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Duraswitch IslandTM integration constructionDuraswitch Industries has developed, patented and proven a new electronic switch solution that is revolutionizing flat panel designs, by allowing manufacturers to combine push buttons, encoder rotaries and cursor controls into a single flex circuit. Called IslandTM integration, this simple design allows for the placement of various switch technologies onto low cost flex circuitry, providing considerable cost savings to OEMs. Each switch component is packaged in a thin adhesive foam matrix. The foam provides structural integrity as well as an environmental seal. By using this new integration solution, manufacturers can shorten assembly time, reduce materials and lower the production costs. Island technology is a perfect fit for current industry trends and n e x t - g e n e r a t i o n products. Industry TrendsIn competitive economic times, m a n u f a c t u r e r s require leaner operations in order to remain competitive. Tough environmental standards are also pushing OEMs to look for technologies that help reduce waste and harmful contaminants used in their processes. According to industry studies, OEMs continue to shift away from utilizing discrete electromechanical switches and towards integrating new, and/or alternative technologies that provide greater value and help them differentiate themselves in the marketplace. Along with this movement come important trends in electronic switch products, such as: demand shifting from individual components to total solutions; a shift away from PCBs to flex circuitry; a shift from generic keypads to unique keypad designs that differentiate products; and demand shifting toward products with lower contact current ratings. Industry ChallengesThe Medical industry is an excellent example of the trend towards fully electronic solutions that provide state-of-the-art design features. OEMs in this sector have traditionally had three options in panel designs: panels with push buttons and discrete rotaries (with the rotaries being integrated during the final manufacturing process), panels with discrete rotaries only (which are also incorporated during the OEM's final production process), or panels that require many push buttons. Each of these three designs poses numerous challenges.Integrated panel designs utilizing push buttons and rotaries or the rotary switch only require manufacturers to deal with a multi-layered process that includes ordering the key pads and rotors from separate vendors, and a costly, labor and material intensive assembly routine. Integrating the rotaries necessitates leaving holes in the panel, fastening the rotor, and soldering the connections. In addition to this time consuming procedure, the holes for the rotor assemblies go completely through to the electronics, making the panel difficult to seal. Furthermore, the solder and adhesive interconnections between individual components and the circuit electronics has been a source of failure and complexity due to the extreme performance requirements of the medical industry. Rotary and Push Button Integration
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Duraswitch Revolutionizes Switch Integration!Despite the fact that consumers continue to prefer rotaries with their keypads, OEMs have been stuck without a cost-effective method to integrate this type of switch into their new electronic panels, and most have dropped them from their designs.In recent years OEMs have leaned towards the push button only option utilizing membrane or tact switches in panels, mainly because these components are inexpensive and widely available. This type of push button panel generally features many switches, creating a human interface that is often confusing, not to mention failure prone. The short term cost savings also translates into short-term durability and reliability. Advantages of Duraswitch IslandTM In answer to these challenges, Duraswitch has developed a cost-effective, total solution that incorporates its unique, thin profile, electronic switch technologies in a groundbreaking, flat panel design, called IslandTM integrated construction. Push button, encoder rotary, mouse control switches, and analog devices can be packaged together using this simple construction, consisting of a flex circuit substrate, a foam matrix, and an overlay. With this construction, OEM's receive a complete keypad with all switch components fully integrated from a single supplier. There is very little manufacturing labor involved for the OEM. They simply mount it on the backer and connect the flex circuit. Benefits of Island Integration ConstructionAn important benefit of Island integration construction is cost savings driven by the ability to utilize inexpensive flex circuitry in the place of PCBs. Not only are flex circuits cheaper in themselves, but there is a further reduction in manufacturing costs by eliminating connectors and solder joints required for PCB construction,.Island construction also gives engineers an option they've never had before - that is, the ability to mount rotaries or cursor controls on a flex circuit. As a result of this, designers of next-generation products now have an opportunity to reintroduce consumer-preferred rotary controls into their panel designs.Labor savings is another cost benefit of Island construction. No fastening, no soldering, and no wiring harnesses are required for Island designs, representing a substantial reduction in assembly time and material for OEMs. The keypad panels come fully assembled and ready to mount into place.Design flexibility is another big advantage of the Island solution. By combining all the circuitry in a flex circuit whose connectors can be placed anywhere on the primary circuit board, increased real estate is available for additional electronic functions. PCBs no longer have to be designed to the location of the rotors, and large holes in the circuitry are eliminated. Environmental sealability is a much sought after feature in all industries. In the Island construction, each individual component is contained in an isolated Island foam matrix. This foam matrix combined with the overlay, eliminates the possibility of fluids and contaminants coming in contact with the electronics and causing the switch to fail. The panel can thus be exposed to extreme environments, moisture and liquids, as well as
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Duraswitch Revolutionizes Switch Integration!harsh chemicals and acidic solutions, for extensive periods without compromising the integrity of the circuit.Finally, all interconnects between individual components, even rotary components, are intrinsically formed in the circuitry. This design eliminates the need for failure-prone component interconnections such as solder or conductive adhesives. Switching ElementsThe Island integration construction was designed to be used in conjunction with the patented Duraswitch product line of thin profile electronic switches. Based on a revolutionary new technology utilizing magnets, these cost-effective, simple components are easy to manufacture, very reliable and durable, as well as highly customizable. The thiNcoderTM Product LineThinnest Profile On The MarketthiNcoder is the only encoder rotary technology in the world that can be mounted on a flex circuit. It features the lowest profile on the market -- with a package thickness below the overlay of less than .087". This unique technology gives OEMs the ability to inexpensively incorporate rotaries with their push buttons and other switches in flat panel designs. Easy to manufacture and lightweight, thiNcoder features the quality of an optical encoder at a fraction of the cost. The basic concept is shown in Figure 1. This ingenious, uncomplicated switching element incorporates magnets and gold plated balls as integral parts of the design. In the bottom of the rotor sub assembly rare earth magnets are placed on one side of a flex circuit, with traces and gold plated balls on the other. The gold plated balls act as an armature and are attracted to the contacts on the circuit by a magnetic field emanating from the magnets. As the subassembly is moved laterally in any direction, the balls follow the magnet while maintaining contact with the substrate. The rolling action of the balls maintains good electrical contact and produces no wear or erosion of the individual switch contacts, giving thiNcoder an extremely long life. In contrast, most technologies use a wiping or scraping motion that will cause wear and failure after only several thousand rotations, while thiNcoder has been tested to over 100,000 successful rotations. Additionally, this encoder rotary has a mechanical shock tolerance that exceeds 100 G's, and the ability to withstand extreme temperatures. And, because this technology can be sealed, it can readily withstand harsh environments and exposure to chemicals, moisture, liquids and cleaning solvents.The thiNcoder product line offers a large variety of customization options, including: encoder and potentiometer designs; dual functions (push, on/off, turn); low energy circuit capability - dry circuit compatible; and customized shafts, detents/stops, and knobs.PushGateTM push buttonThe next generation . . . This extraordinary, cost-effective component combines the tactile feel of a traditional electromechanical pushbutton with the thin profile of a membrane switch in a simple, durable technology. By providing unheard of thiNcoder basic concept Figure 1
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Duraswitch Revolutionizes Switch Integration!MagnaMouse Figure 1Pushgate Figure 1reliability and keeping its crisp, consistent 'click' for millions of actuations, PushGate has shifted the paradigm for combining form and function in next-generation products. A magnet and a metal armature - two simple components - form the basis for the patented PushGate design (seen in Figure 1). During switch actuation, and as the PushGate is initially depressed, the armature breaks away from the magnet and spontaneously makes contact with the circuits below. This contact creates a very definite, crisp, tactile "CLICK". Upon release, the magnet then draws the armature back up to its original position. By harnessing the natural force of magnetism and utilizing an armature that does not bend or flex, Duraswitch has created a device that is not prone to the problems of collapsing domes, teasing, early failure or the inconsistent actuation force associated with conventional membrane switches. The PushGate is also exceptionally well suited to flat panel designs; can be environmentally sealed, and delivers superior performance when exposed to extreme temperatures and harsh environments. Furthermore, it lends itself easily to elastomerics, keycaps and embossing, in addition to having full key illumination capabilities. PushGate custom designs also include: normally open or normally closed options, multiple outputs, and shielding capability.MagnaMouseTM cursor controlFewer parts = Lower CostsMagnaMouseTM has raised the bar on standards for next-generation cursor controls. This simple, compact, durable switch is perfect for anywhere you would interact with a screen or menu. Like the Duraswitch PushGateTM pushbutton, this switch features two simple components - a magnet and a unique metal armature. The principal of the MagnaMouse is shown in its most basic form in Figure 1. The armature of the MagnaMouse features a center contact pad in addition to a 360-degree outer contact pad. Actuation is achieved by depressing the armature at any desired position on top of the actuating button. When the armature is depressed, as shown in Figure 2, the armature rocks off of its center pad and makes contact with the outside pad. The outside contact pad on the substrate determines the specific function to be actuated. Figure 2Contact Made to Center PadActuation Force Applied HereContact Made to Outside PadGraphic OverlayMagnaMouse Cut-away
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Duraswitch Revolutionizes Switch Integration!By utilizing magnetism and using fewer parts than other cursor control devices, Duraswitch has created an innovative solution that is remarkably durable and reliable, as well as easier and less expensive to manufacture than its counterparts. MagnaMouse offers many other benefits that provide a multitude of design opportunities to engineers. For example, this switch can also be environmentally sealed and renders superior performance when exposed to extreme temperatures, high altitudes and harsh environments. It can be easily integrated into a thin film package; remains robust throughout its lifetime; has almost unlimited 360° directional capabilities; and offers touch-sensitive acceleration capabilities, digital or analog output, and the possibility of numerous custom key cap configurations.SummaryDuraswitch's Island integrated construction provides a simple, low cost method for incorporating a variety of switch products onto a single flex circuit. Utilizing this method of construction, OEM's can decrease manufacturing costs, keep up with consumer trends in the market place, increase their design flexibility, improve the quality of their individual switch components, and provide a better human interface for their customers. Duraswitch continues its commitment to research and development and making significant advances in electronic switch solutions. Future products in the Duraswitch portfolio will also be compatible with the Island integration construction, giving engineers ever-increasing flexibility in their designs. Other Duraswitch documents on membrane-switches.comFor more information on Duraswitch technology refer to technical document sections entitled: Encoder, Tactile/Magnetic, and Mouse Devices, or visit our company's website at www.duraswitch.com.About DuraswitchDuraswitch holds numerous U.S. and foreign patents for its technology, which is available worldwide through the company's licensees. Duraswitch's patented new technologies are used to operate or control products in a wide variety of commercial, industrial and consumer applications. These next-generation electronic switch designs address trends in the market today, providing: high durability and reliability, sealability against harsh environments, illumination capabilities, and ergonomic, user-friendly interfaces in flat-panel and slim-profile designs that allow multiple switch and switch type integration. Duraswitch Industries, Inc. engineers, markets and licenses electronic switches under its patented switch technology (US Patent Nos. 5,523,730 / 5,666,096 / 5,867,082 / 5,990,772 / 6,023,213 / 6,069,545 / 6,069,552 / 6,130,593 / 6,137,387 / 6,262,646). More information on current and emerging technologies, as well as licensing opportunities are available at www.duraswitch.com or call 480.586.3300.