Abstract:
An improved game controller. D-pad keys are positioned above a printed circuit board-with plungers guided by housing apertures. The D-pad key is top-loaded into contact with the housing to simplify manufacture and operating reliability. The D-pad key can be depressed downwardly until it contacts a pivot supported by a pivot post. The combination of elements permits significant design flexibility in the orientation and shape and operation of a D-pad key. Front mounted triggers replace front mounted buttons attached to a separate vertical printed circuit board. The triggers function with the main printed circuit board, thereby reducing cost and enhancing product reliability.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to the field of keys used in electronic game controllers. More particularly, the invention relates to improved game controller keys having fast response and reliable action in response to a person&#39;s operating control. 
     Game controllers provide the link between a gamer and a video game. Game controller keys depress internal elastomeric switches which close an electrical connection on a printed circuit board. By closing preprogrammed switches, a gamer&#39;s acts are transferred to a video game console which reacts with a preprogrammed on-screen game event. 
     Flat oriented game controllers position the majority of keys in a horizontal plane and position the forward keys in a vertical plane. To operate the forward keys to actuate electronic switches, separate, small, vertically oriented circuit switches are normally installed in the forward area of the controller in an orientation perpendicular to the printed circuit board. The vertical circuit boards contain elastomeric switches actuatable by the forward keys and for transmitting the generated signals to the larger, main printed circuit board and then to the video game console. The design, manufacture and mass production of the smaller vertically oriented circuit boards comprise a significant cost of game controller manufacture. 
     Such forward keys are normally similar in shape, size and touch, and are equally positioned relative to the displacement form the game controller centerline. During the frantic pace of game play, the forward keys are often confused because the touch is indistinguishable to the touch. Accordingly, incorrect key presses and the consequential on-screen action can result from such confusion. 
     Conventional game controllers have a key set known as a D-pad which comprises the key typically experiencing the heaviest utilization. Conventional D-pads comprise a single key having four compass point edges. When the D-pad is pressed by a gamer, an elastomeric key within an enclosure is depressed to close an electronic connection. This connection is transmitted to the console of the electronic gaming system so that a preprogrammed screen event is displayed. Such event can comprise a global icon movement in the direction of the press. 
     The travel range of D-pad keys is limited, and the elastomeric switches wear out during the intense cycles experienced during game controller play. D-pad keys can wear and separate from the clamshell housing during the middle of game play, resulting in game interruption and the consequential frustration. Additionally, conventional D-pad keys require relatively bulky skirt sections which increase key weight and reduce the responsiveness of the keys. 
     SUMMARY OF THE INVENTION 
     The present invention provides a game controller comprising a housing having an aperture through at least one portion of the housing, a printed circuit board within the housing, a switch proximate to the printed circuit board for selectively operating the printed circuit board, a key insertable through the housing aperture for engagment with the housing, wherein said key is moveable relative within a selected movement range relative to the housing, at least one plunger positioned between the key and the switch for translating movement of the key to the switch, and a pivot for limiting movement of the key toward the switch. 
     In other embodiments, the controller comprises a housing having an aperture through at least one portion of the housing, a printed circuit board within the housing, a switch proximate to the printed circuit board for selectively operating the printed circuit board, a pivot engaged with the housing, and a trigger rotatable about the pivot for engagement with the switch, wherein movement of the trigger causes the trigger to contact the switch. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates a schematic for a game controller. 
     FIG. 2 illustrates a prior art D-pad key. 
     FIG. 3 illustrates a D-pad key having plungers for supporting the D-pad key above an elastomeric switch. 
     FIG. 4 illustrates an isometric view of the components. 
     FIG. 5 illustrates prior art front keys combined with a separate vertical printed circuit board. 
     FIG. 6 illustrates two triggers for operation with a main printed circuit board. 
     FIG. 7 illustrates isometric views of left and right trigger components. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The invention relates to video game controller keys having superior action and reliability. FIG. 1 illustrates a top view of game controller  10  having D-pad  12 , control keys  14 , function keys  16 , and front mount keys  18 . D-pad  12  comprises the key experiencing the heaviest use during game play. As shown in FIG. 1, the exterior user interface of D-pad  12  is shaped in the form of a cross. Each extreme of the cross may be depressed to create directional movement in the desired game play direction. Control keys  14  are depressed by the player&#39;s right hand thumb and right index or middle fingers. Control keys  14  are assigned to specific actions in the game. Front mounted keys  18  are depressed by the left and right index or middle fingers and are assigned to specific game actions. Function keys  16  typically comprise low-use keys for controller and game setup and are not used during actual game play. 
     FIG. 2 illustrates a conventional, bottom-loaded D-pad  20  wherein four electronic switches  22  are positioned between D-pad  20  and housing printed circuit board  24  in the 12, 3, 6, and 9 o&#39;clock positions. D-pad  20  includes pivot  28  integrated within D-pad  20  and having pivot end  30  in contact with printed circuit board  24 . The lateral gap  32  between enclosure top clamshell or housing  34  and D-pad  36  is relatively large to permit characteristic “wobble” resulting from angular movement of D-pad about pivot  28 . D-pad  20  has thumb surfaces  38  at the top. Bottom, right, and left surfaces. Conventional pivot  28  is integrated into D-pad  20  as illustrated, requiring extra mass and consequential response lag. Pivot  28  contacts printed circuit board  24  when one of thumb surfaces  38  is depressed, and elastomer membrane switch  40  having domes  42  is depressed. Upon such action, carbon pill  44  attached to the underside of dome  42  is contacted against a grid of exposed electrical tracks on printed circuit board  24 . An electrical short results, causing a circuit actuation. Printed circuit board  24  comprises the backbone of the controller  10  electronics, and includes exposed grids of tracks forming electrical switches underneath elastomer membrane switch  40 . 
     D-pad  20  includes large skirt  46  around a perimeter which is bottom loaded against housing  34 . The relatively large skirt  46  must be sufficiently large to cover lateral gap  32  as D-pad  20  is moved relative to housing  34 . Gap  48  between pivot  28  and printed circuit board  24  is required in the relaxed position to reduce rattling contact therebetween as D-pad  20  is pressed against housing  34  by elastomer membrane switch  40 . Accordingly, pivot  28  is functional only after D-pad  20  is depressed by the player. 
     One significant limitation of conventional D-pads such as that illustrated in FIG. 2 is that the height of the components and the component travel is limited. The present invention eliminates this limitation by providing a unique combination of elements. FIG. 3 illustrates D-pad  50  integrated with housing  52  through a housing aperture. The clearance between D-pad  50  and housing  52  is identified as gap  54 , which is substantially smaller than lateral gap  32  shown in FIG.  3 . One or more clips  56  are attached to the lower portion of D-pad  50  for engagement with housing  52 . Clips  56  or D-pad  50  are sufficiently flexible to permit the installation and engagement of clips  56  with upper clamshell of housing  50 . Although clips  56  are illustrated as being integrated within D-pad  50 , clips  56  could comprise separate components or could be integrated within housing  52  in other embodiments of the invention. 
     Plungers  58  are positioned in contact with D-pad  50 , and have plunger bells  60  in contact with elastomer membrane switch  62  having domes  64 . When D-pad  50  is depressed, a plunger  58  is moved downwardly so that the respective plunger bell  60  contacts a dome  64  for activation of switches on printed circuit board  66  as previously described. Movement of plunger  58  is constrained by plunger guides  68  attached to pivot post  70  so that movement of plungers  58  is substantially vertical. Pivot post  70  comprises a rounded top identified as pivot  72  for contact with pivot depression  74  formed in D-pad  50 . Pivot depression  74  centers D-pad  50  relative to pivot  72  and provides for slight angular movement therebetween. Pivot post  70  is attached to printed circuit board  66  and provides a fixed distance between printed circuit board  66  and pivot  72 . 
     Gap  76  is located between pivot  72  and D-pad  50  so that D-pad  50  floats on plungers  58  in the user ready position. When D-pad  50  is depressed on one or more sides, gap  76  is closed to limit downward movement of D-pad  50 . The unique combination of components provides extraordinary flexibility in the design, orientation and location of D-pad  50 . Although the height of prior art D-pads is limited above the printed circuit board, the present invention permits significant increases in the distance between D-pad  50  and printed circuit board  24 . A smaller lateral clearance gap  54  can be smaller, providing more accurate movement and aesthetic appeal. 
     FIG. 4 illustrates a three dimensional view of the invention showing plunger bell openings  78  which permit trapped air to escape therethrough. Additionally, plunger bell openings  78  permit the molding of each tooth  80  for facilitating a locking connection between plunger bell  60  against elastomer membrane switch  62 . Each plunger bell tooth  80  can grip an exterior surface of dome  64  during installation to prevent plunger bell  60  from separating from elastomer membrane switch  62 . Keying ring  82  can integrate with a tab on D-pad  50  to provide proper orientation during component assembly. 
     D-pad  50  is separated from elastomer membrane switch  40  as a selected distance because of the integral function provided by plungers  58 . This feature of the invention permits curved, ergonomically shaped shell surfaces placed at odd heights with variable height or irregularly shaped keys. Virtually unlimited design flexibility in key shape is possible because the distance of D-pad  50  is liberated by plungers  58  from close proximity to printed circuit board  66 . If an outer edge of D-pad  50  is depressed, plungers  58  travel downwardly to establish, consistent and uniform contact with the underlying switch circuits. Elastomer membrane switch  40  cannot be skewed to one side, significantly reducing elastomer wear by providing reliable contact with each operation of D-pad  50 . 
     Another significant feature provided by the invention is the top-loaded assembly compared with bottom-loaded assembly typically used in game controllers. D-pad  50  cannot fall out during assembly or during rugged game play because clips  56  retain D-pad  50  in position, and preventing D-pad  50  from extending more than the selected distance from printed circuit board  66 . By top-loading D-pad  50 , the conventional skirt is eliminated. This reduction in mass provides quicker, more responsive operation. Additionally, D-pad  50  pivots on pivot  72  which provides smooth, responsive see-saw action as the grooved surface illustrated as pivot depression  74  cooperates with pivot  72 . The pivot point provided by pivot  72  is significantly higher than conventional game controllers, and does not depend on the wobble motion required by other game controllers. 
     To assemble the components, D-pad  50  is clipped in from the top over the connecting links provided by plungers  58  after plunger bells  60  are friction fit onto the tops of domes  42 . Plungers  58  then travel up and down with domes  42  as plunger tooth  80  assist with the friction fit of plungers  58  against domes  42 . The assembly is turned over and the assembly formed by elastomer membrane switch  40  and plungers  58  are fitted by inserting plungers  58  through plunger guides  68 . This configuration eliminates rattles as plungers  58  are squeezed slightly between elastomer membrane switch  40  and D-pad  50 . 
     By using two or more plungers  58  having different lengths, or by altering the level of the lower part of D-pad  50  or of printed circuit board  66 , D-pad  50  can be placed at many different angles and is not constrained in a parallel position relative to printed circuit board  66 . Although the orientation of plungers  58  relative to D-pad  50  have been illustrated, the same concept can be implemented for control keys, triggers, and other key devices. Pivot  72  is illustrated a separate from D-pad  50 , however pivot  72  could be inverted and attached to D-pad  50  in other embodiments of the invention. Plungers  58  can comprise separate components or can be integrated within D-pad  50 . 
     FIG. 5 illustrates a representative example of prior art forward keys  84  which are operable with an index or middle finger to actuate elastomeric switches  86  mounted on vertical printed circuit boards  88 . Forward keys can be attached to housing  52  with screws, clips, or a subassembly to housing  52 . Cable connection  90  can connect vertical printed circuit boards  88  to main printed circuit board  66 , requiring additional expense and providing failure paths. 
     FIG. 6 illustrates one embodiment of the invention wherein triggers  92  and  94  perform the operating function provided by forward keys  84 . Triggers  92  and  94  can be pulled backwardly from the initial position and pivot about axle  96  retained within the game controller housing  52 . As shown in detail in FIG. 7, each trigger  92  and  94  has a trigger radius from axle  96  which maintains a constant clearance from housing  52  during operation of triggers  92  and  94 . Axle  96  is positioned within cylinders  100  integrated into triggers  92  and  94 . Hammer  98  is attached to each trigger  92  and  94  to contact elastomeric membrane switches  40  and to close circuits on printed circuit board  66 . 
     This feature of the invention eliminates the vertical printed circuit board found in conventional game controllers, and significantly reduces manufacturing cost. Additionally, the invention eliminates the wire connections between vertical and main printed circuit boards which are subject to failure. 
     Although the invention has been described in terms of certain preferred embodiments, it will become apparent to those of ordinary skill in the art that modifications and improvements can be made to the inventive concepts herein without departing from the scope of the invention. The embodiments shown herein are merely illustrative of the inventive concepts and should not be interpreted as limiting the scope of the invention.