JPH0336255B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates generally to electrical switch assemblies, and more particularly to an improved switch assembly having a plurality of switches in a predetermined arrangement. The present invention relates to a method of manufacturing an aggregate. The present invention has particular utility in connection with key switches in keyboard assemblies, and will be described in connection with this particular utility in the following description.

Electrical switch assemblies adapted to sense the depression of a key on a keyboard and generate a signal indicative of the depression of the key are well known in the art. In general, conventional keyboard switches are
a plurality of discontinuous conductor tracks separated from each other on one or both sides of the circuit board, and a plurality of switching means for selectively electrically connecting the conductor tracks carried on one side; A circuit board is provided. Typically, the switching means comprises individual contacts spaced apart from the conductor tracks, supported on a plate remote from the switching means of the circuit board. Resilient spring means are provided to hold the planar contacts apart, so that the individual switches are normally in the open position. For example, U.S. Pat. No. 4,018,999 (Robinson, et al.) discloses a circuit board having a plurality of switches formed on one side of an insulating circuit board in a predetermined arrangement. A keyboard switch assembly is disclosed having a protective and insulating cover provided over the circuit board to retain and seal the keyboard. According to that patent, each switch includes an elastically deformable sled biasing element having an annular outer contact portion and a concentric inner contact portion. The biasing element is formed to coincide with the outer contact portion and has an annular peripheral edge positioned to protrude therefrom at an end of the outer contact portion. In operation, a downward force is applied to an upwardly projecting portion of the operating element;
The element is thereby deformed downwardly into contact with the inner contact, thereby completing the electrical circuit of the inner and outer contacts.

Other types of keyboard switches are covered by U.S. Patent No.
No. 3653038 (inventor, web, et al.). The US patent discloses a snap-acting capacitive electrical signal device used as a switch. Its basic structure comprises a metal target that forms one "plate" of the capacitor. A mid-height curvature spring located close to the target and separated by space forms the other plate of the capacitor. It has a depressable push button or key located adjacent to and coaxially arranged with the sled spring. The medium-height sled spring and the connected depressable pushbutton are
It is held in aligned position by suitably located circular holes formed in the central insulated support or guide plate.

Still other examples of keyboard switches include U.S. Pat. No. 3,383,487 (inventor, Weiner), U.S. Pat.
U.S. Patent No. 3,789,167 (Inventor, Seeger, et al.), U.S. Patent No. 3,53860771 (Inventor, Lin, et al.), U.S. Patent No. 4,083,100 (Inventor, Flint, et al.), U.S. Patent No. 4,042,439 (Inventor, Lin, et al.) U.S. Patent No. 4,085,306 (Inventor: Dunlop), U.S. Patent No. 4,195,210 (Inventor: Pond, et al.), U.S. Patent No. 4,218,603 (Inventor: Sato),
U.S. Patent No. 4,218,600 (inventor, Kisner), and U.S. Patent No. 4,254,309 (inventor, Jiyeon Sung)
There is.

The prior art keyboard switches described above are relatively expensive to manufacture. Such prior art formats require many parts that must be manufactured in parts and inventoried. Also, the precise alignment of the various operating members with respect to the connected contacts presents a manufacturing problem. Although some solutions to the alignment problem have been proposed, the alignment solution reported in U.S. Pat. No. 4,083,100 (inventor, Flint) has proven to be highly inaccurate. Moreover, complicated and expensive equipment was required. For example, the inventor
The Robinson, et al. patent directs that the operating member be first oriented to the circuit board by a suitable template. However, the template is moved before the insulating sheet is mounted on the circuit board. This presents a problem in that the operating member, once aligned with the circuit board, must be held separate from the template. To solve the latter problem, the inventors, Robinson et al., propose assembling the operating elements to a circuit board on a specially designed transfer table. The latter is configured to receive the circuit board and hold it in place by means of an externally supplied vacuum or magnetic member. Of course, the transfer table is not only a complex and expensive configuration in the assembly process, but also requires precise alignment because the transfer table, circuit board, and template all have to be precisely aligned. It is difficult. Also, when the template is moved, the operating members are in an exposed position with respect to the circuitry, and although the circuit board is protected, it can be damaged or accidentally moved out of its designated position during assembly. Also, the insulating sheet is not necessarily aligned with the top of the rotary plate, and the operating members may move prior to attachment, causing sudden displacement of one or more operating members. Furthermore, with this technique, the insulating sheet is supported only on top of the operating member and is not held flat immediately before being attached to the circuit board. Therefore, wrinkles or similar defects in the insulating sheet material near the periphery of the operating member may
The circuit board is not reliably positioned, resulting in misalignment of the operating member. Since the operating member may be separated and the circuit board may be moved, even if initially properly aligned, the operating member may be moved out of its designated position during use. These and other limitations regarding precise alignment, ease of manufacture, switch reliability, and manufacturing cost are inherent considerations in the manufacture of many prior art keyboard switch assemblies and switch assemblies. has been done. Additionally, many prior art keyboards have experienced mechanical and/or electrical problems during use. Regarding the latter problem, the prior art typically plated the switch contact members with a non-corrosive metal such as gold. Such plating requirements are significant to manufacturing costs. Furthermore, the internal connections deteriorate due to loss of material in the interconnect switch contact members that are repeatedly activated and deactivated.

It is an essential object of the present invention to provide a new and improved electrical switch assembly that overcomes the aforementioned and other problems in the prior art. Yet another object of the invention is to provide a highly reliable electrical switch, particularly for use in keyboard applications, and a low cost method for manufacturing an electrical switch of the type described above. be.
A more specific object is to provide a new and improved keyboard switch characterized by extremely high reliability and a low cost method for manufacturing a general purpose switch.

In general, the present invention includes a switch contact carrying an array of resiliently flexible electrically conductive conductors forming one or more circuit conductor paths, and which is an integral extension of the circuit conductor paths. An electrical switch assembly is provided which essentially comprises a dielectric carrier panel that provides a dielectric support panel. The dielectric carrier panel has a plurality of holes or cavities at predetermined positions in the carrier panel, and the switch contact portion is at least partially above or within the holes or cavities. be located. The switch contacts typically include a pair of "L-shaped" or "golf club-shaped" fingers. L-shaped fingers are
Extending from an edge surface in the carrier panel defining the associated hole or cavity, passing over or within each hole or cavity and terminating close together at the free ends of the fingers. The free ends of the L-shaped fingers are located at a distance from each other, so that the circuit conductor tracks connected to them are normally open, but are sufficiently abutted to each other that the carrier panel A slight deviation of the finger from its normal position on the surface moves the free end, thereby closing the switch. In other examples, the free ends of the L-shaped fingers are placed in contact with each other so that slight deviation of the fingers from their normal position breaks the contact. In a preferred embodiment of the invention, the switch assembly includes a protective overlay layer formed of a flexible dielectric sheet material covering at least a portion of the conductor and switch contacts; It includes a resin-molded operating section placed above. The array of electrically conductive conductors and integral switch contacts are
by photographic imaging and etching or by additional techniques such as cambering by plating or soldering, and/or by mechanical planing and/or
Alternatively, it is formed by a die-cutting technique using a precise die, which will be described in detail later.

In order to better understand the purpose and nature of the invention, reference is made in detail to the accompanying drawings.

As used herein, the words "left" and "right", "upper" and "lower", and "upwardly" and "downwardly" each refer only to directions relative to each other in the illustrations of the accompanying drawings. used to indicate
However, those skilled in the art will recognize that, in actual manufacture, the switch assembly may be adapted to other configurations than those shown in the accompanying drawings.

One embodiment of an electrical switch assembly according to the present invention is shown assembled as a keyboard in Figures 1-4 of the accompanying drawings. Figures 1 to 4
In the illustrated embodiment, the keyboard 18 includes a flexible laminated circuit assembly made of a flexible dielectric material, which is an insulating material for general purpose flexible printed wiring boards. A film or substrate sheet 62 of Mylar (available from DuPont) 0.0254 to 0.1270 millimeters (0.001 to 0.005 inch) or thicker (available from DuPont) and 0.0127 to 0.0127 thick adhesively secured to the surface 26 of the substrate sheet 62.
0.0254 mm (0.0005-0.0010 inch)
or more, and has a plurality of conductive circuit conductor paths 24a, b formed of a conductive flexible metal such as copper or more. (The thickness of the material will vary widely depending on the choice of material and the dimensions of the switch. As will become clear in the discussion below, geometrically larger switches generally require heavier or thicker materials.) (Geometrically smaller switches require lighter or thinner materials.) The conductive circuit traces of the flexible circuit assembly 20 are formed by photographic images and etchings, as described in detail below. Formed by technology. (For illustrative purposes, a portion of circuit assembly 20 is shown in the drawing and substrate sheet 62 is omitted.) Circuit assembly 20 is formed by screen printing supported on a flexible dielectric polymeric substrate. It may also include a flexible conductive material, such as a silver-filled epoxy resin, or it may include one or more internal conductive conductive tracks and a plurality of flexible insulating sheets. The electrically conductive traces have dimensions and shapes that correspond to the required design criteria, such as current carrying capacity and the coupling structure of the circuit and the switch.

The circuit assembly 20 is secured to a hard resin molded base member 30 by adhesive or mechanical means, as will be described in detail below. Foundation member 30
is a flat, rigid plate formed of an electrically insulating material, such as a glass-backed thermoflex polyester polymer, and is positioned as required relative to the switch contact 34, as will be described in detail below. It has a plurality of cavities or blind holes 32 at predetermined positions corresponding to. In addition, the base member 30 has a thickness
The 1.5748 millimeter (0.062 inch) phenolic resin plate may consist of a rigid plate formed of electrically insulating material with holes or blind holes at the predetermined locations described above.

The circuit conductor paths 24a, b, .
connected to. The switch contact is normally in the open position. Each of the switch contact portions 34 is connected to the conductor path 2
A first left contact member 40 which is an integral extension of 4b
and a second right contact member 42 which is an integral extension of the conductor track 24a. Obviously, busbar members or contact terminals 36a and 36b are electrically connected to an external circuit (not shown) of circuit assembly 20.

Each of contact members 40 and 42 is generally L
The support beams or legs 48 and 50 of the external agent, forming a shaped or golf club shaped member, are positioned fixedly on the top surface 52 of the base member 30 at the edge of the hole 32. Support legs 48 and 50 interdigitate within and extend across hole 32 .
As shown in FIG. 2, support legs 48 and 50 are approximately the same length. One leg can be longer than the other if necessary. Members 40 and 42
The free ends 54 and 56 of the top surface 5
2 and the plane of the support legs 48,50. That is, it extends downwardly at an angle from the plane of surface 52. Additionally, free ends 54 and 5
6 is positioned (bent) upward at a certain angle with respect to the plane of the surface 52, as shown in FIGS. 16a, b and 17a, b. As shown in FIG. 2, free ends 54 and 56 are slightly spaced apart inside or above hole 32.

The illustrated electrical switch assembly is completed with a protective overlay layer 100 of flexible insulating sheet material fixedly positioned over the upper surface of the circuit assembly 20. An overlay layer 100 includes an operating portion 102 positioned over the free ends 54 and 56 of the switch contact members.
(See FIGS. 3 and 4; dielectric film 22 has been omitted from FIGS. 4a and 4b for ease of illustration). Other,
The switch assembly includes actuators located at the free ends 54 and 56 of the switch contact members directly overlying the overlay layer without any intervening material.

5-13 illustrate a preferred method of forming electrical switch assemblies according to the present invention, employing photographic imaging and etching to form the circuit and switch patterns. However, the circuit and/or switch patterns may be formed by employing additional techniques such as electroplating, mechanical die-cutting techniques, screen printing of metal-doped epoxy conductive inks or shaped wires or conductors. be done.

A thin film or foil of copper, 0.0127 mm (0.0005 inch) thick, adhered to a polymeric film substrate coated with an adhesive of 0.0127 mm (0.005 inch) Mylar 62 (DuPont trademark for polyester film). An elastic flexible laminated sheet material 60 consisting of 64 is prepared as shown in FIG. 6a. Top or laminated sheet 60
The metal film surface 64 of is cleaned using conventional cleaning techniques, and the cleaned surface is coated with a conventional resist layer 70 in a coating step 68 (FIG. 5), as shown in FIG. 6b. Ru. Positive resists are preferred so that multiple imaging and development steps are employed, as will be apparent from the description below. A variety of positive resists are known in the art and sought after on the market. In this example,
Shipley's AZ in Newton, Mass.
Type positive resist is used. Resist layer 70 is exposed in an imaging step 72 to form a positive artwork image of circuit traces and contact members 40 and 42. The exposed resist areas 70a (FIG. 6c) are altered and removed from the sheet by a subsequent development operation. The laminate sheet is immersed in a resist special solvent (e.g. sodium hydroxide solution) and developed in a development step 73, so that the exposed portions of the resist layer 70a are all flat circuits, as shown in FIG. Welding is performed, leaving a resist layer 70b as a positive image of the conductor tracks and switch contacts.

The next step involves etching the exposed metal areas of the metal foil by contacting the laminate sheet with an acid etchant solution in an etching step 74. Etching removes metal from all uncovered areas of the metal film leaving the areas of the metal film covered by resist 70, as shown in FIG.

The next step in the process is an imaging step 72 in which the free ends 54 and 56 of the switch contacts are
includes selective re-exposure and development of the resist to expose selected areas 75 of the resist layer 70, which are the areas that will essentially become exposed. This area of exposed resist layer 70 changes as described above,
In a development step 73, the resist layer 70 is removed from the laminate sheet by dipping and developing the laminate sheet in a special solvent, so that the exposed portions of the resist layer 70 are dissolved to expose the metal areas 75 of the foil 64. The unexposed portions of resist layer 70 are left as circuit conductor exposure and protective coverings for support legs 48 and 50, as shown in FIG.

Further steps include plating the exposed metal areas 75 of the foil 64 with a non-corrosive metal 76 by conventional plating techniques, such as electroplating, in a plating step 79 as shown in FIG. Mylar film 62 effectively masks all of the bottom surfaces of circuit traces and contact members 40 and 42, while resist area 70 masks all surfaces of the top of the metal foil (other than exposed areas 75). However, as a result, electroplating of metal is carried out selectively only in the area of the switch contact which ultimately becomes the operating contact area of the switch. As a result, the formation of switch contacts by plating is a particularly simple procedure and the metal consumption in the plating process is also relatively low. The structure in the steps up to now is shown in FIG.

A further step in the process involves forming (molding) the cut operating switch contacts. Cutting and shaping are performed in the cutting and shaping process 92
The cutting and forming steps can be accomplished with a single precision die or with split dies. For convenience of illustration, the cutting and shaping steps are described in two separate stages. In a first step, mylar support 62, plated area 76 and legs 48 and 50 are cut at 77 in a conventional manner. The resulting structure is shown in FIG. In a second step, the plated area 76 of the contact member is heated using a heated metal die and a continuous mold (see Figures 12 and 13) to apply pressure to the plated area 76. It is permanently formed or shaped (deflected) upwardly from the plane of the substrate 62 by molding and cooling, or by vacuum forming techniques known in the art. (For illustration purposes, the structure is shown in a perspective view.) At this stage, the plated area 76 is preferably
It is shaped or folded to extend at an angle of 45° to 115°, and the fold is permanently set to the mylar film by heat forming or other conventional means. As shown in FIG. 13 by way of example, the plated area 76 is placed on a template 91 (metallic area of the template) of appropriate dimensions, covered with a silicone rubber receiver 93, and placed in the silicone rubber receiver sufficiently. Pressure and heat (150°) are applied to permanently set the mylar layer 62 in a certain shape for a certain period of time. The controlled bending is such that the closest edges of free ends 54 and 56 are spaced 0.254 to 0.635 millimeters (0.010 to 0.025 inches) apart at the closest distance. Obviously the spacing between free ends 54 and 56 is a matter of design choice and adjusted accordingly for the particular application.

The structure according to FIGS. 12 and 13 has a cut free end 5 located on the geometric center of the cavity or hole 32 of the panel in the installation step 90.
4 and 56 against a rigid perforated panel or resin molded base member 30. Obviously the cavities or holes 32 will be in a predetermined pattern according to the pattern of the particular switch.

The final step is to cover the final switch structure with a flexible dielectric overlay layer 100. The overlay layer 100 includes an operating section 102 that is a resin-molded knob-shaped, hemispherical, or similar curved disc-shaped elastic flexible member placed over the switch contact section. do. The overlay layer 100 is secured by adhesive along the line of the switch assembly to form a sealing unit. In addition, an overlay layer 100, a base member 30,
and circuit board assembly 20 are mechanically coupled as a unit by thermoformed and appropriately positioned fixing posts 109. A fixation post 109 integrally molded with base member 30 extends through and is integrally positioned with appropriately located holes 108 in circuit board assembly 20 and overlay layer 100. (In Figures 3a and 3b, fixing post 109 is shown before and after being thermoformed.) Having the post integral with the hole makes the switch assembly simple and reliable. It will be recognized by those skilled in the art.

Structures resulting from the above are shown in FIGS. 1-4.

Several of the advantages of the present invention over prior art switches will be recognized by those skilled in the art. One is
The switch and supporting electrical circuitry are formed by simple photographic imaging and etching techniques, and simple mechanical die cutting and molding operations. Additionally, the switch assembly has a virtually infinite number of geometric designs. The switch assembly has several parts and the assembly and alignment problems associated with prior art switches are essentially eliminated. Furthermore, the switch action and switch spring constant are subject to a variety of easy modifications, including the size of the aperture, the arrangement and shape of the actuator, and the selection of materials employed. Furthermore, the invention is particularly advantageous in manufacturing due to the simple assembly technique and provides high reliability as the switch contact area can be plated with a precious metal (eg gold) with minimal material costs. Furthermore, during operation of the switch body, a wiping action is performed on the surface of the switch contact portion, thereby removing an oxide film formed on the switch, thereby improving the reliability of the switch.

Various modifications can be made in carrying out the invention. For example, as illustrated in FIG. 14, the required circuit and switch patterns are made by directly die-cutting a 0.127 mm (0.005 inch) thick phosphor bronze spring metal plate. The switch contacts are formed in a precision die cutting process 200 to permanently set the spring material itself. The other operations of cutting and forming the circuit are done in a single step.
The final structure is constructed using the appropriately prepared resin molded base member 30 described above in the installation step 204.
and assembled into the overlay layer member 100,
In Figures 15a and 15b the switch contacts are shown in the open and closed positions.
A feature and advantage of the process of FIG. 14 is that keyboards or other switch assemblies with uniformly located switches can be manufactured quite cost-effectively by a simple die-cutting operation. Furthermore, by using a plated laminate of strips as the starting metal sheet material and proper circuit and switch design, a switch with plated contacts can be produced at low cost. Strip plated laminates are available commercially in a variety of weights and sizes.

Further, as shown in FIGS. 16a and 16b, the switch contact free ends 54 and 56 are
It is molded upward with respect to the surface 52, that is, in the direction of the operating portion 102.

Furthermore, in another embodiment of the present invention, FIG.
As shown in FIG.
and 56 extend upwardly from the plane of base member 30' in the normally closed position. The operation of this switch is as follows:
Shown in Figure b. What is noted in FIGS. 17a and 17b is that the switch contact portion is formed upward from the resin-molded base member 30' within the resin hemisphere formed in the dielectric cover member 100'. Is Rukoto. (In FIGS. 17a and 17b, the dielectric cover member 100
constitutes a "carrying panel", while the resin hemisphere constitutes a "blank copper" adapted to the switch contact area. )
A particular advantage of the switch configuration in FIGS. 17a and 17b is that the cross-sectional area of the switch can be particularly thin. Further, the base member 30' need not be flat as shown in the figures, but may be partially circular.

Yet another embodiment according to the invention is shown in Figures 18a and 18b. The switch contact part is
A spring electric wire 213 plated at the free end 210 is formed into an L shape. In this embodiment the thermoforming operation is eliminated.

Still another embodiment according to the present invention is shown in FIG. 19a.
and shown in FIG. 19b. The switch contacts and associated circuitry are sandwiched between a pair of flexible dielectric polymeric hemispherical sheets 212. The operation of the switch is as described above. Still other variations will be apparent to those skilled in the art. Switches other than keyboard switches, such as rotary switches and dual in-line package switches (so-called DIP switches), may be advantageously manufactured using the present invention.

In addition, in the above-mentioned embodiment, a cavity or a blind hole provided in the base member is shown, but the invention is not necessarily limited to this. ), an aperture, etc. can be used.

In the above-described embodiments, a protective overlay layer is provided above the circuit assembly, but this is not necessarily essential, and such a protective overlay layer can be omitted. In that case, the operating section would be supported by a suitable support other than the protective overlay layer.

Therefore, all matters contained in the foregoing description should be construed as illustrative;
It should not be interpreted as limiting.

[Brief explanation of the drawing]

FIG. 1 is a top view of an electrical switch assembly integrated into a keyboard as one embodiment of the present invention, and FIG. 2 is an enlarged view of the structure of the central portion of the electrical switch assembly of FIG. 1. The top view, Figure 3a, is
Figure 2 is an enlarged cross-sectional side view of the electrical switch assembly of Figure 1, with the switches shown in the open position; Third
Figure b is a side view of the same as Figure 3a, with the switch shown in the closed position; Figure 4a is an enlarged perspective view of a portion of the electrical switch assembly of Figure 1; The switch shows the open position,
FIG. 4b is an enlarged perspective view of the same as FIG. 4a, with the switch shown in the closed position; FIG. 5 is a step for manufacturing the electrical switch assembly of FIG. 1; 6 to 11 are top views of the electrical switch assembly in each step of the process shown in FIG. 5, and FIG.
Perspective view of the jig used in the process shown in the figure, No. 13
The figure is an enlarged perspective view of a portion of the electrical switch assembly molded using the jig of FIG. 12, and FIG. 14 is another example of the process for manufacturing the electrical switch assembly according to the present invention. Process diagram showing the 15th
Figure 15a is an enlarged side view of another example of an electrical switch assembly according to the invention, with the switch shown in the open position; Figure 15b is an enlarged side view of the same as Figure 15a; Figure 16a is an enlarged side view of another example of an electrical switch assembly according to the present invention, with the switch shown in the closed position, and Figure 16b with the switch shown in the open position.
is an enlarged side view of the same as in Fig. 16a;
FIG. 17a is an enlarged side view of yet another example of an electrical switch assembly according to the present invention, with the switch shown in the closed position, and FIG. 17b is an enlarged side view showing the switch in the closed position. Fig. 3 is an enlarged side view of the same device as in a, with the switch in the open position;
Figure 8a is an enlarged side view of yet another example of an electrical switch assembly according to the invention, with the switch shown in the open position; Figure 18b is an enlarged side view of the same as Figure 18a; 19a is an enlarged side view of yet another example of an electrical switch assembly according to the present invention, with the switch shown in the open position, and FIG.
Figure 9b is an enlarged side view of the same as Figure 19a, with the switch shown in the closed position. (Explanation of symbols), 18...Keyboard, 20...
...Laminated circuit assembly, 24, 24a, 24b...
...Circuit conductor path, 26...Surface, 30...Foundation member, 32...Hole, 34...Switch contact portion, 36
a, 36b... Contact terminal, 40... Contact member (left), 42... Contact member (right), 48, 50...
Support leg, 52... Top surface, 54, 56... Free end, 60... Laminated sheet, 62... Substrate, 64
...Copper foil, 68...Coating process, 70...Resist, 70a...Dissolved area, 70b...Remaining area,
72... Image forming process, 73... Development process, 74
...Etching process, 75...Exposed metal area, 7
6... Non-corrosive metal, 77... Die-cut part, 79...
...Plating process, 90...Mounting process, 91...Mold cutting, 92...Molding process, 94...Finishing, 100
... Overlay layer, 102 ... Operation member, 10
9... Fixed column, 190... Die cutting, 200... Die cutting cutting process, 204... Mounting process, 210...
...Metting part, 212... Hemispherical sheet, 213...
...Spring wire, So...Overlay stop,
Smb...Mold base stop.

Claims (1)

Claims: 1. An electrical switch assembly comprising at least one hollow space 32 formed in one side 52 of a carrying panel 30, 100 made of a dielectric material.
and at least one conductive circuit disposed in said carrier panel and formed of an elastic and flexible electrically conductive material and including at least one switch means, each switch means being located in said hollow space or in said carrier panel. In an electrical switch assembly including a pair of contact members 34 outside the hollow space, the contact members are connected to the conductor circuits 24a, 24b.
and a pair of bent L-shaped finger parts 40 and 42 arranged inwardly at a predetermined distance from the edge of the hollow space, the pair of L-shaped finger parts being integral with the hollow space. A collection of electrical switches, characterized in that they occupy the same plane adjacent to the edges and extend beyond one finger in said hollow space to each other, a portion of which extends above or below one surface 52. body. 2. The electrical switch assembly of claim 1, wherein the electrically conductive material is a metallic conductor. 3. The electrical switch assembly of claim 1, wherein said conductive material is a thin metal foil 64 supported at least partially on a flexible dielectric substrate 62. 4. The electrical switch assembly according to claim 1, wherein the conductive material is a screen-printed circuit pattern formed of epoxy resin containing metal powder supported on a flexible dielectric substrate 62. . 5. The contact end portions 54, 56 of the pair of L-shaped finger portions 40, 42 are at least partially plated with a non-corrosive conductive metal 76. Electrical switch assembly. 6. The electrical switch assembly of claim 1 further comprising operating means 102 at least partially covered by the contact members 54, 56. 7. The operating means comprises an overlying flexible dielectric material 100 and an operating element 102 integral with the flexible dielectric material 100.
Electrical switch assembly as described in Section. 8. An electrical switch assembly as claimed in claim 1, wherein said switch means are arranged in a predetermined keyboard pattern. 9 electrical switch assembly, at least one hollow space 32 formed in one side 52 of the carrying panel 30, 100 made of dielectric;
and at least one conductive circuit disposed in said carrier panel and formed of a resilient and flexible dielectric material and including at least one switch means, each switch means being located in said hollow space or in said carrier panel. In a method for manufacturing an electrical switch assembly including a pair of contact members 34 outside a hollow space, the steps include: (a) preparing an elastically flexible conductive sheet; and (b) selecting the conductive sheet. (c) forming the continuous switch contact members to form L-shaped finger portions 40, 42; (d) shaping at least a portion of the L-shaped finger portion so as not to deform it; (e) preparing a dielectric substrate having a hollow space at a predetermined position on one surface; and (f) The conductor circuit and the pattern of the L-shaped finger portion are fixedly positioned on the surface thereof, together with the L-shaped finger portion positioned within or at least partially covered by the hollow space. A method for manufacturing a switch assembly. 10 The cutting step (c) and the shaping step
9. The manufacturing method according to claim 9, wherein (d) is completed by one punching and shaping operation. 11 In the selection area of the switch contact member 34,
depositing the conductive circuit to create a raised contact area on the L-shaped finger portion substantially formed;
Claim 9 further comprising the step of fixedly positioning the pattern of conductive circuits with the raised contact area positioned within or at least partially covered by the hollow space.
Or the manufacturing method according to item 10. 12. The method according to claim 9, 10 or 11, further comprising the step of fixedly positioning the flexible dielectric covering means 100 in the pattern of the conductive circuit opposite the dielectric carrying panel 30. Production method. 13. Molding the switch contact member 34 at least partially out of the plane of the conductive sheet so that the switch contact member 34 is not deformed, and the molding causes the free end portions 54, 56 of the L-shaped fingers to be adjacent to each other. The method according to item 11 or 12.