Patent ID: 6821467
Filing Date: 2004-11-23
Classification: H01H,Y10T

Abstract:
A method of making a thin film keypad comprising:forming at least one keycap attachment region on a thin film material, each said keycap attachment region including at least one molding material passage region, wherein forming said keycap attachment region includes cutting at least one flap from said thin film material to form said material passage region; placing said thin film material into a molding tool having at least one keycap mold cavity such that each said molding material passage region is located within each said keycap mold cavity, respectively, wherein said molding tool includes a gate for injecting said molding material, and wherein said gate is inserted through said material passage region such that said gate moves said flap into said keycap mold cavity; and injecting a molding material through said molding material passage region in said thin film material and into said keycap mold cavity such that at least one keycap is molded onto a top surface of said thin film material, and wherein said molding material flows around portions of said thin film material and hardens on opposite sides of said portions of said thin film material to form at least two anchor portions such that said keycap is mechanically secured to said thin film material, and wherein one of said anchor portions is formed by said molding material flowing around said flap and hardening on opposite sides of said flap.