SWITCH SHEET MANUFACTURING METHOD AND APPARATUS

Abstract: The present invention is provided with an automatic manufacturing method of a switch sheet comprising a concave face switch and an apparatus thereof. A refuse removing tape 7 is stuck on a lower surface of a film separator 4 so that an adhesive layer thereof may fit it before a first punch device 14 forms first holes in the film separator 4. Then, a processing tape 5 is stuck on an upper surface of the film separator 4 so that an adhesive layer of the processing tape may fit it before a second punch device 15 punches the processing tape 5 in a setting shape at the same time while forming second holes through the processing tape 5, the film separator 4 and the refuse removing tape 7. After that, the punched processing tape is wound to be stripped when pulling out the film separator 4 and the refuse removing tape 7 on which the processing tape 5 in a setting shape is stuck.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a manufacturing method of a switch sheet and to a correlated manufacturing apparatus. The switch sheet is of the type constituting a component part of a concave face switch used for a portable telephone or the like. 2. Description of the Prior Art Portable telephones are widely used realizing compactness and low price. Some advanced prior art designs provide thinner, more compact, more lightweight and cheaper ones than the earlier ones. Referring to a switch used for constituting contact points of ten keys of a portable telephone and various kinds of function keys or the like, a concave face switch 1 illustrated in Fig. 3 is adopted instead of a silicon rubber switch (see Fig. 4) and a membrane switch adopted at the beginning. The concave face switch 1 can be thin and gives a mechanically stable touch. It is easy to use because timing of a mechanical reverse is equal to that of an electrical touch. The concave face switch 1 comprises a switch sheet 2 on which a metallic dome 3 is stuck. The metallic dome is arranged directly on the base at a portable telephone body, thereby constituting an electrical contact point. First, the switch sheet 2 included in the concave face switch 1 has a state wherein, as shown in Fig. 2, fixing holes 4a, holes 4b for matching a position, holes 4c for exposing dome and LED lighting holes 4d are formed in a film separator 4 by a punch and the like while holes 5a for matching a position and LED lighting holes 5b are formed in a processing tape 5 (sticking tape) by a punch and the like, a processing tape 5 is manually stuck in the film separator 4 by an operator, thereby producing it, so as to coincide holes for matching a position 4b with 5a, i.e., so as to coincide the LED lighting holes 4d with 5b and a protective liner 6 is stuck on a back surface side thereof for supplying it to a maker (operator). In the switch sheet 2 delivered to a maker in this way, the metallic dome 3 is manually stuck on a back surface (adhesive layer) of the processing tape 5 by the maker one by one through holes 4c for exposing the dome of the film separator 4, thereby manufacturing the concave face switch 1. After that, a surface sheet on which numerals and symbols of various kinds of functions and an alphabet or the like are printed is stuck on a surface of the switch sheet 1 before being. fixed in the portable telephone body by means of the fixing holes 4a. As mentioned above, a method in which the switch sheet comprising the concave face switch is manufactured by the maker sticking the film separator manually on the processing tape results in problems in that a positioning gap occurs easily, a yield is low and production rate is limited. Therefore, one tried to manufacture switch sheets automatically, however, at present this does not show a satisfying technical result. In other words, as shown in Fig. 2, various kinds of holes formed in the film separator not always coincide with various kinds of holes formed in the processing tape while it is required to form holes separately in the film separator and the processing tape, respectively. In case of forming various kinds of holes in the processing tape, a back surface of the processing tape has an adhesive layer to hold the metallic dome, but in case of forming holes after feeding it, the adhesive layer is stuck on a side of a manufacturing apparatus, thus making continued operation impossible. Although it can be thought that holes are formed in the film separator before holes are formed in the processing tape and that the processing tape is piled thereon, some kinds of switch sheets require that holes are formed in the processing tape only so as to be partially overlapped with the holes formed in the film separator. In this case, holes formed in the film separator in advance make it impossible to have a reaction force of a blade such as to punch or the like in an overlapped portion, thus causing a problem in that holes of the processing tape cannot surely be opened. Document JP-A-1-200525 discloses the use of different preformed films, which are bonded together, in order to produce a switch sheet. In this context there are provided a lower fixed point contact point tape, a spacer tape, an upper fixed contact point tape, a movable contact point tape and two cover tapes. While the cover tapes are fed from respective reels, the tapes are overlapped in the above sequence and pressed, thereby bonding a lower fixed contact point board. Cover sheets are bonded to the upper surface of a movable contact point board placed on the upper fixed contact point board. Taking the above problems into consideration, it is an object of the present invention to provide a manufacturing method of a switch sheet and a correlated manufacturing apparatus for manufacturing a switch sheet which a concave face switch comprises, automatically. SUMMARY OF THE INVENTION In a manufacturing method of a switch sheet according to the present invention the steps outlined in claim 1 are provided. In other words, a refuse removing tape for removing refuses is stuck on a lower surface of a film separator so as to fit an adhesive layer of the refuse removing tape, before one or a plurality of first holes are formed in the film separator and then, a processing tape is stuck on an upper surface of the film separator piled on the refuse removing tape so as to fit an adhesive layer of the processing tape before the processing tape is punched in a setting shape at the same time while one or a plurality of second holes are formed through at least the processing tape or both of the processing tape and film separator, and the processing tape, the film separator and the refuse removing tape are fed integratively while the punched processing tape is rolled for stripping. Moreover, a manufacturing apparatus of a swich sheet according to the present invention comprises the features of claim 4. Such an apparatus encompasses a feeding reel for feeding a film separator, a feeding reel for feeding a refuse removing tape, a first punch device including a processing metal mold for forming one or a plurality of holes in the film separator piled on the refuse removing tape, a feeding reel for feeding a processing tape, a second punch device including a processing metal mold for punching the processing tape, piled on the film separator by the second sticking means, in a setting shape, and for forming one or a plurality of holes through the processing tape, the film separator and the refuse removing tape, a winding device for winding the punched processing tape, and a feeder for feeding together the processing tape punched in a setting shape, the film separator and the refuse removing tape, wherein the first punch device forms the first holes in the film separator, and the second punch device punches the processing tape in a setting shape and simultaneously forms the second holes in at least the processing tape or both of the processing tape and film separator. After the refuse removing tape is stuck on the lower surface of the film separator so as to fit the adhesive layer of the refuse removing tape, the first holes are formed in the film separator. Then, the processing tape is stuck on the upper surface of the film separator piled on the refuse removing tape so as to fit the adhesive layer of the processing tape, before the processing tape is punched in a setting shape at the same time while the second holes are formed through at least the processing tape or both of the processing tape and the film separator. In feeding the film separator and the refuse removing tape on which the processing tape having the setting shape is stuck, the punched processing tape is wound for stripping. As a result, a switch sheet including holes, respectively formed corresponding to the processing tape and the film separator, can be automatically manufactured. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic descriptive view illustrating a manufacturing apparatus of a switch sheet according to the present invention. Fig. 2 is a exploded perspective view illustrating a switch sheet. Fig. 3 is a sectional view of a concave face switch. Fig. 4 is a sectional view of a rubber switch. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, an embodiment of the invention is described in detail below. In Fig. 1, a manufacturing apparatus 10 of a switch sheet 2 according to the present invention is illustrated, which comprises a feeding reel 11 for feeding a film separator 4 in a rolling state, a feeding reel 12 for feeding a refuse removing tape (adhesive tape) 7 in a rolling state, a feeding reel 13 for feeding a processing tape (adhesive tape) 5 in rolling state, a first punch device 14 for forming various kinds of first holes in the film separator 4 piled on the refuse removing tape 7, a second punch device 15 for punching the processing tape 5 in a setting shape, piled on the film separator 4 on the refuse removing tape 7 and simultaneously for forming various kinds of second holes through the processing tape 5, the film separator 4 and the refuse removing tape 7, a winding device 16 for winding a processing tape 51 as a punching mark wherein a setting shape has been punched, a feeder 17 for holding a processing tape 52 in a setting shape, the film separator 4 and the refuse removing tape 7 and pulling them out, a winding device 18 for winding the refuse removing tape 7, a winding device 19 for winding the processing tape 52 including various kinds of formed holes, in a setting shape, and the switch sheet 2 on which the processing tape 52 including various kinds of formed holes is stuck, and a feeding reel 20 for feeding a protective liner 6 (a mold releasing paper) stuck on a back surface of the switch sheet 2. The refuse removing tape 7 is fit in the feeding reel 12 to turn an adhesive layer thereof toward an upper surface so that the adhesive layer thereof may stick on a lower surface of the film separator 4, and the processing tape 5 is fit in the feeding reel 13 to turn the adhesive layer thereof toward a lower surface so that the adhesive layer thereof may stick on an upper surface of the film separator 4. On the other hand, the first punch device 14 and the second punch device 15 comprises respectively processing metal molds 141, 151 and crank devices 142, 152 to make the processing metal molds 141, 151 rise and fall, wherein a height of each blade arranged at the processing metal molds 141, 151 and a stroke for rising and falling of each crank device 142, 152 form various kinds of the first holes in only the film separator 4 in the first punch device 14 and they punch only the processing tape 5 in a setting shape in the second punch device 15 at the same time while they form various kinds of the second holes through the processing tape 52 punched in the setting shape, the film separator 4 and the refuse removing tape 7 Moreover, the winding device 16 for winding the processing tape 51, the feeder 17 for feeding the processing tape 52 in the setting shape piled on the film separator 4 on the refuse removing tape 7, the winding device 18 for winding the refuse removing tape 7 and the winding device 19 for winding the switch sheet 2 include respectively motors which are not shown in Figures, each of which is synchronized for operation. In other words, when the punch apparatus 14, 15 are operated with the result that the processing metal molds 141, 151 fall, the winding devices 16, 18, 19 and the feeder 17 stop, on the other hand, when the processing metal molds 141, 151 rise, the feeder 17 is operated with the result that a portion of a set length of the processing tape 5 piled on the film separator 4 on the refuse removing tape 7 is pulled out, whereby the winding devices 16, 18 and 19 are respectively operated to wind each of the processing tape 51, the refuse removing tape 7 and the switch sheet 2 at the same length. Then, the manufacturing apparatus 10 having such a structure is employed to manufacture the switch sheet 2, which is described. First, roll bodies of the film separator 4, the refuse removing tape 7 and the processing tape 5 are fit in the feeding reels 11, 12, 13 toward each set direction before each edge is pulled out to decide their positions on a center line, thereby limiting deviations of right or left direction to their feeding directions by a limiting roller which is not shown. And the film separator 4 is laid on the adhesive layer of the refuse removing tape 7 to be stuck each other thereby making it pass through the first punch device 14. Next, on the film separator 4 piled on the refuse removing tape 7, the processing tape 5 is laid to be stuck before making it pass through the second punch device 15 so as to be led to the feeder 17 and held therebetween. Thus, the processing tape 5, the film separator 4 and the refuse removing tape 7 are stuck in order of the upper to be incorporated before the feeder 17 is operated, thereby enabling each of the processing tape 5, the film separator 4 and the refuse removing tape 7 to be pulled out at the same length. Then, when the processing tape 5, the film separator 4 and the refuse removing tape 7 which are integratively stuck are fed through the feeder 17, the refuse removing tape 7 is separated from the film separator 4, thereby sticking the edge thereof on the winding device 18 for winding. On the other hand, the processing tape 5 and the film separator 4 from which the refuse removing tape 7 are separated are stuck on the protective liner 6 which is fed from the feeding reel 20 on a side of the film separator 4 to be incorporated with the result that it is wound by the winding device 19. By the way, the film separator 4 and the refuse removing tape 7 are integratively stuck, wherein, when the first punch device 14 is operated, the processing metal mold 141 rises and falls according to a stroke portion thereof through the crank device 142, thereby forming various kinds of the first holes in only the film separator 4. In this case, the punched refuses of the punched film separator 4 are stuck on the adhesive layer of the refuse removing tape 7. Then, when an operation for punching holes by the first punch device 14 is completed, the processing tape 5 is stuck on the film separator 4. The processing tape 5, the film separator 4 and the refuse removing tape 7 are integratively stuck, wherein, when the second punch device 15 is operated, the processing metal mold 151 rises and falls according to a stroke portion thereof through the crank device 152 thereby punching only the processing tape 5 in a setting shape, at the same time while various kinds of the second holes are formed through the processing tape 5, the film separator 4 and the refuse removing tape 7. Thus, the operation of punching holes by the second punch device 15 is completed, the processing tape 5, the film separator 4 and the refuse removing tape 7 which are fed through the feeder 17 wind the processing tape 5 through the winding device 16, whereby the punched refuse portions 51 wherein the setting shape is punched by the processing metal mold 151 is stripped from the film separator 4 to be wound. On the other hand, the punched processing tape 52 of the setting shape is stuck on the film separator 4 through the adhesive layer thereof. In the same way, the processing tape 5, the film separator 4 and the refuse removing tape 7 are fed through the feeder 17, wherein the refuse removing tape 7 is wound through the winding device 18 whereby the refuse removing tape 7 is stripped from the film separator 4 to be wound. In this case, the punched refuses of the film separator 4 punched by the first punch device 14 are stuck on the adhesive layer of the refuse removing tape 7, wherein, at this time, various kinds of the first holes formed by the first punch device 14 are opened. As a result, even if, the second holes formed by the second punch device 15 in the processing tape 5 is partially overlapped with the first holes formed by the first punch device 14 in the film separator 4, the punched refuses of the film separator 4 is stuck on the refuse removing tape 7 without removing, whereby, in an operation of making holes of the processing tape 5, the punched refuses enables reaction force of the processing metal mold 151 to be held, thereby ensuring forming the holes in the processing tape 5. Then, the switch sheet 2 comprising the processing tape 52, in a setting shape, wherein various kinds of holes are formed and the film separator 4 wherein various kinds of holes are formed is wound through the winding device 19 so as to manufacture the roll shaped switch sheet 2. At this time, it is wound together with the protective liner 6 on the side of the film separator 4 in order to give a protection so that dusts or the like may not be adhered to the adhesive layer of the partially exposed processing tape 52 i.e., the adhesive layer for sticking the metallic dome 3 by the holes formed in the film separator 4. The switch sheet 2 manufactured in this way is supplied to a processing maker, the protective liner 6 is removed before the metallic dome 3 is stuck on the back surface (adhesive layer) of the processing tape 52 exposed through the holes formed in the film separator 4, thereby manufacturing the concave face switch 1. Furthermore, if a client is desired, there is a case that the processing tape 5, the film separator 4 and the refuse removing tape 7, wherein operations of punching holes by the punch apparatus 14 and 15 are completed without sticking the protective liner 6, are integratively piled to be wound as they, and formed in a roll shape so as to be shipped to the processing maker. In this case, the processing maker strips the refuse removing tape 7 with the result that the switch sheet 2 can be obtained. Though the present embodiment shows an illustration wherein the second punch device 15 is operated to form the second holes through the processing tape 5, the film separator 4 and the refuse removing tape 7, it may punch the holes in only the processing tape 5, or through the processing tape 5 and the film separator 4 by adjusting the height of the blade and the rising and falling stroke of the processing metal mold 141 of the second punch device 15. As mentioned above, according to the manufacturing method of the switch sheet of the present invention, the switch sheet, wherein the holes respectively corresponding to the film separator and the processing tape are formed, can be automatically manufactured without assistance. According to the manufacturing method of the switch sheet of the present invention, a combination of a simple structure enables the switch sheet including respectively the necessary holes in the processing tape and the film separator to be continuously manufactured. Industrial Applicability As is described above, the present invention is suitable for manufacturing the switch sheet which is a component part of the concave face switch used in the portable telephone or the like.

Claims: A manufacturing method of a switch sheet comprising the steps of: sticking a refuse removing tape (7) having an upper surface and a lower surface on a lower surface of a film separator (4) so as to fit an adhesive layer formed on the upper surface, forming one or a plurality of first holes in the film separator (4) piled on the refuse removing tape (7), sticking a processing tape (5) having an upper surface and a lower surface on an upper surface of the film separator (4) piled on the refuse removing tape (7) so as to fit an adhesive layer formed on the lower surface of the processing tape (5), punching the processing tape (5) in a setting shape, and simultaneously forming one or a plurality of second holes through at least the processing tape (5) or both of the processing tape (5) and the film separator (4), feeding integratively the processing tape (5), the film separator (4) and the refuse removing tape (7), and stripping refuse portions of the processing tape (51) after being punched in a setting shape off the upper surface of the film separator (4). A manufacturing method of a switch sheet according to claim 1 further comprising a step of stripping the refuse removing tape (7) off the lower surface of the film separator (4) after stripping the refuse portions of the processing tape (5) off the upper surface of the film separator (4). A manufacturing method of a switch sheet according to claim 2 further comprising a step of winding the film separator (4) together with a protective liner (6) on the lower surface thereof after stripping the refuse removing tape (7) off the lower surface of the film separator (4). A manufacturing apparatus of a switch sheet comprising: a feeding reel (11) for feeding a film separator (4), a feeding reel (12) for feeding a refuse removing tape (7) having an upper surface and a lower surface, the upper surface has an adhesive layer thereon, a first sticking means, positioned at subsequent stages of the both feeding reels (11, 12), for sticking the refuse removing tape (7) on a lower surface of the film separator (4) so as to fit the adhesive layer of the refuse removing tape (7), a first punch device (14), positioned at a subsequent stage of the first sticking means, having a processing metal mold for forming one or a plurality of holes in the film separator (4) piled on the refuse removing tape (7) by the sticking means, a feeding reel (13) for feeding a processing tape (5) having an upper surface and a lower surface, the lower surface has an adhesive layer thereon, a second sticking means, positioned at a subsequent stage of the first punch device (14), for sticking the processing tape (5) on an upper surface of the film separator (4) in a state piled on the refuse removing tape (7) forwarded from the first punch device (14) so as to fit the adhesive layer of the processing tape (5), a second punch device (15) including a processing metal mold for punching the processing tape (5), piled on the film separator (4) by the second sticking means, in a setting shape, and for forming one or a plurality of holes through the processing tape (5), the film separator (4) and the refuse removing tape (7), a winding device (16), positioned at a subsequent stage of the second punch device (15), for winding refuse portions of the processing tape (5) punched by the second punch device (15), and a feeder (17), positioned at a subsequent stage of the winding device (16), for feeding integratively the processing tape (5) punched in a setting shape, the film separator (4) and the refuse removing tape (7), wherein the first punch device (14) forms the first holes in the film separator (4), and the second punch device (15) punches the processing tape (5) in a setting shape and simultaneously forms the second holes in at least the processing tape (5) or both of the processing tape (5) and the film separator (4). A manufacturing apparatus of a switch sheet according to claim 4 further comprising a refuse removing tape winding device (18), positioned at a subsequent stage of the feeder (17), for stripping the refuse removing tape (7) off the film separator (4), and for winding the refuse removing tape (7). A manufacturing apparatus of a switch sheet according to claim 5 further comprising a feeding reel (20), positioned at a subsequent stage of the refuse removing tape winding device (18), for feeding a protective liner (6), and a winding device (19) for winding the film separator (4) together with the protective liner (6), fed from the reel (20), on a lower surface of the film separator (4).

Inventors: KATO TERUYUKI, KATO, TERUYUKI, KATO, Teruyuki, Kabushiki Kaisha Kato Seiko
Applicants: HOSIDEN CORP, KATO SEIKO KK, HOSIDEN CORPORATION, KABUSHIKI KAISHA KATO SEIKO
Application year: 1995
Main classification: B29D31
IPC codes: H01H13, B32B7, B29L31, H01H11, B32B38, B29L9, B29D99