Abstract: A flexible magnetically coupled pushbutton switch assembly has a coupler layer magnetically held against a flexible layer that has flaps that function as flexible armatures. The flexible armatures are normally magnetically coupled to the coupler layer. The coupler layer is a sheet of magnetic receptive rubber material that includes debossed spacers, and there are embossed crowns in the flexible armatures. The embossed crowns fit into openings in the coupler layer so that a switch user may manipulate the flexible armatures. The debossed spacers support the flexible layer above a bottom layer such that there are armature cavities for the flexible armatures. An arrangement of electrical conductors is affected when a switch user selectively manipulates a flexible armature so that an electrical circuit connected to the electrical switch is opened or closed when the switch is actuated.

Abstract: A magnetically coupled pushbutton switch may be improved by adding protuberances to the top of an armature to create a weak heel on the armature. The protuberances impose a physical barrier which prevents the weak heel from becoming fully magnetically coupled to the magnetic coupler layer, so the initial tactile feedback is lost. Eliminating the double tactile feedback of a magnetically coupled pushbutton switch has some significant advantages over the prior art. Now, a very light actuation force will move an armature with a weak heel from the rest position to a partially actuated position, but without sacrificing any of the final tactile feedback. The improved armature design also makes it possible to use a magnetically coupled pushbutton switch to produce a dual output. The initial travel of a dual output switch does not create any feedback to the user, so there is no longer a need to stabilize the bottom of the heel end of the armature.

Abstract: A magnetically coupled pushbutton switch may be improved by adding protuberances to the top of an armature to create a weak heel on the armature. The protuberances impose a physical barrier which prevents the weak heel from becoming fully magnetically coupled to the magnetic coupler layer, so the initial tactile feedback is lost. Eliminating the double tactile feedback of a magnetically coupled pushbutton switch has some significant advantages over the prior art. Now, a very light actuation force will move an armature with a weak heel from the rest position to a partially actuated position, but without sacrificing any of the final tactile feedback. The improved armature design also makes it possible to use a magnetically coupled pushbutton switch to produce a dual output. The initial travel of a dual output switch does not create any feedback to the user, so there is no longer a need to stabilize the bottom of the heel end of the armature.

Abstract: A flexible magnetically coupled pushbutton switch assembly has a coupler layer magnetically held against a flexible layer that has flaps that function as flexible armatures. The flexible armatures are normally magnetically coupled to the coupler layer. The coupler layer is a sheet of magnetic receptive rubber material that includes debossed spacers, and there are embossed crowns in the flexible armatures. The embossed crowns fit into openings in the coupler layer so that a switch user may manipulate the flexible armatures. The debossed spacers support the flexible layer above a bottom layer such that there are armature cavities for the flexible armatures. An arrangement of electrical conductors is affected when a switch user selectively manipulates a flexible armature so that an electrical circuit connected to the electrical switch is opened or closed when the switch is actuated.

Abstract: A magnetically coupled switch that utilizes a flex armature has a user manipulated holder that carries at least one magnetic coupler made of magnetic material. The flex armature is a substantially flat piece of flexible magnetic material that is magnetically attracted to the at least one magnetic coupler. A carrier layer having electrical conductors formed thereon is intermediate the flex armature and magnetic coupler such that the electrical conductors are electrically connected by the flex armature where the flex armature is magnetically attracted to the magnetic coupler. In the absence of a magnetic coupler, the flex armature is normally spaced from the electrical conductors on the carrier layer. Preferably, there is a bottom cover that encloses a cavity that contains the flex armature, and the bottom cover includes at least one shock dimple that secures at least part of the flex armature to the carrier layer.

Abstract: An electrical switch, such as a two-position rocker or a momentary rocker switch, has an electrically conductive armature made of magnetic material that includes at least two faces extending from a common vertex. The armature is mounted to pivot about its common vertex to bring at least one of the armature faces into and out of electrical shorting relationship with electrical conductors of the switch that, preferably, are formed directly on a nonconductive sheet magnet coupler layer. The sheet magnet coupler layer magnetically attracts and holds the rocker armature in a switch position until a user applied actuating force is applied to a face of the armature such that the armature pivots to another switch position and, preferably, the switch is provided with an armature illumination system.

Abstract: A magnetically coupled switch that utilizes a flex armature has a user manipulated holder that carries at least one magnetic coupler made of magnetic material. The flex armature is a substantially flat piece of flexible magnetic material that is magnetically attracted to the at least one magnetic coupler. A carrier layer having electrical conductors formed thereon is intermediate the flex armature and magnetic coupler such that the electrical conductors are electrically connected by the flex armature where the flex armature is magnetically attracted to the magnetic coupler. In the absence of a magnetic coupler, the flex armature is normally spaced from the electrical conductors on the carrier layer. Preferably, there is a bottom cover that encloses a cavity that contains the flex armature, and the bottom cover includes at least one shock dimple that secures at least part of the flex armature to the carrier layer.

Abstract: An impact absorbing system for a flat switch panel has an impact spacer. The impact spacer, a rigid layer that is fixed to an energy-absorbing layer, attaches to the top surface of a flat switch panel just under the overlay. During a condition of switch abuse, the impact absorbing system disperses the energy from a high impact actuation force over a large area of the rigid layer, which in turn causes a large volume of energy-absorbing layer material to be deformed, directing the otherwise damaging impact away from a raised part of the switch that normally accepts a user provided actuation force. Preferably there is an embossed area in the rigid layer and a pip on the raised part of the switch, both improving the function and tactile feedback of the switch. The most preferred embodiment includes a polycarbonate backer on the bottom of the flat switch panel to additionally protect switch components from being damaged by a high impact actuation force.

Abstract: A magnetically coupled pushbutton switch having hard electrical conductors is discrete and may be used in place of a dome tact switch. The hard electrical conductors of the magnetically coupled pushbutton switch are uniquely arranged and may be soldered to a circuit board or surface mounted. Additionally, modifications and improvements made to the switch allow it to maintain good tactile response even though the switch may be as compact as a smaller tactile dome switch. A further benefit of the switch is its ability to be normally open, normally closed, or both. This capability stems from the unique arrangement of the hard electrical conductors that, in one preferred embodiment, extend over the top of a magnetically coupled switch armature. All of the hard electrical conductors are arranged within the switch so that the pushbutton armature of the switch is movable into and out of shorting relationship with the electrical conductors to change the circuit logic for a circuit incorporating the switch.

Abstract: An electrical switch, such as a two-position rocker or a momentary rocker switch, has an electrically conductive armature made of magnetic material that includes at least two faces extending from a common vertex. The armature is mounted to pivot about its common vertex to bring at least one of the armature faces into and out of electrical shorting relationship with electrical conductors of the switch that, preferably, are formed directly on a nonconductive sheet magnet coupler layer. The sheet magnet coupler layer magnetically attracts and holds the rocker armature in a switch position until a user applied actuating force is applied to a face of the armature such that the armature pivots to another switch position and, preferably, the switch is provided with an armature illumination system.

Abstract: A magnetically actuated pushbutton switch has individual switch modules pre-assembled as standalone subassemblies. Each subassembly has a platform with a cavity on its underside. A portion of the platform is magnetized. A metallic armature is held in the cavity by the magnetic attraction of the platform. The switch subassemblies are mounted on a substrate that has electrodes thereon. The armature is movable into and out of shorting relation with the electrodes. Plugs on the platform may align with holes on the substrate to locate the subassemblies.

Abstract: A circuit element has a substrate with a set of spaced switch leads thereon and an overlay magnetically retained on the substrate with a shorting strap on the overlay in facing relation with the conductors of the substrate. The shorting strap is arranged to engage at intersection points at least two of the switch leads when the overlay is in place on the substrate to electrically connect the two switch leads. The shorting straps of different overlays are uniquely arranged to connect selected pairs of switch leads.

Abstract: A magnetically coupled pushbutton switch has a coupler magnet layer that normally holds an electrically conductive magnetic armature spaced from a substrate layer. An overlay having an overlay electrical conductor formed thereon covers the pushbutton switch. The overlay electrical conductor, which electrically contacts a crown on the armature, is part of a set of electrical conductors that is normally closed. When a user provided actuation force causes the armature to break away from the coupler magnet layer, the set of electrical conductors is opened.

Abstract: An electrical switch, such as an automotive power window up/down switch, has an electrically conductive dual armature that is normally magnetically held in coupled engagement with a sheet magnet. The dual armature, a rectangular piece of metal, has first and second free ends. If a user applied force acts on the first free end of the dual armature, then the first free end breaks away from the sheet magnet and travels into first electrical contacts that are normally spaced from the dual armature, and the second free end functions as a fulcrum for the dual armature. Conversely, if a user applied force acts on the second free end, then the second free end breaks away from the sheet magnet and travels into second electrical contacts that are normally spaced from the dual armature, and the first free end functions as a fulcrum for the dual armature. Preferably, there is a physical barrier that prevents simultaneous actuation of the two switching functions.

Abstract: A magnetically actuated switch has a magnet coupler layer spaced from a set of electrodes formed on a substrate. The electrodes include spaced contacts. The coupler layer normally holds a conductive armature spaced from the contacts. An aperture in the coupler layer provides access to the armature for application of an actuating force by an actuator. The actuator has a base portion mounted on the coupler layer and a force-receiving portion cantilevered from the base portion. The actuator has a width greater than that of the armature. Alternately, the armature itself can include a base portion pivotable on the substrate and a multi-wide force-receiving portion cantilevered from the base portion.

Abstract: An electrical switch has spaced, facing coupler and carrier layers with a set of electrodes formed on the facing surfaces thereof. There is an aperture in the coupler layer. A conductive armature is disposed in the space between the coupler and carrier, aligned with the aperture. The coupler is a magnet and the armature is made of magnetic material so the armature is normally held in engagement with the coupler. A user can press on any part of the armature through the aperture to cause a first portion of the armature to break away from the armature and contact the electrodes on the carrier while a second portion of the armature remains in contact with the coupler. The electrodes are arranged to provide an output which is dependent upon the location of contact with the armature. The armature is rotatable to different positions. A resilient member may be interposed at the interface of an armature post and the carrier.

Abstract: This concerns a method and kit for converting a flat panel switch to a raised panel switch by mounting a rotary switch thereto. The flat panel switch has a carrier layer. A set of electrodes forming an electrical circuit is disposed on the carrier. The kit includes a rotor having a head mounted in a front cover. A stem attached to the head extends through the front cover for actuation by a user. An electrical contact member is connected to the head for movement therewith. The contact member is associated with the electrodes to alter the condition of the electrical circuit upon actuation of the rotor. The front cover has latches that extend through perforations in the carrier for engagement with a back cover. The latches lock the front and back cover in place on the carrier.

Abstract: A magnetically actuated pushbutton switch has individual switch modules pre-assembled as standalone subassemblies. Each subassembly has a platform with a cavity on its underside. A portion of the platform is magnetized. A metallic armature is held in the cavity by the magnetic attraction of the platform. The switch subassemblies are mounted on a substrate that has switch contacts thereon. The armature is movable into and out of shorting relation with the contacts. A major spacer on the substrate has openings aligned with the switch contacts for receiving the subassemblies. An overlay film covers the subassemblies and major spacer. The armature may have a lens therein for transmitting backlighting. The platform can be magnetized at the time of installation on the substrate.

Abstract: An armature retainer for a magnetic switch retains an armature adjacent an internal surface of a carrier sheet with electrodes thereon forming switch contacts. The retainer includes a polishing pad, a backing layer and openings for the armature to reside therein. Both the armature and the retainer are adhered to the carrier surface by a magnet attraction. One or more magnets are carried in a rotor mounted on the external side of the carrier surface for rotary, linear or complex motion. When a user manipulates a knob attached to the rotor, the magnets rotate the armature and the armature retainer. The polishing pad cleans particles from the carrier surface as the retainer rotates. A shaft receiving opening may be used to tend to keep the armature retainer centered. Grooves embedded in the polishing pad surface are used to collect larger deposits.

Abstract: An electrical switch has a substrate with at least one pair of spaced switch contacts arranged to be shorted by an electrically conductive armature. The armature defines a central axis with first and second portions on either side of the axis which portions terminate at first and second edges. The armature is normally held spaced from the contacts by magnetic attraction to a coupler layer disposed in spaced relation to the substrate. The armature is movable by an actuating force to engagement with the substrate. The armature separates from the coupler layer by a double pivoting motion. An actuating force applied to the armature remote from its central axis causes one edge of the armature nearest the actuating force to break away from the coupler layer. The armature then pivots about the opposite edge of the armature until the one edge bottoms on the substrate.