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 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: 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.