Patent ID: 6305073
Filing Date: 2001-10-23
Classification: G06F,H01H,Y10T

Abstract:
A method of forming a membrane switch, comprising:(a) providing a first substrate having a first electrically conductive surface;(b) providing a flexible second substrate having a second electrically conductive surface;(c) providing an intermediate spacer defining a central aperture, the second substrate being depressible through the central aperture of the intermediate spacer to contact the first substrate, providing the intermediate spacer comprising:(i) providing a dielectric third substrate including third and fourth surfaces,(ii) applying at least one first electrode including at least one first contact portion on the fourth surface of the third substrate,(iii) applying at least one second electrode including at least one second contact portion on the fourth surface,(iv) applying a first adhesive layer to the third surface of the third substrate,(v) applying a second adhesive layer to the fourth surface of the third substrate, the second adhesive layer defining at least one first aperture adapted to overlie the at least one first contact portion of the at least one first electrode on the fourth surface, the second adhesive layer further defining at least one second aperture adapted to overlie the at least one second contact portion of the at least one second electrode on the fourth surface,(vi) defining at least one hole extending through the at least one first contact portion of the at least one first electrode between the third substrate and the first adhesive layer, the hole having a cross-sectional area that is smaller than that of the first contact portion,(vii) pouring conductive epoxy material into the first aperture and the hole, the conductive epoxy providing an electrical conduction path between the first contact portion and the first adhesive layer, and(viii) pouring conductive epoxy material into the second aperture defined through the second adhesive layer to overlie the second contact portion, the conductive epoxy providing an electrical conduction path between the second contact portion and the second adhesive layer; and(d) securing the intermediate spacer between the first surface of the first substrate and the second surface of the second substrate, the first adhesive layer of the intermediate spacer being associated with the first conductive surface of the first substrate to maintain the first electrode in electrical contact with the first conductive surface, and the second adhesive layer of the intermediate spacer being associated with the second conductive surface of the second substrate to maintain the second electrode in electrical contact with the second conductive surface.