten oder Eingabegeräte sowie Verwendungen solcher Kontaktelemente.The present invention relates to a contact element for the intermittent contacting of printed conductors on a printed circuit board, in particular for flexible safety mats or input devices. Furthermore, it relates to a method for the production of flexible safety mats or input devices and uses of such contact elements.

STAND DER TECHNIKSTATE OF THE ART

Silikonschaltmatten werden immer häufiger auch im Automobilbereich eingesetzt so z.B. zum Schalten von z.B. Spiegelverstellern, Fensterhebern, etc.Silicone control mats are increasingly used in the automotive sector, such. for switching e.g. Mirror adjusters, window regulators, etc.

In widerstandscodierten Schaltungen ist es entscheidend, dass ein sehr niederohmiges und zuverlässiges Kontaktelement zur Verfügung steht. Werden hochohmige respektive unzuverlässige Kontaktelemente verwendet, so kommt es zu Kontaktstörungen oder gar Ausfällen. Ebenfalls von grosser Wichtigkeit ist, dass insbesondere für die direkte Schaltung von Motoren hohe Ströme von z.B. 200mA geschaltet werden können.In resistance-coded circuits it is crucial that a very low-resistance and reliable contact element is available. If high-resistance or unreliable contact elements are used, contact malfunctions or even failures occur. Also of great importance is that especially for the direct connection of motors high currents of eg 200mA can be switched.

Bei solchen Schaltmatten ist typischerweise eine flexible Matte beispielsweise aus Silikon über einer Leiterplatte angeordnet. Auf der Leiterplatte sind Leiterbahnen angeordnet, welche an den zu betätigenden Stellen Unterbrechungen aufweisen. Auf der Unterseite der flexiblen Matte aus Silikon und diese Unterbrechungen überbrückend sind, beabstandet von der Leiterplatte, Kontaktelemente angeordnet. Diese Kontaktelemente werden typischerweise als Kontaktpillen bezeichnet. Wird die flexible Matte im richtigen Bereich heruntergepresst, so erfolgt eine Kontaktierung.In such safety mats typically a flexible mat, for example made of silicone over a circuit board is arranged. On the circuit board tracks are arranged, which have interruptions at the points to be actuated. On the underside of the flexible mat of silicone and bridging these interruptions, spaced from the circuit board, contact elements are arranged. These contact elements are typically referred to as contact pills. If the flexible mat is pressed down in the right area, contacting takes place.

Für solche Anwendungen werden heute normalerweise zwei verschiedene Arten von Kontaktpillen verwendet, beide mit gravierenden Nachteilen:For such applications, two different types of contact pills are normally used today, both with serious disadvantages:

Karbonpille:Carbon Pill:

Silikonmaterial wird mit Karbon oder anderen elektrisch leitenden Partikeln leitfähig gemacht, in Platten gepresst und ausgestanzt und dann im Kompressionswerkzeug mit der Schaltmatte zusammenvulkanisiert.Silicone material is made conductive with carbon or other electrically conductive particles, pressed into plates and punched out and then vulcanized together with the switching mat in the compression tool.

Nachteil dieser Pillen ist stets, dass der Überganswiderstand vom Anpressdruck abhängig ist, d.h. wenn die Taste nur ganz leicht gedrückt wird, entsteht ein sehr hoher Schaltwiderstand, welcher falsch interpretiert werden kann. Dies ist insbesondere dann, wenn unterschiedliche Funktionalitäten in Serie über den gleichen Leiterpfad über meist grössenordnungsmässig unterschiedliche Widerstände codiert werden sollen, nicht akzeptabel, da entsprechend beispielsweise bei einer nur leichten Aktuierung eine völlig andere, zufälligerweise im gleichen Leiterpfad angeordnete Funktionalität ausgelöst wird. Auch werden vielfach nicht wirklich tiefe Übergangswiderstände (<1Ohm) erzielt.Disadvantage of these pills is always that the contact resistance is dependent on the contact pressure, i. if the button is pressed very lightly, a very high switching resistance arises, which can be misinterpreted. This is unacceptable, especially if different functionalities are to be coded in series over the same conductor path via resistors that are usually of the highest order of magnitude, since, for example, a completely different functionality, which is randomly arranged in the same conductor path, is triggered with only slight actuation. Also often not really deep contact resistance (<1ohm) are achieved.

Goldpille:Gold Pill:

Ein Kupferblech wird auf der einen Seite mit einer Silikonschicht laminiert, auf der anderen mit Nickel und Gold beschichtet. Aus dem Blech werden dann Pillen gestanzt, welche mit der Schaltmatte im Kompressionswerkzeug zusammenvulkanisiert werden.A copper sheet is laminated on one side with a silicone layer, on the other with nickel and gold coated. From the sheet then pills are punched, which are vulcanized together with the switching mat in the compression tool.

Nachteil dieser Pille ist der hohe Materialpreis und die hohen Ausschussraten im Prozess sowie die hohe Anfälligkeit auf Verschmutzung. Sobald ein Staubkorn zwischen die Pille und die Leiterplatte gerät, wird der Kontakt aufgrund seiner starren Struktur isoliert und fällt aus. Ein weiterer Nachteil ist, dass die Goldpille erst bei einem gewissen Anpressdruck anspricht und nicht bei unmittelbarem Kontakt mit der Leiterplatte.Disadvantage of this pill is the high material price and the high reject rates in the process and the high susceptibility to contamination. As soon as a speck of dust gets between the pill and the circuit board, the contact is isolated due to its rigid structure and fails. Another disadvantage is that the gold pill only at one responds to certain contact pressure and not in direct contact with the circuit board.

Metallgewebe:Metal mesh:

In der DE 23 35 907 , der US 5,047,602 , der EP 0 938 111 und anderen wird zudem die Möglichkeit beschrieben, ein gewobenes oder nicht gewobenes Fasergefüge aus Metall- oder Karbonfasern oder aus leitfähig beschichteten Fasern als Kontaktbereich für einen Schalter vorzusehen. Nachteilig an solchen Lösungen ist ganz analog zu den Partikeln in der genannten Karbonpille die Tatsache, dass stets sichergestellt werden muss, dass die Fasern tatsächlich in genügendem Kontakt sind, um die Leitfähigkeit sicherzustellen. Zudem ist gerade diese Kontaktierung eine Eigenschaft, welche sich bei intensiver Betätigung eines Schalters schnell verschlechtert, und die Fasern haben die Tendenz, bei Alterung zu brechen.In the DE 23 35 907 , of the US 5,047,602 , of the EP 0 938 111 and others also describe the possibility of providing a woven or non-woven fiber structure of metal or carbon fibers or of conductively coated fibers as the contact area for a switch. A disadvantage of such solutions is quite analogous to the particles in said carbon pill the fact that it must always be ensured that the fibers are actually in sufficient contact to ensure the conductivity. In addition, it is precisely this contacting which is a characteristic which rapidly deteriorates upon intensive operation of a switch, and the fibers tend to break when aged.

Aus einem völlig anderen technischen Gebiet, namentlich aus dem Gebiet der Kontaktvorrichtungen für die Verbindung von Leiterplatten, ist in der US 2005/0042895 bekannt, dass es möglich ist, zur Erzeugung eines Kontakts zwischen zwei Leiterplatten, wenn diese über eine Steckverbindung verbunden werden sollen, Kontaktelemente zu verwenden, welche aus einem Metallschwamm bestehen.From a completely different technical field, namely in the field of contact devices for the connection of printed circuit boards, is in the US 2005/0042895 It is known that it is possible to use contact elements which consist of a metal sponge for producing a contact between two printed circuit boards, if they are to be connected via a plug connection.

DARSTELLUNG DER ERFINDUNGPRESENTATION OF THE INVENTION

Der Erfindung liegt demnach die Aufgabe zugrunde, ein verbesserte flexible Schaltmatte mit einem Kontaktelement zur intermittierenden Kontaktierung von Leiterbahnen auf einer Leiterplatte oder einem ähnlichen Träger mit unterbrochenen Leiterbahnen zur Verfügung zu stellen. Dies insbesondere zur Anwendung für flexible Schaltmatten oder Eingabegeräte, so z. B. für den Automobilbereich.The invention is therefore based on the object to provide an improved flexible switching mat with a contact element for the intermittent contacting of printed conductors on a printed circuit board or a similar carrier with interrupted conductor tracks available. This particular for use for flexible safety mats or input devices, such. B. for the automotive sector.

Die Lösung dieser Aufgabe wird durch die Merkmale des Hauptanspruchs gegeben.The solution to this problem is given by the features of the main claim.

Der Kern der Erfindung besteht somit darin, einen Metallschwamm zu verwenden, welcher einerseits durch das darin vorhandene zusammenhängende Netzwerk aus Metall eine wohldefinierte Leitfähigkeit respektive einen wohldefinierten ohmschen Widerstand aufweist, wenn die Leiterbahnen überbrückt werden. Ausserdem verfügt ein Metallschwamm inhärent über eine gewisse Flexibilität und elastische Deformierbarkeit, was insbesondere bei wiederholtem Betätigen und beispielsweise bei schräger Betätigung stets eine gute Kontaktierung gewährleisten kann. Auch Schmutzpartikel können durch die Flexibilität gewissermassen aufgefangen werden.The core of the invention is thus to use a metal sponge, which on the one hand by the existing contiguous network of metal has a well-defined conductivity respectively a well-defined ohmic resistance when the interconnects are bridged. It also has a Metal sponge inherently on a certain flexibility and elastic deformability, which can always ensure a good contact especially with repeated actuation and, for example, oblique actuation. Dirt particles can also be absorbed by the flexibility.

Insbesondere gegenüber der Verwendung eines Metallgewebes oder von Karbonfasern ergeben sich bei Verwendung eines Metallschwammes als Kontaktelement unter anderem folgende unerwartet funktionswesentliche Vorteile:

  • Die Kontakte an der Oberfläche des Metallschaumes sind fix und kohärent über das Gitter miteinander verbunden, während beim Metallgewebe die Verbindung lose ist. Metallschaum erhöht deshalb die Kontaktsicherheit besonders bei den kritischen geringen Kontakt-Anpresskräften enorm. Wenn sich der Widerstand bei geringen Kontakt-Anpresskräften erhöht, ist eine Verwendung in widerstands-codierten Schaltungen nur sehr bedingt möglich und mit grossem Risiko von Fehlfunktionen verbunden.
  • Karbonfasern haben einen höheren Widerstand als Metallschaum. Mit Karbonfasern erreicht man 2 Ohm während der Metallschaum 0.2 Ohm erreicht. Zudem brauchen die Karbonfasern einen gewissen Anpressdruck, um gut zu leiten, was wiederum bei den kritischen geringen Kontakt-Anpresskräften ein entscheidender Nachteil ist.
  • Metallschaum kann Ströme bis zu 500mA bei 12V schalten, während Metallgewebe bedingt durch die sehr dünnen Metallfäden bereits bei geringen Strömen Abbrand erleidet und ausfällt.
  • Die Herstellung von Kontaktpillen aus Metallschaum ist ein einfacher Stanzvorgang, während das sehr dünne Metallgewebe wegen des faserigen Charakters nur schwierig gestanzt werden kann in jedem Fall zuerst laminiert werden muss, um ein Durchdringen mit dem isolierenden Silikon während des Moulding-Prozesses zu verhindern. Die Herstellkosten von Kontaktpillen aus Metallschaum sind entsprechend geringer.
  • Materialkosten von Metallschaumpillen sind geringer als Metallgewebe
In particular with respect to the use of a metal mesh or of carbon fibers, the following unexpectedly functionally significant advantages result when using a metal sponge as a contact element:
  • The contacts on the surface of the metal foam are fixedly and coherently connected to each other via the grid, while the metal fabric, the connection is loose. Metal foam therefore increases the contact reliability enormously, especially at the critical low contact pressure forces. When the resistance increases at low contact pressure forces, use in resistance-coded circuits is very limited and associated with a high risk of malfunction.
  • Carbon fibers have a higher resistance than metal foam. With carbon fibers one reaches 2 ohms while the metal foam reaches 0.2 ohms. In addition, the carbon fibers need a certain contact pressure in order to conduct well, which in turn is a crucial disadvantage in the critical low contact-contact forces.
  • Metal foam can switch currents up to 500mA at 12V, while metal mesh suffers from burns due to the very thin metal filaments even at low currents and fails.
  • The production of metal foam contact pills is a simple punching operation, while the very thin metal fabric is difficult to be stamped because of the fibrous nature, in each case it must first be laminated to prevent penetration of the insulating silicone during the molding process. The production costs of contact pills made of metal foam are correspondingly lower.
  • Material costs of metal foam pills are lower than metal mesh

Gemäss einer ersten bevorzugten Ausführungsform handelt es sich beim Metallschwamm um einen Metallschwamm, welcher ein im wesentlichen zusammenhängendes Netzwerk auf metallischer Basis aufweist, um die oben genannte Funktionalität sicher übernehmen zu können. Insbesondere verfügt der Metallschwamm gleichzeitig bevorzugtermassen über ein im wesentlichen zusammenhängendes Netzwerk aus Hohlräumen (im Englischen i.d.R. sogenannter metal sponge). Grundsätzlich ist es aber auch möglich, so genannte Metallschäume (im Englischen i.d.R. sogenannte metallic foams) zu verwenden, bei welchen die Hohlräume kein im wesentlichen vollständig zusammenhängendes Netzwerk ausbilden, sondern vielmehr in Form von Poren ausgebildet sind.According to a first preferred embodiment, the metal sponge is a metal sponge which has a substantially contiguous metallic-based network in order to be able to reliably assume the abovementioned functionality. In particular, at the same time, the metal sponge preferably has a substantially coherent network of cavities (in English so-called metal sponge ) . In principle, however, it is also possible to use so-called metal foams (in English so-called metallic foams ) in which the cavities do not form a substantially completely coherent network, but rather are in the form of pores.

Im folgenden soll unter dem Begriff Metallschwamm verstanden werden, dass es sich dabei um ein zusammenhängendes Netzwerk auf metallischer Basis handelt, welches über Hohlräume in Form eines im wesentlichen zusammenhängende Netzwerkes verfügt.In the following, the term metal sponge is understood to mean that it is a coherent network on a metallic basis, which has cavities in the form of a substantially contiguous network.

Gemäß der Erfindung sind die Hohlräume des Metallschwammes wenigstens im wesentlichen vollständig mit einem elastomeren Material gefüllt. Diese Bauweise zeichnet sich überraschenderweise durch eine hervorragende Funktionalität aus. Das in den Hohlräumen angeordnete elastomere und damit elastische Material führt dazu, dass der so im wesentlichen vollständig gefüllte Metallschwamm als Ganzes bleibend elastische Eigenschaften erhält. Während ein "leerer" Metallschwamm resp. Metallschaum insbesondere bei starker mechanischer Belastung, wenn die Hohlräume nicht mit elastischem Material gefüllt sind, u.U. auch irreversibel deformiert werden kann, ist dies bei einem solchen gefüllten Metallschwamm nicht mehr möglich infolge des in den Hohlräumen angeordneten elastischen Materials. Es wird auch verhindert, dass das metallische Netzwerk bei Belastung bricht und die Leitfähigkeit so beeinträchtigt wird. Auf der anderen Seite ist aber durch das Netzwerk aus metallischem Material die Leitfähigkeit zuverlässig und stets gleichbleibend. Auf diese Weise kann ein Kontaktelement in einem erstaunlich einfachen Herstellungsprozess zur Verfügung gestellt werden, welches auch bei intensiver wiederholter und sogar grober Benutzung seine Funktion hervorragend langfristig übernehmen kann.According to the invention, the cavities of the metal sponge are at least substantially completely filled with an elastomeric material. This design is surprisingly characterized by excellent functionality. The arranged in the cavities elastomeric and thus elastic material causes the thus substantially completely filled metal sponge as a whole receives permanently elastic properties. While an "empty" metal sponge resp. Metal foam especially under heavy mechanical load, if the cavities are not filled with elastic material, and may also be irreversibly deformed, this is no longer possible in such a filled metal sponge due to the arranged in the cavities elastic material. It also prevents the metallic network breaking under load and thus affecting the conductivity. On the other hand, due to the network of metallic material, the conductivity is reliable and always consistent. In this way, a contact element can be made available in an astonishingly simple manufacturing process, which can take over its function excellent long-term even with intensive repeated and even rough use.

Besonders einfach ist die Konstruktion, weil das Kontaktelement in Form einer Kontaktpille mit der Schaltmatte oder mit einem Element der Schaltmatte verbunden ist, wobei die Schaltmatte respektive das Element der Schaltmatte aus einem elastomeren Material besteht, und dieses elastomere Material die Hohlräume des Metallschwammes im wesentlichen vollständig durchdringt.Particularly simple is the construction, because the contact element is connected in the form of a contact pillar with the switching mat or with an element of the switching mat, wherein the switching mat respectively the element of the switching mat consists of an elastomeric material, and this elastomeric material, the cavities of the metal sponge substantially completely penetrates.

Beim elastomeren Material kann es sich um ein Material ausgewählt aus: Silikon Elastomer, Flüssigsilikon-Gummi, Flüssigsilikon-Kautschuk, thermoplastisches Elastomer oder Gummi handeln. Mit anderen Worten werden jene Materialien verwendet, welche typischerweise im Bereich von Schaltmatten bereits jetzt Anwendung finden.The elastomeric material may be a material selected from: silicone elastomer, liquid silicone rubber, liquid silicone rubber, thermoplastic elastomer or rubber. In other words, those materials are used which are typically already used in the field of safety mats.

Eine ganz besonders einfache Konstruktion, welche sich durch einen einfachen, zuverlässigen Produktionsprozess und niedrige Herstellungskosten auszeichnet, ist möglich, wenn es sich beim elastomeren, in den Hohlräumen angeordneten Material um das Material der Schaltmatte handelt und gewissermassen Material der Schaltmatte wenigstens teilweise in die Kontaktpille eindringt. Das Material der Schaltmatte durchdringt dann die Kontaktpille wenigstens teilweise, was einerseits dazu führt, dass die Kontaktpille fest mit der Schaltmatte verbunden ist, und was andererseits dazu führt, dass die Kontaktpille die oben diskutierten nachhaltigen elastischen Eigenschaften erhält.A very simple construction, which is characterized by a simple, reliable production process and low production costs, is possible if it is the material of the switching mat in the elastomeric, arranged in the cavities material and to some extent material of the switching mat at least partially penetrates into the contact pellet , The material of the switching mat then penetrates the contact pill at least partially, which on the one hand leads to the contact pill being firmly connected to the switching mat, and on the other hand leads to the contact pill receiving the above-discussed lasting elastic properties.

Eine andere bevorzugte Ausführungsform ist dadurch gekennzeichnet, dass das Kontaktelement in Form einer Kontaktpille vorliegt, deren Hohlräume wenigstens teilweise, bevorzugt in wenigstens einem Oberflächenbereich, mit einem elektrisch leitenden elastomeren Material gefüllt sind, wobei es sich dabei bevorzugt um mit Graphit oder Metall-Partikeln wie z. B. Nickel-Partikeln versetztes elastomeres Material, insbesondere bevorzugt um mit Graphit oder Metall-Partikeln wie zum Beispiel Nickel-Partikeln versetztes elastomeres Silikon handelt. Eine Erhöhung der Leitfähigkeit kann auch erreicht werden, indem das Kontaktelement in Form einer Kontaktpille vorliegt, und die Kontaktpille auf der den Leiterbahnen zugewandten Oberfläche mit einer zusätzlichen metallischen Beschichtung, insbesondere aus Gold oder Chrom, versehen ist.Another preferred embodiment is characterized in that the contact element is in the form of a contact pill whose cavities are at least partially, preferably in at least one surface area, filled with an electrically conductive elastomeric material, wherein it preferably with graphite or metal particles such as z. Example, nickel particles offset elastomeric material, particularly preferably with graphite or metal particles such as nickel particles offset elastomeric silicone. An increase in the conductivity can also be achieved by the contact element being in the form of a contact pill, and the contact pill on the surface facing the strip conductors is provided with an additional metallic coating, in particular of gold or chromium.

Im Zusammenhang mit dem Begriff Kontaktpille muss präzisiert werden, dass es sich dabei um kreisförmige, gewissermassen kreiszylinderförmige Elemente handeln kann, dass es sich aber auch um ovale, hexagonale, quadratische, rechteckige oder beliebige andere Grundformen handeln kann. Typischerweise handelt es sich bei der Kontaktpille um ein kreisförmiges Kontaktelement.In connection with the term contact pill it must be specified that these may be circular, to some extent circular cylindrical elements, but that they may also be oval, hexagonal, square, rectangular or any other basic shapes. Typically, the contact pill is a circular contact element.

Beim Material des Metallschwammes handelt es sich vorzugsweise um ein Metall ausgewählt aus der Gruppe: Nickel, Chrom, Gold, Aluminium, Kupfer oder daraus gebildete Legierungen oder Mischungen. Auch Schäume oder Schwämme, welche stratifiziert aus unterschiedlichen Metallen bestehen, sind möglich.The material of the metal sponge is preferably a metal selected from the group: nickel, chromium, gold, aluminum, copper or alloys or mixtures formed therefrom. Also foams or sponges, which are stratified of different metals, are possible.

Solche Schwämme können beispielsweise in einem Abscheideprozess (CVD, chemical vapour deposition) hergestellt werden, wobei ein Kunststoffschaum mit Metall beschichtet wird und anschliessend der Kunststoff entfernt wird, so dass ein zusammenhängender Metallschwamm mit zusammenhängenden Hohlräumen entsteht. Bevorzugt werden Metallschäume resp. Metallschwämme mit einer mittleren Porengrösse im Bereich von 100 - 1000 µm, bevorzugt im Bereich von 550-700 µm, insbesondere bevorzugt im Bereich von 600-650 µm. Das Kontaktelement liegt bevorzugt in Form einer Kontaktpille mit einer Dicke im Bereich von 0.5-3 mm, bevorzugt im Bereich von 0.5-0.9 mm vor. Der Metallschwamm verfügt vorteilhafter Weise über eine Dichte im Bereich von 200-800 g/m2, insbesondere bevorzugt im Bereich von 300-500 g/m2, dies bezogen auf eine Materialdicke von 1.6 mm.Such sponges can be produced for example in a deposition process (CVD, chemical vapor deposition), wherein a plastic foam is coated with metal and then the plastic is removed, so that a contiguous metal sponge with coherent cavities formed. Preferably, metal foams resp. Metal sponges with an average pore size in the range of 100-1000 μm, preferably in the range of 550-700 μm, particularly preferably in the range of 600-650 μm. The contact element is preferably in the form of a contact pill with a thickness in the range of 0.5-3 mm, preferably in the range of 0.5-0.9 mm. The metal sponge advantageously has a density in the range of 200-800 g / m 2 , particularly preferably in the range of 300-500 g / m 2 , based on a material thickness of 1.6 mm.

Des weiteren betrifft die vorliegende Erfindung ein Verfahren zur Herstellung einer Schaltmatte respektive eines Elementes einer Schaltmatte (z.B. Silikondom), wie sie weiter oben beschrieben wurde. Das Verfahren ist dadurch gekennzeichnet, dass ein solches Kontaktelement in ein Kompressionswerkzeug, ein Spritzgusswerkzeug oder ein Transfer-Moulding-Werkzeug, bevorzugt an für die Kontakte vorgesehenen Vertiefungen, eingelegt wird, anschliessend eine Elastomermischung eingelegt respektive zugeführt und/oder eingeschossen wird, und bei geschlossenem Werkzeug Druck und Temperatur im Werkzeug derart eingestellt werden, dass das Elastomer niederviskos wird und in den Metallschwamm wenigstens teilweise eindringt. Druck und Temperatur im Werkzeug werden bevorzugtermassen derart eingestellt, dass das Elastomer im wesentlichen vollständig in den Metallschwamm des Kontaktelementes in Form einer Kontaktpille eindringt.Furthermore, the present invention relates to a method for producing a switching mat or an element of a switching mat (eg, silicone dome), as described above. The method is characterized in that such a contact element is inserted into a compression tool, an injection molding tool or a transfer molding tool, preferably at recesses provided for the contacts, then an elastomer mixture is inserted or supplied and / or injected, and when closed Tool pressure and temperature can be adjusted in the tool so that the elastomer is low viscosity and at least partially penetrates into the metal sponge. Pressure and temperature in the tool are preferably set such that the Elastomer substantially completely penetrates into the metal sponge of the contact element in the form of a contact pill.

Das Kontaktelement kann in Form einer Kontaktpille vorgelegt werden, welche aus einer Metallschwammplatte in einem Stanzverfahren oder einem Schneidverfahren, bei welchem bevorzugt eine teilweise Verdichtung des Metallschwammes bewirkt wird, hergestellt werden. Die Kontaktpille und/oder die Metallschwammplatte können vor respektive nach dem Stanzprozess wenigstens teilweise mit einem elektrisch leitenden oder nicht leitenden elastomeren Material gefüllt oder mit einem Rakel-, Druck- oder Sprayverfahren beschichtet werden, oder mit einer zusätzlichen metallischen Beschichtung, insbesondere aus Gold oder Chrom, versehen werden. Wird bereits die Metallschwammplatte mit einem elastomeren Material gefüllte, so kann ein solches Kontaktelement anschliessend auch an den entsprechenden Stellen einer Schaltmatte aufgeklebt oder sonst mit dieser verbunden werden (z.B. von unten auf einen Silikondom).The contact element can be presented in the form of a contact pill, which are produced from a metal sponge plate in a stamping process or a cutting process, in which preferably a partial compression of the metal sponge is effected. The contact pill and / or the metal sponge plate can be filled before or after the stamping process at least partially with an electrically conductive or non-conductive elastomeric material or coated by a squeegee, pressure or spray method, or with an additional metallic coating, in particular of gold or chromium be provided. If the metal sponge plate is already filled with an elastomeric material, such a contact element can then also be glued or otherwise connected to the corresponding points of a switching mat (for example, from below onto a silicone dome).

Weiterhin betrifft die vorliegende Erfindung die Verwendung eines Schaltmatten oder in Elementen resp. Bestandteilen für Schaltmatten oder Eingabegeräten wie beispielsweise Tastaturen, oder Eingabegeräte insbesondere aus dem Automobilbereich wie Fensterheber, Spiegelversteller, und/oder zur direkten Schaltung von Motoren. Letzteres ist möglich, da die erfindungsgemässen Kontaktelemente vergleichsweise hohe Ströme zuverlässig schalten können.Furthermore, the present invention relates to the use of a safety mats or in elements resp. Components for safety mats or input devices such as keyboards, or input devices especially from the automotive sector such as windows, mirrors, and / or for direct connection of motors. The latter is possible since the contact elements according to the invention can reliably switch comparatively high currents.

Weitere mögliche Verwendungen bestehen zur Realisierung einer Tastenfunktion in einem flexiblen Silikonarmband oder allgemeiner in einer Silikonschaltmatte. Ganz allgemein kann ein Metallschaum oder ein Metallschwamm als flexible Kontaktbahn in Elastomer, wie z.B. in Silikon, eingebettet sein. So als flexibles Tastpad.Other possible uses are to realize a key function in a flexible silicone wristband or more generally in a silicone keypad. In general, a metal foam or metal sponge may be used as a flexible contact sheet in elastomer such as e.g. embedded in silicone. So as a flexible touchpad.

KURZE ERLÄUTERUNG DER FIGURENBRIEF EXPLANATION OF THE FIGURES

Die Erfindung soll nachfolgend anhand von Ausführungsbeispielen im Zusammenhang mit den Zeichnungen näher erläutert werden. Es zeigen:

Fig. 1
eine schematische Darstellung eines Schaltbereiches einer Schaltmatte (Silikondom) nach dem Stand der Technik;
Fig. 2
eine schematische Darstellung eines Schaltmattenelementes für eine Motorsteuerung, wobei in a) eine Ansicht von oben auf das gesamte Bauteil, in b) eine Ansicht von oben auf die Blende, in c) eine Ansicht von oben auf die Schaltmatte, in d) eine Ansicht von oben auf die Leiterplatte, in e) eine perspektivische Ansicht auf die Schaltmatte und in f) ein Schnitt durch eine Schaltmatte entlang der gepunktete Linie in Figur 2c) dargestellt ist;
Fig. 3
a) ein Element einer Schaltmatte mit Metallschaum als Kontaktpille; b) Metallschaum ohne Füllung; c) vollständig mit Elastomer gefüllter Metallschaum; d) im Oberflächenbereich mit Elastomer gefüllter Metallschaum; e) Metallschaum gemäss d) mit zusätzlicher metallischer Beschichtung;
Fig. 4
a) - d) einzelne Schritte eines möglichen Verfahrens zur Herstellung einer Kontaktpille; und
Fig. 5
ein weiteres Ausführungsbeispiel, in welchem eine integrierte flexible Schaltmatte dargestellt ist.
The invention will be explained in more detail with reference to embodiments in conjunction with the drawings. Show it:
Fig. 1
a schematic representation of a switching range of a switching mat (Silicone dome) according to the prior art;
Fig. 2
a schematic representation of a switching mat element for a motor control, wherein in a) a view from above of the entire component in b) a view from above of the panel in c) a view from above of the switching mat, in d) a view of on top of the printed circuit board, in e) a perspective view of the switching mat and in f) a section through a switching mat along the dotted line in Figure 2c ) is shown;
Fig. 3
a) an element of a safety mat with metal foam as a contact pill; b) metal foam without filling; c) completely filled with elastomer metal foam; d) in the surface area filled with elastomer metal foam; e) metal foam according to d) with additional metallic coating;
Fig. 4
a) - d) individual steps of a possible method for producing a contact pill; and
Fig. 5
a further embodiment, in which an integrated flexible switching mat is shown.

WEGE ZUR AUSFÜHRUNG DER ERFINDUNGWAYS FOR CARRYING OUT THE INVENTION

Die vorliegende Erfindung ist insbesondere im Zusammenhang mit Schaltmatten zu verstehen, wie sie zunächst allgemein an Hand der Figuren 1 und 2 erläutert werden sollen.The present invention is to be understood in particular in connection with safety mats, as initially generally referred to the hand FIGS. 1 and 2 be explained should.

Figur 1 zeigt einen Schnitt durch den Schaltbereich einer Schaltmatte. Auf einer Leiterplatte 1 sind Leiterbahnen 2, 3 vorgesehen. Diese Leiterbahnen sind an einer definierten Stelle unterbrochen, und an dieser Stelle soll durch eine manuelle Eingabe (Drücken i.S. einer Tastatur) von oben eine Kontaktierung, das heisst eine Überbrückung der beiden Leiterbahnen 2, 3 ermöglicht werden. Zu diesem Zweck befindet sich auf der Leiterplatte eine Schaltmatte, welche in diesem konkreten Fall aus einer Kunststoffkappe 4 besteht, unterhalb welcher jeweils in den Schaltbereichen flexible Elemente beispielsweise aus Silikon angeordnet sind. Diese flexiblen Elemente bestehen aus einem Silikondom 5, welcher nach oben mit der Kunststoffkappe 4 verbunden ist. Seitlich neben der Unterbrechung der Leiterbahnen ist dieser Dom 5 über eine Membrane 5a mit der Schaltmattenbasis 6 auf der Leiterplatte abgestützt. Der Dom 5, die Membrane 5a und die Basis 6 sind einstückig aus einem flexiblen Material hergestellt. Ein solches Element wird auch als Silikontaste bezeichnet. Auf der Unterseite des Domes 5 ist eine Kontaktpille 7 befestigt. FIG. 1 shows a section through the switching area of a switching mat. On a circuit board 1 printed conductors 2, 3 are provided. These traces are interrupted at a defined location, and at this point should be made possible by a manual input (pressing iS a keyboard) from above a contact, that is a bridging of the two tracks 2, 3. For this purpose, located on the circuit board, a switching mat, which consists in this specific case of a plastic cap 4, below which are arranged in each case in the switching areas flexible elements, for example made of silicone. These flexible elements consist of a silicone dome 5, which is connected to the top with the plastic cap 4. Laterally next to the interruption of the printed conductors, this dome 5 is supported on the printed circuit board via a membrane 5a with the switching mat base 6. The dome 5, the diaphragm 5a and the base 6 are integrally made of a flexible material. Such an element is also called a silicone button. On the underside of the dome 5, a contact pill 7 is attached.

Wird nun die Kunststoffkappe 4 von oben beispielsweise mit einem Finger nach unten gedrückt, so erfolgt nach Erreichen einer Schwellenkraft ein Einknichen der Membrane 5a, und die Kontaktpille 7 wird auf die Leiterplatte 1 respektive auf die beiden von links respektive von rechts zugeführten Leiterbahnen 2, 3 herunter gepresst. Da es sich bei der Kontaktpille um ein leitendes Element, beispielsweise eine Karbonpille oder eine Goldpille handelt, werden somit die Leiter 2 und 3 miteinander verbunden, und es erfolgt eine Schaltung. Nach loslassen schnellt der Silikondom aufgrund der Elastizität des Materials bei der Membran 5a wieder in seine ursprüngliche, in Figur 1 dargestellte Position zurück, was dazu führt, dass die Verbindung wieder unterbrochen wird, da die Kontaktpille nach oben aus dem Kontaktbereich entfernt wird.Now, if the plastic cap 4 is pressed from above, for example, with a finger down, takes place after reaching a threshold force Einknichen the membrane 5a, and the contact pill 7 is printed on the circuit board 1 respectively to the two from the left respectively from the right conductor tracks 2, 3rd pressed down. Since the contact pill is a conductive element, for example a carbon pill or a gold pill, the conductors 2 and 3 are thus connected to one another and a circuit is effected. After releasing the silicone dome speeds due to the elasticity of the material in the membrane 5a back to its original, in FIG. 1 shown position, which causes the connection is interrupted again, since the contact pill is removed upward from the contact area.

Etwas spezifischer ist diese Situation in Figur 2 dargestellt, wo beispielsweise die Schaltung eines Fensterhebers oder eines Spiegels, das heisst eine Anwendung im Automobilbereich, im Detail dargestellt ist. Figur 2a) zeigt eine Aufsicht auf ein solches Schaltelement, welches aus einer Blende 17 besteht, welche, wie dies in Figur 2b) ersichtlich ist, kreisförmige Aussparungen aufweist. Durch diese Aussparungen greifen von unten zwei Tasten 18 hindurch. Dabei ist es möglich, dass über die Tasten eine Plastikkappe 4 aufgeklebt oder aufgelegt ist.More specific is this situation in FIG. 2 represented where, for example, the circuit of a window lifter or a mirror, that is an application in the automotive sector, is shown in detail. FIG. 2a ) shows a plan view of such a switching element, which consists of a diaphragm 17, which, as in FIG. 2b ), has circular recesses. Grab through these recesses from below two buttons 18 through. It is possible that a plastic cap 4 is glued or laid over the keys.

Die Schaltmatte besteht in diesem Fall aus zwei eigentlichen Schalt-Elementen, wie dies in den Figuren 2c) einer Aufsicht von oben, sowie in 2e) einer perspektivischen Ansicht, und in 2f), einem Schnitt entlang der gepunkteten Linie in Figur 2c) ersichtlich ist. Unterhalb dieser Schaltmatte 4 ist die in Figur 2d) dargestellte Leiterplatte 1 angeordnet, auf welcher zwei getrennte Leiterpfade angeordnet sind, welche jeweils unterhalb der Tasten 18 über Kontaktierbereiche 20 verzügen, das heisst in diesen Bereichen 20 sind die Leiter unterbrochen und sollen dort durch die Kontaktpillen 7 der Schaltmatte überbrückt werden, sofern die Schaltmatte entsprechend betätigt wird. Auch hier ist die Schaltmatte aus einem flexiblen elastischen Material wie beispielsweise Silikonkautschuk gefertigt und besteht einstückig aus einem Dom 5, einer Membrane 5a sowie der Basis 6, wobei zwischen der Basis und dem Dom ein frei stehender Hohlraum ausgebildet ist, in welchem von unten die Kontaktpillen 7 befestigt sind.The switching mat consists in this case of two actual switching elements, as in the Figures 2c 2e) in a perspective view, and in FIG. 2f), a section along the dotted line in FIG Figure 2c ) can be seen. Below this switching mat 4 is in Figure 2d ) shown arranged on which two separate conductor paths are arranged, which in each case underneath the keys 18 via Kontaktierbereiche 20, that is in these areas 20, the conductors are interrupted and should be bridged by the contact pills 7 of the switching mat, if the switching mat is operated accordingly. Again, the switching mat is made of a flexible elastic material such as silicone rubber and consists of one piece Dom 5, a diaphragm 5a and the base 6, wherein between the base and the dome, a free-standing cavity is formed, in which from below the contact pills 7 are attached.

Ziel der vorliegenden Erfindung ist es, gewissermassen eine Lösung zu finden, welche die Vorteile der beiden eingangs genannten Technologien der Karbonpille und der Goldpille kombiniert und gleichzeitig deren Nachteile eliminiert. D.h. die Weichheit der Karbonpille (Schmutz wird eingeschlossen, günstig im Preis) soll mit den elektrischen Eigenschaften der Goldpille (sehr tiefer Übergangswiderstand, unabhängig von Betätigungskraft) kombiniert werden.The aim of the present invention is, so to speak, to find a solution which combines the advantages of the two technologies mentioned above of the carbon pill and the gold pill and at the same time eliminates their disadvantages. That The softness of the carbon pill (dirt is trapped, low in price) should be combined with the electrical properties of the gold pill (very low contact resistance, independent of actuation force).

Dies wird erreicht durch das Verwenden eines Metallschwammes als Material für die Kontaktpille 7, bevorzugt wird ein Nickel-Metallschwamm mit einer Porosität von z.B. 100 PPI (Poren Pro Inch) und einer Dichte von z.B. 400 gr/m2 bei einer Dicke von typischerweise 1.6 mm eingesetzt. Dies ist schematisch in Figur 3a) dargestellt.This is achieved by using a metal sponge as the material for the contact pill 7, preferably a nickel-metal sponge having a porosity of, for example, 100 PPI (pores per inch) and a density of, for example, 400 gr / m 2 at a thickness of typically 1.6 mm used. This is schematically in FIG. 3a ).

Aus dem Metallschaum resp. -schwamm werden Kontaktpillen gestanzt. Dabei kann der Schaum resp. Schwamm bei Bedarf etwas komprimiert werden. Das Verfahren zur Herstellung der Kontaktpillen wird weiter unten im Zusammenhang mit Figur 4 erläutert.From the metal foam resp. spongy contact pills are punched. In this case, the foam resp. Sponge can be compressed if necessary. The method of making the contact pills is discussed below FIG. 4 explained.

Die Schwammpillen werden im Kompressionswerkzeug an den für die Kontakte vorgesehenen Vertiefungen eingelegt, anschliessend wird eine Elastomermischung eingelegt oder eingeschossen resp. zugeführt, und das Werkzeug geschlossen. Durch den Druck (Typischerweise 150kg/cm2) und die Temperatur im Werkzeug (Typischerweise 170°C) wird das Elastomer niederviskos und dringt wenigstens teilweise in den Metallschwamm ein. Gleichzeitig wird der Metallschwamm durch den Druck im Kompressionswerkzeug zusammengepresst und bildet eine ziemlich homogene Fläche, z.T. mit Elastomer durchsetzt, auf der unteren Seite. Diese Fläche dient nun als Kontaktelement, wobei der Schwamm als "Netz" nicht nur an der Oberfläche leitet, sondern über die ganze Pille.The sponge pills are placed in the compression tool on the recesses provided for the contacts, then an elastomer mixture is inserted or injected respectively. fed, and the tool closed. Due to the pressure (typically 150kg / cm 2 ) and the temperature in the tool (typically 170 ° C), the elastomer becomes low in viscosity and at least partially infiltrates the metal sponge. At the same time, the metal sponge is compressed by the pressure in the compression tool and forms a fairly homogeneous surface, partly interspersed with elastomer, on the lower side. This surface now serves as a contact element, the sponge as a "net" not only leads to the surface, but over the whole pill.

Solche Metallschwammpillen weisen annähernd die elektrischen Eigenschaften der Goldpillen auf, ohne dabei schmutzanfällig zu sein, und sind dazu günstig herzustellen.Such metal sponge pills have approximately the electrical properties of the gold pills, without being susceptible to dirt, and are cheap to manufacture.

In der einfachsten Ausführung handelt es sich bei der Pille aus Metallschwamm um eine aus Metallschwamm gestanzte oder ausgeschnittene Pille, welche ansonsten nicht weiter modifiziert ist. Diese Situation ist in Figur 3b) dargestellt. Dieser elektrisch leitende Metallschwamm oder -schaum wird im Werkzeug mit isolierendem Silikon zusammenvulkanisiert oder in anderer Weise auf die Schaltmatte aufgebracht, z.B. durch Kleben, Klemmen, etc.In the simplest version, the metal sponge pill is a metal sponge-punched or cut-out pill, which is otherwise unmodified. This situation is in FIG. 3b ). This electrically conductive metal sponge or foam is vulcanized in the tool with insulating silicone or otherwise applied to the keypad, eg by gluing, clamping, etc.

In einer anderen Ausführung wird die Metallschwamm-Pille vor ihrer Befestigung an der Schaltmatte respektive ihrer Integration in die Schaltmatte bereits wenigstens teilweise mit elastomerem Material, welches nicht leitend oder zusätzlich elektrisch leitend ausgebildet sein kann. Der Metallschaum wird mit einem elektrisch leitenden oder nicht leitenden Material ganz oder teilweise gefüllt. Dies kann z.B. mit Graphit oder Metallstaub versetztes Silikon sein. Eine solche vollständig mit Material gefüllte Metallschwamm-Pille ist in Figur 3c) schematisch dargestellt. Aus diesen Platten werden dann die Pillen gefertigt.In another embodiment, the metal sponge pill is already at least partially with elastomeric material, which may be non-conductive or additionally electrically conductive prior to its attachment to the keypad or their integration into the switching mat. The metal foam is completely or partially filled with an electrically conductive or non-conductive material. This can be for example with graphite or metal dust offset silicone. Such a completely filled with metal sponge pill is in Figure 3c ) shown schematically. From these plates, the pills are then made.

In einer weiteren Ausführung wird die Metallschwamm-Pille zur besseren Leitfähigkeit wenigstens auf der den Kontakten, das heisst den Leiterbahnen zugewandten Seite zusätzlich beschichtet. Mit anderen Worten wird der Metallschwamm mit elektrisch leitfähigem Material auf einer oder beiden Seiten beschichtet. Die Beschichtung kann z.B. mit einem Rakel oder Sprayverfahren durchgeführt werden. Eine solche Beschichtung 10 ist schematisch in Figur 3d) dargestellt.In a further embodiment, the metal sponge pill is additionally coated for better conductivity at least on the side facing the contacts, that is to say the printed conductors. In other words, the metal sponge is coated with electrically conductive material on one or both sides. The coating can For example, be carried out with a doctor blade or spray method. Such a coating 10 is shown schematically in FIG 3d figure ).

Eine zusätzliche Ausführung besteht darin, dass die Metallschwamm-Pille veredelt wird. Dazu kann der Metallschwamm auf einer, beiden Seiten oder durchgängig zusätzlich mit Gold oder einer anderen hochwertigen Schicht beschichtet werden, um die Leitfähigkeit zu erhöhen und den Abbrand zu vermindern. Die Metallschaumpille wird mittels Bedampfen oder Elektrobeschichten etc. zum Bespiel vergoldet. Dies kann bei allen Varianten auf einer oder beiden Seiten durchgeführt werden. Alternativ können die gestanzten Pillen in einer Trommel beschichtet werden. Eine solche Ausführung in Kombination mit einer Beschichtung 10 ist schematisch in Figur 3e) dargestellt.An additional embodiment is that the metal sponge pill is refined. For this purpose, the metal sponge can be coated on one, both sides or throughout additionally with gold or another high-grade layer in order to increase the conductivity and to reduce the burnup. The metal foam pill is gilded by steaming or electroplating etc. for example. This can be done on all variants on one or both sides. Alternatively, the punched pills may be coated in a drum. Such an embodiment in combination with a coating 10 is shown schematically in FIG FIG. 3e ).

Als allgemeine Vorteile dieser Konstruktion lassen sich unter anderem aufzählen:

  • Kostengünstigkeit
  • Keine Modifikation bestehender Werkzeuge nötig
  • Übergangswiderstand unabhängig vom Kontaktdruck
  • Schmutz- und Staubunempfindlichkeit
  • Tiefer Übergangswiderstand
  • Hohe Schaltströme möglich, was zum Beispiel die direkte Steuerung von Motoren erlaubt.
  • Unmittelbare Kontaktgabe bei Berührung mit der Leiterplatte.
As general advantages of this construction can be enumerated among other things:
  • inexpensiveness
  • No modification of existing tools needed
  • Transition resistance independent of the contact pressure
  • Dirt and dust insensitivity
  • Low contact resistance
  • High switching currents possible, which allows, for example, the direct control of motors.
  • Immediate contact when touching the circuit board.

Spezifische Details:Specific Details: Metallschwamm:Metal sponge:

Grundsätzlich gibt es verschiedene Arten von porösen metallischen Trägern:

  • sogenanntes zelluläres Metall oder "cellular metal": Der Raum ist in diskrete Zellen aufgeteilt. Die Grenzen dieser Zellen sind aus massivem Metall gebildet, und die Innenräume sind hohl. Idealerweise sind die individuellen Zellen alle voneinander getrennt.
  • sogenanntes poröses Metall oder "porous metal": das Metall enthält eine Vielzahl von Poren, das heisst geschlossene gekrümmte Gasräume mit einer glatten Oberfläche.
  • sogenannter Metallschaum oder "metal(lic) foam": Schäume sind eine spezielle Form von porösen Metallen. Ein solcher Schaum entsteht aus einem flüssigen Schaum, in welchem Gasblasen fein verteilt in der Flüssigkeit vorhanden sind.
  • sogenannter Metallschwamm oder "metal sponge": der Raum wird von einem kontinuierlichen und verbundenen Netzwerk von Metall gefüllt in Koexistenz mit einem ebenfalls zusammenhängenden Netzwerk von Hohlräumen. Hergestellt werden solche Metallschwammprodukte z.B. im CVD (Chemical vapour Deposition) Verfahren, wo ein Kunststoffschaum mit Metall beschichtet wird und in einem zweiten Schritt dann der Kunststoff entfernt wird, sodass nur ein Metallschwamm übrig bleibt.
Basically, there are different types of porous metallic carriers:
  • So-called cellular metal or "cellular metal": The space is divided into discrete cells. The boundaries of these cells are made of solid metal, and the interiors are hollow. Ideally, the individual cells are all separated from each other.
  • so-called porous metal or "porous metal": the metal contains a multitude of pores, ie closed curved gas spaces with a smooth surface.
  • so-called metal foam or "metal (lic) foam": foams are a special form of porous metals. Such a foam is formed from a liquid foam in which gas bubbles are finely distributed in the liquid.
  • so-called metal sponge or "metal sponge": the space is filled by a continuous and interconnected network of metal in coexistence with a likewise interconnected network of cavities. Such metal sponge products are produced, for example, in the CVD (Chemical vapor Deposition) process, where a plastic foam is coated with metal and in a second step, the plastic is removed so that only a metal sponge remains.

Infrage für die vorliegende Erfindung kommen leitfähige Metallschäume sowie Metallschwämme, wobei Letztere bevorzugt sind.In question for the present invention are conductive metal foams and metal sponges, the latter being preferred.

Solche Metallschwämme bestehen beispielsweise aus Nickel, Nickel beschichtet z.B. mit Chrom oder Gold, Aluminium, Kupfer etc. Verschiedene Porengrössen können verwendet werden, typisch 400 um.Such metal sponges are made, for example, of nickel, nickel coated e.g. with chromium or gold, aluminum, copper, etc. Different pore sizes can be used, typically 400 μm.

Konkret geeignet ist beispielsweise das Produkt: Incofoam Ni Purity; in einer Dicke im Bereich 1.7mm - 2.3mm, 1.7mm bevorzugt (kann noch flacher gewalzt werden), mit einer Dichte (jeweils bezogen auf eine Materialdicke von 1.6 mm) von 400-800g/m2, bevorzugt von ca. 400 g/m2, Zellgrösse 550-700µm, 610 µm bevorzugt. Erhältlich von Inco Special Products.Specifically suitable is, for example, the product: Incofoam Ni Purity; in a thickness in the range of 1.7 mm - 2.3 mm, 1.7 mm preferred (can be even flattened), with a density (in each case based on a material thickness of 1.6 mm) of 400-800g / m 2 , preferably of about 400 g / m 2 , cell size 550-700μm, 610 microns preferred. Available from Inco Special Products.

Ein mögliches Verfahren zur Herstellung von derartigen Kontaktpillen 7 aus einer Metallschwammplatte 14 ist in Figur 4 dargestellt. Wie in Figur 4a) ersichtlich, wird ein z. B. kreisrundes Stanzwerkzeug 12 mit einem konzentrisch angeordneten Stempel 13 respektive Ausstosser verwendet. Das Stanzwerkzeug 12 verfügt an seiner Spitze über eine auf der Aussenseite konisch ausgebildete Verjüngung, welche zur eigentlichen Schnittkante führt.A possible method for producing such contact pills 7 from a metal sponge plate 14 is shown in FIG FIG. 4 shown. As in FIG. 4a ), a z. B. circular punching tool 12 with a concentrically arranged punch 13 respectively ejector used. The punching tool 12 has at its tip a tapered on the outside taper, which leads to the actual cutting edge.

Die Metallschwammplatte 14 wird auf einer weichen Unterlage 15 vorgelegt, und das Stanzwerkzeug 12 wird mit zurückgezogenem Stempel 13 in die Metallschwammplatte 14 stanzend eingeführt.The metal sponge plate 14 is placed on a soft pad 15, and the punch 12 is inserted punched with retracted punch 13 into the metal sponge plate 14.

In einem nächsten Schritt (vergleiche Figur 4b) wird der so abgetrennte Stanzling 16 (die Pille) mit dem Stempel 13 soweit verdichtet, wie dies für die geplante Anwendung erforderlich ist, typischerweise auf 0.7mm.In a next step (compare FIG. 4b ), the thus severed punch 16 (the pill) is compacted with the punch 13 as far as required for the intended application, typically at 0.7 mm.

Anschliessend wird, wie dies in Figur 4c dargestellt ist, das Stanzwerkzeug 12, 13 zurückgezogen, wobei der Stanzling 16 im Stanzwerkzeug haften bleibt. Zur Unterstützung kann im Stempel eine magnetische oder auf Unterdruck basierende Vorrichtung (Ansaugung) vorgesehen sein.Subsequently, as in Figure 4c is shown, the punching tool 12, 13 withdrawn, wherein the punched product 16 adheres in the punching tool. To support a magnetic or vacuum-based device (suction) may be provided in the stamp.

Anschliessend wird das Stanzwerkzeug 12, 13 verschoben und, wie dies in Figur 4d) dargestellt ist, der Stanzling 16, respektive die Kontaktpille, mit dem Ausstosser 13 aus dem Stanzwerkzeug 12 entfernt und beispielsweise in einem Behälter aufgefangen oder auch gleich in eine Form eingelegt.Subsequently, the punching tool 12, 13 is moved and, as in FIG. 4d ), the punched product 16, respectively the contact pill, with the ejector 13 removed from the punching tool 12 and collected, for example, in a container or even inserted into a mold.

In Figur 5 ist ausserdem eine weitere Möglichkeit der Verwendung eines solchen Metallschwammes oder eines Metallschaumes dargestellt. In einer flexiblen Matte 21 aus einem Elastomer, im konkreten Fall aus Silikon sind zwei Leiter 2 und 3 aus Metallschaum respektive Metallschwamm derart eingebettet und vom Elastomer respektive Silikon durchdrungen, dass sie in einem Bereich übereinander geführt sind. Zwischen den beiden Leitern ist in diesem Bereich ein Hohlraum 22 vorhanden. Die Leiter sind am an den Stellen 24 mit einer entsprechenden Elektronik oder mit Schaltkreisen verbunden, und wird nun in einem schematisch dargestellten Tastenbereich 23 von oben (oder gleichermassen von unten) ein Druck auf diese Matte 21 ausgeübt, so kontaktieren die beiden Leiter 2, 3 aufgrund der Flexibilität der Matte 21 und stellen somit eine Tastenfunktion zur Verfügung. Eine solche Matte kann wiederum dadurch hergestellt werden, dass die Leiter beispielsweise als ungefüllte Metallschäume oder Metallschwämme in einer Form vorgelegt werden und anschliessend das Elastomer unter Ausbildung der Struktur gemäss Figur 5 zugeführt wird.In FIG. 5 In addition, another possibility of using such a metal sponge or a metal foam is shown. In a flexible mat 21 made of an elastomer, in the concrete case of silicone, two conductors 2 and 3 made of metal foam or metal sponge are embedded in such a way and penetrated by the elastomer or silicone, respectively, that they are guided over one another in one area. Between the two conductors, a cavity 22 is present in this area. The conductors are connected at the points 24 with appropriate electronics or circuits, and is now in a schematically shown key area 23 from above (or equally from below) exerted a pressure on this mat 21, so contact the two conductors 2, 3rd due to the flexibility of the mat 21 and thus provide a key function. Such a mat can in turn be produced by presenting the conductors, for example, as unfilled metal foams or metal sponges in a mold, and then the elastomer to form the structure according to FIG FIG. 5 is supplied.

Beschichtung:coating:

Elektrisch leitfähige oder nicht leitfähige Elastomere können in Verfahren wie beispielsweise Rakel, Spray, Siebdruck, Tampondruck, etc. aufgebracht werden.Electrically conductive or non-conductive elastomers can be applied in processes such as doctor blade, spray, screen printing, pad printing, etc.

Als Basismaterial für Beschichtung oder als flexibles Füllmaterial kann Flüssigsilikon 3631 von Dow Corning verwendet werden.As a base material for coating or as a flexible filler, Dow Corning 3631 liquid silicone may be used.

Als leitende Partikel können z.B. Nickel-beschichtete Karbonpartikel von Inco Special Products verwendet werden.As conductive particles, e.g. Nickel-coated carbon particles can be used by Inco Special Products.

Als Paste für eine Beschichtung (Basismaterial + Partikel fertig gemischt) kann Xyshield Typ XY800 Nickel Plated Graphite von Laird Technologies verwendet werden.As a paste for a coating (base material + particles ready mixed), Xyshield Type XY800 Nickel Plated Graphite from Laird Technologies can be used.

Als flexibles Füllmaterial kann HTV Silicone, evt. mit Farbpigmenten; z.B. Typ B6670, 30-80 Shore A, 70 Shore A bevorzugt, von Dow Corning verwendet werden. ,As a flexible filling material can HTV silicone, possibly with color pigments; e.g. Type B6670, 30-80 Shore A, 70 Shore A preferred, to be used by Dow Corning. .

Veredelung:finishing:

Materialien wie Gold, Chrom, etc. können in Verfahren wie beispielsweise Sputter, Bedampfen, Galvanisieren, etc aufgebracht werden.Materials such as gold, chromium, etc. can be applied in processes such as sputtering, vapor deposition, electroplating, etc.

Schaltmatte/Elastomer:Safety Mat / elastomer:

Typischerweise wird HTV Silikon Elastomer für Schaltmatten verwendet, die vorliegende Erfindung lässt sich aber auch mit Flüssigsilikon Liquid Silicone Rubber (LSR), thermoplastischen Elastomeren (TPE) oder Gummi jeglicher Art realisieren.Typically, HTV silicone elastomer is used for mats, but the present invention can also be implemented with liquid silicone liquid silicone rubber (LSR), thermoplastic elastomers (TPE) or rubber of any kind.

Verarbeitung:

  • Der Metallschlamm kann zu Pillen gestanzt werden und direkt ins Kompressionswerkzeug eingelegt werden.
  • Der Metallschwamm kann mit Elastomer zu Platten geformt werden, aus welchen dann die Kontaktpillen gestanzt oder geschnitten (auch Lasertechniken) werden. Diese werden dann wiederum im Werkzeug mit dem Silikon zusammenvulkanisiert.
  • Zur Verbesserung der Leitfähigkeit können auch Pillen mit Metallschwamm und leitendem Elastomer (Elastomer + leitende Partikel) hergestellt werden.
  • Anstelle von Kompressionswerkzeugen können die Pillen auch in Spritzgusswerkzeuge, Transfer Moulding Werkzeuge oder andere eingelegt werden.
Processing:
  • The metal sludge can be punched into pills and inserted directly into the compression tool.
  • The metal sponge can be formed into sheets with elastomer, from which the contact pills are then punched or cut (also laser techniques). These are then vulcanized together in the mold with the silicone.
  • To improve conductivity, you can also use metal sponge and pills conductive elastomer (elastomer + conductive particles) are produced.
  • Instead of compression tools, the pills can also be placed in injection molds, transfer molding tools or others.

Haftung der Pille an Schaltmatte:Adhesion of the pill to the safety mat:

  • Formschluss: Silikon fliesst in Struktur von MetallschwammPositive locking: Silicone flows into structure of metal sponge
  • Chemisch: Füllmaterial/Beschichtung geht chemische Bindung mit Silikon einChemical: Filler / Coating chemically bonds with silicone
  • Kleben: Pillen werden an fertige Schaltmatte aufgebracht durch Kleben Kontaktpille:Glue: Pills are applied to finished safety mat by gluing contact pill:
  • Rund, viereckig, beliebige FormRound, square, any shape
  • Dicke: Metallschwamm-Dicke von Ausgangsmaterial oder Metallschwamm resp. -schaum beim Stanzprozess oder Schneidprozess zusätzlich komprimiert.Thickness: Metal sponge thickness of starting material or metal sponge resp. Foam additionally compressed during the punching process or cutting process.

Folgende Anwendungen eines solchen Kontaktelementes sind beispielsweise möglich:

  • Schaltmatten allgemein
  • Kontaktpillen für Fensterheber, Spiegelversteller, etc.
  • Direktes Schalten von Motoren
  • Ersetzt heute verwendete Low Resistance Pillen und Gold Pillen
  • Als flexible Leiterbahnen mit integriertem Kontaktelement direkt im Silikon eingebettet.
  • Generell als flexible Kontaktbahn aus Metallschaum resp. -schwamm, welcher im Elastomer, d.h. z.B. in einem Silikon, in Form einer Bahn o.ä. eingebettet ist. So z.B. für Sicherheitsanwendungen z.B. als flexible Kontaktbahn im Silikon eingebettet, die bei einer Durchtrennung (Unterbruch des Stromkreises) einen Alarm auslösen kann.
  • Als EMV Abschirmung wenn der Metallschaum grossflächig im Silikon eingebettet wird, sei es in Form eines Netzes oder vollflächig.
The following applications of such a contact element are possible, for example:
  • Safety mats in general
  • Contact pills for windows, mirror adjusters, etc.
  • Direct switching of motors
  • Replaces low resistance pills and gold pills used today
  • As flexible strip conductors with integrated contact element embedded directly in the silicone.
  • Generally as a flexible contact track made of metal foam resp. sponge, which in the elastomer, ie for example in a silicone, in the form of a web o. is embedded. For example, for safety applications embedded as a flexible contact track in the silicone, which can trigger an alarm in a cut (interruption of the circuit).
  • As EMC shielding when the metal foam is embedded in the silicone over a large area, be it in the form of a net or over the entire surface.

BEZUGSZEICHENLISTELIST OF REFERENCE NUMBERS

11
Leiterplattecircuit board
2,32.3
Leiterbahnenconductor tracks
44
KunststoffkappePlastic cap
55
Silikondomsilicone dome
5a5a
Membranemembrane
66
SchaltmattenbasisKeypad base
77
Kontaktelement, KontaktpilleContact element, contact pill
88th
Metallschwammmetal sponge
99
gefüllter Metallschwammfilled metal sponge
1010
beschichteter Bereich von 8coated area of 8
1111
veredelter Bereich von 8refined area of 8
1212
Stanzwerkzeugpunching tool
1313
Stempel/AusstosserPunch / ejector
1414
MetallschwammplatteMetal sponge sheet
1515
weiche Unterlagensoft documents
1616
gepresster Stanzlingpressed diecut
1717
Blendecover
1818
Tastebutton
1919
Aussparung für Taste in BlendeRecess for button in aperture
2020
Kontaktbereich auf LeiterplatteContact area on circuit board
2121
Silikonmattesilicone mat
2222
Hohlraumcavity
2323
TastbereichDetection range
2424
Anschlüsse für LeiterConnections for conductors

Claims (16)

  1. A flexible keypad (4-6) having a contact element (7) for the intermittent contacting of conductor tracks (2, 3) on a circuit board, wherein the contact element in the form of a contact pill (7) is contacted with a keypad (4-6) or with an element (5, 6) of a keypad, and wherein the keypad (4-6), respectively the element (5,6) of the keypad, consist of an elastomeric material,
    characterized in that
    the contact element consists of a metal sponge (8) or a metal foam, wherein the cavities of the metal sponge (8), respectively of the metal foam, are essentially completely filled with the elastomeric material of the keypad (4-6), respectively of the element (5,6) of the keypad.
  2. The keypad (4-6) according to claim 1, characterized in that metal sponge (8) is a metal sponge (8) that essentially has a contiguous metal-based network, as well as at the same time an essentially contiguous network of cavities.
  3. The keypad (4-6) according to one of the preceding claims, characterized in that the elastomeric material is a material selected from: silicone elastomer, cured or uncured liquid silicone rubber, thermoplastic elastomer or rubber.
  4. The keypad (4-6) according to one of the preceding claims, characterized in that the elastomeric material arranged in the cavities is the material of the keypad (4-6).
  5. The keypad (4-6) according to one of the preceding claims, characterized in that the contact element takes the form of a contact pill (7), the cavities of which are at least partially filled, preferably in at least one surface region, wherein the electrically conducting elastomeric material is preferably an elastomeric material filled with graphite or metal particles, such as for example nickel particles, in particular preferably an elastomeric silicone filled with graphite or metal particles, such as for example nickel particles.
  6. The keypad (4-6) according to one of the preceding claims, characterized in that the contact element takes the form of a contact pill (7), and in that the contact pill is provided on the surface facing the conductor tracks with an additional metallic coating, in particular of gold or chromium.
  7. The keypad (4-6) according to one of the preceding claims, characterized in that the material of the metal sponge (8), respectively of the metal foam, is a metal selected from the group: nickel, chromium, gold, aluminum, copper or alloys formed therefrom.
  8. The keypad (4-6) according to one of the preceding claims, characterized in that the metal sponge (8), respectively the metal foam, has an average pore size in the range of 100-1000 µm, preferably in the range of 550-700 µm, in particular preferably in the range of 600-650 µm.
  9. The keypad (4-6) according to one of the preceding claims, characterized in that the contact element in the form of a contact pill (7) is formed to a thickness in the range of 0.5-3 mm, preferably in the range of 0.5-0.9 mm.
  10. The keypad (4-6) according to one of the preceding claims, characterized in that the contact element consists of a metal sponge (8) with a density in the range of 200-800 g/m2, in particular preferably in the range of 300-500 g/m2, with reference to a material thickness of 1.6 mm.
  11. A process for producing a keypad (4-6) according to one of the preceding claims, characterized in that the contact element is placed into a compression mold tool, an injection mold tool or a transfer mold tool, preferably on depressions intended for the contacts, an elastomer mixture is subsequently fed, respectively placed in, and, with the tool closed, the pressure and temperature in the tool are set in such a way that the elastomer becomes low in viscosity and at least partially penetrates into the metal sponge.
  12. The process according to claim 11, characterized in that the pressure and temperature in the mold are set in such a way that the elastomer penetrates essentially completely into the metal sponge (8), respectively the metal foam, of the contact element in the form of a contact pill (7).
  13. The process according to one of claims 11 or 12, characterized in that the contact element (7) is presented in the form of a contact pill which was produced from a metal sponge sheet (14), respectively a metal foam sheet, in a punching process, in which preferably a partial compaction of the metal sponge, respectively the metal foam, is brought about.
  14. The process according to claim 13, characterized in that the contact pill (7) and/or the metal sponge sheet (14), respectively the metal foam sheet, is at least partially filled, or coated through a knife-applying, printing or spraying process, with an electrically conducting or nonconducting elastomeric material before, respectively after, the punching process, or is provided with an additional metallic coating, in particular of gold or chromium.
  15. Use of a keypad according to one of claims 1-10, as a keyboards, or input device in particular from the automobile sector such as window openers, mirror adjusters, and/or for the direct switching of motors.
  16. Use of a keypad according to one of claims 1-10, to realize a key function in a flexible silicone armband.
EP06721946.9A 2005-05-06 2006-05-04 Electrically conducting contact and method for production thereof Active EP1878033B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CH8082005 2005-05-06
PCT/CH2006/000244 WO2006119657A1 (en) 2005-05-06 2006-05-04 Electrically conducting contact and method for production thereof

Publications (2)

Publication Number Publication Date
EP1878033A1 EP1878033A1 (en) 2008-01-16
EP1878033B1 true EP1878033B1 (en) 2015-06-24

Family

ID=35482265

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Application Number Title Priority Date Filing Date
EP06721946.9A Active EP1878033B1 (en) 2005-05-06 2006-05-04 Electrically conducting contact and method for production thereof

Country Status (7)

Country Link
US (1) US7964810B2 (en)
EP (1) EP1878033B1 (en)
JP (1) JP5085535B2 (en)
CN (1) CN101171654B (en)
CA (1) CA2607408C (en)
MX (1) MX2007013864A (en)
WO (1) WO2006119657A1 (en)

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Also Published As

Publication number Publication date
CN101171654A (en) 2008-04-30
WO2006119657A1 (en) 2006-11-16
JP5085535B2 (en) 2012-11-28
US7964810B2 (en) 2011-06-21
US20090068857A1 (en) 2009-03-12
CN101171654B (en) 2010-11-24
JP2008541342A (en) 2008-11-20
CA2607408A1 (en) 2006-11-16
MX2007013864A (en) 2008-01-24
CA2607408C (en) 2013-06-11
EP1878033A1 (en) 2008-01-16

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