Membrane switch

Last updated
Electronic membrane switches Electronic membrane switches.jpg
Electronic membrane switches

A membrane switch is a custom switch assembly that can open or close the conducting path in an electrical circuit and requires at least one contact made of or attached to a flexible substrate. Its assembly differs from traditional mechanical switches: a membrane switch's construction consists of various thin layers sandwiched together using pressure-sensitive adhesives. [1] Each layer in a membrane switch assembly serves a different purpose, and custom features require the addition of specialty layers. Typical implementations arrange multiple membrane switches across its layered structure to form a keypad interface that allows human interaction to control electronic systems.

Contents

Unique to membrane switches, they are the only switches that can utilize the benefits of flexible printed electronics. These circuits are generally printed on Polyethylene Terephthalate (PET) or Indium Tin Oxide (ITO) substrates. The ink used for printing the circuit is usually filled with copper, silver, or graphite and therefore conductive.

Construction

The ASTM defines a membrane switch as "a momentary switch device in which at least one contact is on, or made of, a flexible substrate."

A membrane switch typically has 5 or more layers made of flexible substrate.

Common Membrane Switch Layers [2]

•Graphic overlay: The top layer of a membrane switch is the graphic overlay. This layer serves as the user interface, as it will typically show the user how to operate the device. This layer will often be made by digitally printing or screen printing ink onto the back of a hard coated PET or polycarbonate substrate.

•Spacer top adhesive: The spacer top adhesive layer typically goes beneath the graphic and adheres the graphic to the rest of the membrane switch.

•Dome retainer: The dome retainer goes below the spacer top adhesive layer. The dome retainer layer holds the metal domes or shorting pads that will be used to activate the switch. This layer is typically made of thin, flexible PET.

•Spacer adhesive: The spacer adhesive layer goes beneath the dome retainer. This layer includes ventilation cuts that allow air to flow when the tactile switches are actuated.

•Circuit layer: Typically conductive inks are printed on thin flexible PET to make the circuit layer. Silver and carbon inks are most commonly used. Sometimes FPCs or PCBs are used instead. The circuit layer is what allows the membrane switch to function. When the switch is not actuated, the circuit is open and current does not flow. When the user activates the switch by pushing down on the metal dome or shorting pad, the circuit becomes closed and current is able to flow, triggering the appropriate response from the membrane switch.

•Mounting adhesive: The bottom layer of a membrane switch is the mounting adhesive, which is used to attach the membrane switch to the desired application.


The layers of a membrane switch are normally assembled using pressure-sensitive adhesives, although inexpensive designs can be held together by other mechanical means such as a keyboard housing. [3]

Backlighting

There are three standard methods for back lighting membrane switches.

The first option is using Light Emitting Diodes (LEDs) to back light. LEDs can either be surface mounted to the circuit layer or be placed on a separate LED layer. There are two types of LEDs typically used in membrane switch backlighting. Top fire LEDs shine directly upwards and are suitable indicator lights. Side fire LEDs shine sideways and are ideal to use with light guide film to uniformly light large areas of a membrane switch.

A second option is optical fiber. In a typical design, two or more layers of woven fiber-optic cloth are used to form a rectangular light-emitting area. The fibers coming off one end are then bundled into a circular ferrule and coupled to one or more LED light sources. Remote light sources offer 10,000 to 100,000 hours of life. Optical fibers are not affected by extremes in humidity (0% to 100%) or temperature (-40 to + 85 deg C).

The third standard option is to use electroluminescent (EL) lamps. They are lower priced compared to fiber optics and offer additional design flexibility. The color of light emitted from an EL lamp can vary depending on the phosphors that are used. Some common colors are blue/green and yellow/green, white, blue and orange. EL lamps have a half-life of approximately 3000–8000 hours depending upon the quality of the phosphor. Once they reach their half-life, the brightness starts to fade rapidly. EL lamps are thus not a good choice if the lamp is on for an extended period of time. Fading or flashing could double the life of the lamp.

Shielding

A membrane switch is an electrical switch for turning a circuit on and off. It differs from a mechanical switch, which is usually made of copper and plastic parts. A membrane switch is a more integrated and reliable solution consisting of layers, including a flexible printed circuit. Key components in the design and functionality of membrane switches are the conductive materials used for shielding against electrostatic discharge (ESD), electromagnetic interference (EMI), and radio frequency interference (RFI).

Types of Conductive Materials

1.  Printed Conductive Grids: These grids are typically printed onto polyester films and used for their high electrical conductivity. They form a crucial part of the switch's structure, offering protection against electrical disruptions caused by static electricity or external electromagnetic fields.

2.  Indium Tin Oxide (ITO) Films: Known for their excellent conductivity and transparency, ITO films are used in areas of membrane switches that require clear visibility, such as display windows, while also providing effective electromagnetic shielding.

3.  Aluminum Foil: Aluminum foil is employed for its superior conductivity and is particularly effective in providing EMI and RFI shielding in adverse environmental conditions. Its use in membrane switches ensures the durability and reliability of the electronic components under various environmental stresses.

Grounding and Effectiveness

To ensure the effectiveness of these shielding materials, they must be properly grounded. This is typically achieved by connecting them to a metal case, a metallic backplate, or via grounding wires that extend from the circuit tail. Proper grounding is essential for dissipating accumulated electrical charges and minimizing the risk of interference from external electromagnetic fields, thus enhancing the overall reliability and performance of the membrane switch. [4]

Applications

Classic applications of membrane switches include microwave oven panel, air conditioner control panel, TV remote control etc. Tactile feedback of keys can be provided by embossing the top PET layer or embedding metal snap domes, polyester domes or forming the graphic layer.

The benefits of membrane switches include ease of cleaning, sealing ability and their low profile. Membrane switch can be used together with other control systems such as touch screens, keyboards, lighting, and they can also be complicated like the membrane keyboards and switch panels in mobiles and computers. They are reliable, effective, low-cost user interfaces, suitable for a wide range of products, and available with many creative options. [5]

Depending on industry and application, membrane switches are also referred to as membrane keyboards and membrane keypads. [6]

Related Research Articles

<span class="mw-page-title-main">Keyboard technology</span> Hardware technology of keyboards

The technology of computer keyboards includes many elements. Many different keyboard technologies have been developed for consumer demands and optimized for industrial applications. The standard full-size (100%) computer alphanumeric keyboard typically uses 101 to 105 keys; keyboards integrated in laptop computers are typically less comprehensive.

<span class="mw-page-title-main">Organic electronics</span> Field of materials science

Organic electronics is a field of materials science concerning the design, synthesis, characterization, and application of organic molecules or polymers that show desirable electronic properties such as conductivity. Unlike conventional inorganic conductors and semiconductors, organic electronic materials are constructed from organic (carbon-based) molecules or polymers using synthetic strategies developed in the context of organic chemistry and polymer chemistry.

<span class="mw-page-title-main">Switch</span> Electrical component that can break an electrical circuit

In electrical engineering, a switch is an electrical component that can disconnect or connect the conducting path in an electrical circuit, interrupting the electric current or diverting it from one conductor to another. The most common type of switch is an electromechanical device consisting of one or more sets of movable electrical contacts connected to external circuits. When a pair of contacts is touching current can pass between them, while when the contacts are separated no current can flow.

<span class="mw-page-title-main">Electromagnetic compatibility</span> Electrical engineering concept

Electromagnetic compatibility (EMC) is the ability of electrical equipment and systems to function acceptably in their electromagnetic environment, by limiting the unintentional generation, propagation and reception of electromagnetic energy which may cause unwanted effects such as electromagnetic interference (EMI) or even physical damage to operational equipment. The goal of EMC is the correct operation of different equipment in a common electromagnetic environment. It is also the name given to the associated branch of electrical engineering.

<span class="mw-page-title-main">Ground (electricity)</span> Reference point in an electrical circuit from which voltages are measured

In electrical engineering, ground or earth may be a reference point in an electrical circuit from which voltages are measured, a common return path for electric current, or a direct physical connection to the Earth.

<span class="mw-page-title-main">Printed circuit board</span> Board to support and connect electronic components

A printed circuit board (PCB), also called printed wiring board (PWB), is a medium used to connect or "wire" components to one another in a circuit. It takes the form of a laminated sandwich structure of conductive and insulating layers: each of the conductive layers is designed with a pattern of traces, planes and other features etched from one or more sheet layers of copper laminated onto and/or between sheet layers of a non-conductive substrate. Electrical components may be fixed to conductive pads on the outer layers in the shape designed to accept the component's terminals, generally by means of soldering, to both electrically connect and mechanically fasten them to it. Another manufacturing process adds vias, plated-through holes that allow interconnections between layers.

<span class="mw-page-title-main">Flexible electronics</span> Mounting of electronic devices on flexible plastic substrates

Flexible electronics, also known as flex circuits, is a technology for assembling electronic circuits by mounting electronic devices on flexible plastic substrates, such as polyimide, PEEK or transparent conductive polyester film. Additionally, flex circuits can be screen printed silver circuits on polyester. Flexible electronic assemblies may be manufactured using identical components used for rigid printed circuit boards, allowing the board to conform to a desired shape, or to flex during its use.

Indium tin oxide (ITO) is a ternary composition of indium, tin and oxygen in varying proportions. Depending on the oxygen content, it can be described as either a ceramic or an alloy. Indium tin oxide is typically encountered as an oxygen-saturated composition with a formulation of 74% In, 8% Sn, and 18% O by weight. Oxygen-saturated compositions are so typical that unsaturated compositions are termed oxygen-deficient ITO. It is transparent and colorless in thin layers, while in bulk form it is yellowish to gray. In the infrared region of the spectrum it acts as a metal-like mirror.

<span class="mw-page-title-main">Membrane keyboard</span> Type of computer keyboard with pressure pads instead of mechanical keys

A membrane keyboard is a computer keyboard whose "keys" are not separate, moving parts, as with the majority of other keyboards, but rather are pressure pads that have only outlines and symbols printed on a flat, flexible surface. Very little, if any, tactile feedback is felt when using such a keyboard.

<span class="mw-page-title-main">Shielded cable</span> Electric cable with metal jacket (shield) to prevent magnetic interference

A shielded cable or screened cable is an electrical cable that has a common conductive layer around its conductors for electromagnetic shielding. This shield is usually covered by an outermost layer of the cable. Common types of cable shielding can most broadly be categorized as foil type, contraspiralling wire strands or both. A longitudinal wire may be necessary with dielectric spiral foils to short out each turn.

Conductive ink is an ink that results in a printed object which conducts electricity. It is typically created by infusing graphite or other conductive materials into ink. There has been a growing interest in replacing metallic materials with nanomaterials due to the emergence of nanotechnology. Among other nanomaterials, graphene, and carbon nanotube-based conductive ink are gaining immense popularity due to their high electrical conductivity and high surface area. Recently, more attention has been paid on using eco-friendly conductive ink using water as a solvent as compared to organic solvents since they are harmful to the environment. However, the high surface tension of water prevents its applicability. Various natural and synthetic surfactants are now used to reduce the surface tension of water and ensure uniform nanomaterials dispersibility for smooth printing and wide application. Although graphene oxide inks are eco-friendly and can be produced in bulk quantities, they are insulating in nature which needs an additional step of reduction using reducing ink is required to restore the electrical properties. The external reduction process is not suitable for large scale continuous manufacturing of electronic devices. Hence an in-situ reduction process also known as reactive inkjet printing has been developed by various scientists. In the in-situ reduction process the reducing inks are printed on top of the GO printed patterns in order to carry out the reduction process on the substrate.

<span class="mw-page-title-main">Printed electronics</span> Electronic devices created by various printing methods

Printed electronics is a set of printing methods used to create electrical devices on various substrates. Printing typically uses common printing equipment suitable for defining patterns on material, such as screen printing, flexography, gravure, offset lithography, and inkjet. By electronic-industry standards, these are low-cost processes. Electrically functional electronic or optical inks are deposited on the substrate, creating active or passive devices, such as thin film transistors; capacitors; coils; resistors. Some researchers expect printed electronics to facilitate widespread, very low-cost, low-performance electronics for applications such as flexible displays, smart labels, decorative and animated posters, and active clothing that do not require high performance.

<span class="mw-page-title-main">Conductive textile</span> Fabric which can conduct electricity

A conductive textile is a fabric which can conduct electricity. Conductive textiles known as lamé are made with guipé thread or yarn that is conductive because it is composed of metallic fibers wrapped around a non-metallic core or has a metallic coating. A different way of achieving conductivity is to weave metallic strands into the textile.

Silicone rubber keypads are used extensively in both consumer and industrial electronic products as a low cost and reliable switching solution.

<span class="mw-page-title-main">Thermal management of high-power LEDs</span>

High power light-emitting diodes (LEDs) can use 350 milliwatts or more in a single LED. Most of the electricity in an LED becomes heat rather than light. If this heat is not removed, the LEDs run at high temperatures, which not only lowers their efficiency, but also makes the LED less reliable. Thus, thermal management of high power LEDs is a crucial area of research and development. It is necessary to limit both the junction and the phosphor particles temperatures to a value that will guarantee the desired LED lifetime.

<span class="mw-page-title-main">Photonic curing</span> Thermal processing of thin film using pulsed light

Photonic curing is the high-temperature thermal processing of a thin film using pulsed light from a flashlamp. When this transient processing is done on a low-temperature substrate such as plastic or paper, it is possible to attain a significantly higher temperature than the substrate can ordinarily withstand under an equilibrium heating source such as an oven. Since the rate of most thermal curing processes generally increase exponentially with temperature, this process allows materials to be cured much more rapidly than with an oven.

An electrically conductive adhesive is a glue that is primarily used for electronics.

Circuit Scribe is a ball-point pen containing silver conductive ink one can use to draw circuits instantly on flexible substrates like paper. Circuit Scribe made its way onto Kickstarter on November 19, 2013, with its goal of raising $85,000 for the manufacturing of the first batch of pens. By December 31, 2013, Circuit Scribe was able to raise a total of $674,425 with 12,277 'backers' or donors.

<span class="mw-page-title-main">Chip on board</span> Method of circuit board manufacture

Chip on board (COB) is a method of circuit board manufacturing in which the integrated circuits (e.g. microprocessors) are attached (wired, bonded directly) to a printed circuit board, and covered by a blob of epoxy. Chip on board eliminates the packaging of individual semiconductor devices, which allows a completed product to be less costly, lighter, and more compact. In some cases, COB construction improves the operation of radio frequency systems by reducing the inductance and capacitance of integrated circuit leads.

<span class="mw-page-title-main">Copper foil</span> Thin sheet of metal

Copper foil is a thin sheet of copper metal that is widely used in various applications due to its excellent electrical conductivity, malleability, and corrosion resistance. It is an essential material in the electronics industry, especially for manufacturing printed circuit boards (PCBs) and other electronic components.

References

  1. "Membrane Switches". ALMAX. Retrieved 2022-06-18.
  2. "Custom Membrane Switches". Almax-RP. 29 July 2021. Retrieved 12 August 2021.
  3. "Backlighting Membrane Switches". Pannam Imaging.
  4. "Custom Membrane Switches: Shielding Technology". WeGlow Industrial.
  5. "Membrane Switches". KTP Techs.
  6. "Membrane Switches: The Basics". SSI Electronics.