button

Abstract

A button for changing an output based on an applied force is provided. The button includes a contact pad having at least two contacts arranged in a complementary pattern of interdigitated fingers with a spacing between the interdigitated fingers, and an actuator and a conductive layer between a base of the actuator and the contact pad and independent of the actuator and the contact pad, the base of the actuator shaped to increase a surface area of the conductive layer in contact with the contacts when the actuator is pushed toward the contact pad. This increases current flow between the contacts in use as the force applied to the actuator increases.

Description

Technical Field

[0001] This invention relates to a button and a button array. Buttons and button arrays are commonly used as part of a music controller to change the output based on the force applied to the respective button. Background Technology

[0002] Speed ​​pads and speed-sensitive buttons are used in many applications. These applications include those where recognizing, recording, or tracking the speed at which a button is pressed or the force applied to the button pad is important.

[0003] One industry that is increasingly using speed pads is the musical instrument industry. This is because music production is expanding to include digital instruments that can reproduce multiple different instruments within a single unit, as well as instruments that allow music to be controlled, processed, and produced through a single unit.

[0004] These instruments typically include multiple buttons, each of which is a speed pad or speed-sensitive button that can sense the speed at which the button is pressed or the force applied to it. Such instruments also usually include many other features, such as a keyboard and / or volume controls.

[0005] When force needs to be detected, the internal structure of a button typically uses a force-sensing resistor (FSR). However, the standard configuration of buttons using FSRs has been found to be unsatisfactory. This is due to several reasons, including: poor sensitivity, where the button is not triggered by even a light touch, which may limit the user's playing style or usability; small dynamic range, where the signal generated by pressing the button will only increase from a minimum to a maximum value over a small range of force increases, making musical expression difficult to achieve; and poor consistency, which is due to the varying performance of the button between corresponding buttons on the instrument, for example, one button being triggered with half the force required to trigger one of the other buttons, which may be perceived as low quality by the user.

[0006] These issues need to be addressed to achieve more user-friendly and higher-quality products.

[0007] As shown below Figure 1 To describe in more detail, a typical configuration of currently used buttons is a button actuator located on a contact pad on a PCB, with an FSR substrate situated between the button actuator and the PCB. The FSR substrate is separated from the PCB by spacer ink around the contact pad and has a conductive layer on its bottom surface that is pushed into contact with the contact pad when the user pushes the button actuator.

[0008] To address the issues of poor sensitivity and consistency, many manufacturers have attempted solutions by reducing the thickness of the spacer ink to decrease or eliminate the gap between the conductive layer and the contact pad. When the gap is reduced, it means the button will be activated with less force, making it more sensitive to light touches and reducing the variation in the force required to activate all buttons, but this reduces the button's dynamic range. When the gap is removed, it means the button will be activated continuously. This makes the mechanism susceptible to variations between buttons and erroneous triggering. Attempts to overcome these factors include providing users with an adjustable function to electrically control the button's trigger threshold. However, this further reduces the button's dynamic range because even with the lightest touch, there is significant contact between the conductive layer and the contact pad, immediately increasing the button's output to near its maximum.

[0009] Therefore, these issues need to be addressed simultaneously without causing performance degradation of the button. Summary of the Invention

[0010] According to a first aspect, a button is provided for (e.g., adapted to) changing an output based on an applied force, the button comprising: a contact pad having at least two contacts arranged in a complementary pattern of intersecting fingers spaced apart; and an actuator and a conductive layer located between the base of the actuator and the contact pad and independent of the actuator and the contact pad, the base of the actuator being shaped to increase the surface area of ​​the conductive layer in contact with the contacts when the actuator is pushed toward the contact pad, thereby increasing the current flow between the contacts in use as the force applied to the actuator increases.

[0011] The phrase “applied force” is intended to refer to force input, such as force input by a user applying force to a button or its components. The phrase “current flow” is intended to refer to the flow of electric current. The term “independent” is intended to refer to separation, such as mechanical separation, or a component being supported by or attached to an independent component.

[0012] Because the surface area of ​​the conductive layer in contact with the contacts increases with the force applied to the actuator, and because the conductive layer is independent of the actuator and the contact pad, the sensitivity to force applied by the user is enhanced. This also allows the button to have a greater dynamic range, as the minimum force required for the button to be reliably activated (in other words, triggered by a force applied by the user to provide output) is reduced compared to conventional buttons that can detect force. Therefore, small forces can be detected while simultaneously increasing the range of forces the button can operate with.

[0013] The actuator can be non-deformable and / or can be made of any suitable material. However, typically, at least a portion of the actuator is deformable, including the base of the actuator, which is arranged to deform when a force is applied to the actuator and the conductive layer contacts the contact pad. This reduces the need to compress the conductive layer as the amount of force applied to the actuator increases, thus reducing the likelihood of wear and failure of the conductive layer. Of course, the deformable portion of the actuator can be the entire actuator or a part of the actuator.

[0014] The base of the actuator can have any suitable shape to allow an increase in the surface area of ​​the conductive layer in contact with the contact pad when a force is applied to the actuator. Typically, when in a non-deformable state, the base of the actuator has a cross-sectional profile having at least one portion near the contact pad and at least one portion away from the contact pad, with a ramp between them. This provides a mechanically feasible and easily manufactured actuator that allows the amount of force applied by the user to be converted into an increased current, thus allowing for a simple construction and a minimal number of parts, while still allowing for variable output. In this configuration, when the user applies a force to the actuator and the actuator presses the conductive layer against the contact pad, the deformable portion of the actuator deforms to reduce the difference between the distance between the at least one portion near the contact pad and the contact pad and the distance between the at least one portion away from the contact pad and the contact pad, thereby reducing the tilt between them. During use, due to the deformation of the deformable portion, the tilt can be completely reduced, so there is no difference between the distance between the at least one portion near the contact pad and the contact pad and the distance between the at least one portion away from the contact pad and the contact pad.

[0015] Multiple portions may exist near the contact pad and / or multiple portions may exist away from the contact pad. Typically, when the deformable portion of the actuator is in a non-deformable state, only a single portion may exist near the contact pad and / or only a single portion may exist away from the contact pad.

[0016] At least one portion near the contact pad may be located radially outward from at least one portion away from the contact pad. However, typically, at least one portion near the contact pad is radially inward from at least one portion away from the contact pad. This reduces the dependence on the direction of user interaction with the actuator by directing the initial force through the actuator closer to its center point rather than its outer periphery. This improves the consistency of the current output achievable when the button is used, because the force will be directed entirely outward from the center point of the actuator across the rest of the actuator's base rather than from one side (from which the user can push the actuator).

[0017] At least one portion of the actuator, away from the contact pad, can be located at any suitable location on the base of the actuator. Typically, at least one portion of the actuator, away from the contact pad, is located at the outer periphery of the base. This allows the surface area of ​​the conductive layer in contact with the contact pad to increase smoothly and gradually when the user pushes the actuator, rather than rapidly due to the proximity of the distances between the near and far portions of the contact pad, or any undulations in the base radially outward from the far portion to the contact pad. This allows for an improved user experience.

[0018] At least one portion of the contact pad can be located in any suitable position, such as radially outward from the radial center of the actuator base. This allows for curved, flat, or sloping sides between one or more distal and proximal portions of the donut or ring shape. However, typically, at least one portion of the contact pad is located in the radially central region of the actuator base. This allows for a maximum lateral distance between at least one portion of the contact pad and at least one portion of the contact pad located away from it. This lateral distance allows the slope to be as shallow as possible to make the transition from low current output and low force to high current output at high force as smooth as possible, and to give the user as much flexibility as possible to allow the button to detect the desired force.

[0019] The bevel can be curved or non-curved (such as straight). If the bevel is curved, its shape can be concave. Typically, bevels are convex. In other words, a bevel can have a convex shape or can be convex in shape. This provides a greater rate of increase in the surface area of ​​the conductive layer in contact with the contact pad at lower forces compared to the rate of increase in surface area of ​​the conductive layer in contact with the contact pad at higher forces. This allows users greater flexibility at lower forces and therefore a greater ability to distinguish the intensity of light touches. This can also be described as providing “higher resolution” at low forces than at high forces, which is desirable for users who want to create complex outputs. Curved bevels can also be easier to manufacture than straight bevels because it is difficult to create the sharp edges that will be present at the ends of a straight bevel. This will also apply to concave bevels because this will include sharp edges.

[0020] The base of the actuator can be any suitable shape, such as a square, triangle, hexagon, or any other polygonal shape. Typically, the base of the actuator is circular. This further reduces the actuator's dependence on the direction of user interaction with it. This allows for greater consistency in the button's output, regardless of the direction of user interaction with the actuator.

[0021] The contact pad can also be any suitable shape, such as a square, triangle, hexagon, or any other polygonal shape. Typically, when the actuator base is circular, the contact pad is circular. This allows the shape of the contact pad to match the shape of the actuator base, making them mating shapes, and thus making the button more reliable because the force applied to the actuator can be applied to the contact pad in a way that means the entire actuator base and / or contact pad is used, rather than just a portion of the actuator base and / or contact pad.

[0022] The fingers (i.e., the intersecting fingers of the contact pad's contacts) can be oriented in any suitable manner. This can include grouped fingers or fingers intersecting with other fingers in a specific area, and multiple areas can exist. Typically, each finger of the contact can have a longitudinal axis aligned with the length of the corresponding finger, and the longitudinal axis of each finger can be oriented radially relative to the contact pad. This allows for a more uniform arrangement of the fingers compared to fingers intersecting with each other in several areas. The increased uniformity, as the surface area of ​​the conductive layer in contact with the contact pad increases, provides a more linear increase in the possible current output from the contact pad. This simplifies the processing of the current output (which can also be referred to as a "signal"), as the circuitry receiving the signal only needs to be arranged to respond to a linear increase or decrease in the current from the contact pad.

[0023] Each finger of the contact can have any suitable shape, such as having straight edges, a triangular shape, or any other form. Typically, each finger has one or more protrusions extending transversely to the longitudinal axis of the respective finger. This increases the surface area of ​​the contact and the circumference of the finger at each contact. This improves the button's reliability because there is a greater possibility of connection between the contacts. Additionally, this increases the button's dynamic range because the conductive layer has a larger surface area in contact with the actuator when the user applies force. This means a greater amount of accuracy can be achieved between minimum and maximum output. This is possible because the protrusions of adjacent fingers can intersect each other.

[0024] Each finger may have a single protrusion or multiple protrusions, and when multiple protrusions are present, the protrusions can be arranged at any suitable location on the respective finger, such as aligned or adjacent to each other on opposite sides of the finger. Typically, each finger has multiple protrusions extending laterally relative to the longitudinal axis of the respective finger, said protrusions being radially spaced along the longitudinal axis of each respective finger. Having multiple protrusions radially spaced along the length of the finger improves the linearity of the output from the contact pad because the length of the outer periphery in one part of the finger does not increase significantly relative to another part of the finger, which will result in a rapid increase in output because the connection is made at one point along the finger compared to another point along the finger.

[0025] When each finger has multiple protrusions, the protrusions can be arranged in any particular configuration or pattern, such as having all protrusions on one side of the finger, having more protrusions on one side of the finger than the other, or having an asymmetrical protrusion pattern on each side of the respective finger. Typically, the protrusions are arranged symmetrically along the longitudinal axis of each respective finger. This allows for a lower failure rate during manufacturing. This is because such an arrangement avoids significantly narrowed portions on each respective finger due to any asymmetrical pattern, which are more likely to be damaged or improperly formed during the manufacturing of the contact pad.

[0026] One or more protrusions on each finger can have any length (i.e., the distance by which one or more protrusions, or at least their tips, extend from the longitudinal axis of the respective finger). Typically, the length of the protrusion increases based on its proximity to the outer periphery of the contact pad. This increase in protrusion length based on proximity to the outer periphery is intended to indicate that the closer a particular protrusion is to the outer periphery of the contact pad, the longer the protrusion can be. This further increases the length of the outer periphery of each respective finger by giving each finger an undulating shape rather than by a central portion that steadily widens towards the outer periphery of the contact pad. This additional outer periphery length further increases the reliability of the button by providing an increased chance of button actuation when force is applied to the actuator to push the conductive layer into the contact pad.

[0027] Depending on the desired output, two or more contacts may exist on the contact pad. Typically, the contact pad has a first contact and a second contact, each with fingers that intersect with the fingers of the other contact. The fingers of the first contact connect to the circuit at the outer periphery of the contact pad, and the fingers of the second contact connect to the circuit at the inner periphery of the contact pad. The terms "first contact" and "second contact" are intended to denote each of these contacts providing a connection to the contact pad. By providing connections to the circuit at the outer periphery of the first contact and the inner periphery of the second contact, the connections of each contact remain isolated. This reduces the chance of short circuits occurring during manufacturing.

[0028] As described above, there is a gap between each intersecting finger (i.e., a gap between adjacent fingers). This gap can be of any shape, width, or length. Typically, the gap between intersecting fingers is curved. This simplifies manufacturing because there is no need to form sharp corners that are more difficult to manufacture. The curve can be created by one or more protrusions on the corresponding fingers, or it can be created by the shape of the fingers themselves.

[0029] The curve of the spacing between the fingers can be a continuous curve. This is not an alternative to a discontinuous curve. By having a continuous curve, the reliability of the button is improved by producing a regular pattern, and thus provides more possibilities for the intersection between the contacts to be generated.

[0030] Typically, the spacing between intersecting fingers can be of the same width along the length of each spacing. The width of the spacing is intended to represent the shortest distance between one finger and its adjacent finger. By having a consistent width along the length of each spacing, the linearity of the response from the contact pad is improved when the conductive layer is pressed into contact with the fingers, because a consistent number of connections are formed across the entire range of forces that can be applied to the actuator that pushes the conductive layer into the contact pad.

[0031] The contacts of the contact pad can be standard PCB contacts, or they can be coated to protect PCB contacts from corrosion and / or enhance conductivity. Typically, each contact of the contact pad has a carbon ink coating, and the contact between the conductive layer and the contact is provided through the contact between the conductive layer and the carbon ink coating. We have found that using carbon ink as the coating for each contact improves the button's sensitivity to force changes. This is because the carbon ink forms a dome-shaped cross-section when molded, which allows the conductive layer to be molded around the coating when force is applied to the button, thus increasing or decreasing the surface area of ​​the conductive layer in contact with the contact as the amount of force applied is adjusted. Additionally, the ink is non-oxidizing and abrasion-resistant, making it suitable for long-life applications requiring high contact cycles.

[0032] It is worth noting that carbon ink or carbon-based ink is not required. However, to avoid damage to the contact pads through oxidation or corrosion, the contact pads typically require alternative polishing. Suitable alternative coatings would include gold or silver plating. However, gold and silver are more expensive than using carbon ink or carbon-based ink.

[0033] The use of carbon ink coatings may be another reason for using continuous curves for the separation between fingers. This is because inks are typically applied using a screen printing process, and the absence of sharp corners increases the throughput of the screen printing process, thereby improving the manufacturing reliability of the contacts and simplifying manufacturing by reducing the number of sharp corners. Therefore, when using carbon ink coatings on contacts, the spacing between fingers can be a continuous curve.

[0034] The conductive layer can be held between the actuator and the contact pad. This maintains the axial arrangement of the conductive layer, actuator, and contact pad.

[0035] A conductive layer can be suspended between the actuator and the contact pad. This enhances the button's dynamic range by limiting the engagement between the conductive layer, actuator, and contact pad when not in use.

[0036] The conductive layer can be attached to a substrate, which is supported radially outward of the contact pad. This reduces the impact of any substrate to which the conductive layer is attached on the bonding between the conductive layer and the contact pad.

[0037] The substrate can be supported on the surface on which the contact pad rests. This provides a support structure for the substrate.

[0038] The button may also include a cover arranged to provide a housing for the button in use, the cover having an opening that allows contact with the actuator. This provides protection for the upper components of the button while still allowing the user to interact with the actuator. Typically, the actuator is located within the opening of the cover and can extend through the opening.

[0039] The cover may have a pin arranged to protrude from the cover into a support for the contact pad during use, thereby holding the cover at a minimum distance from the support. The pin may be provided by a leg attached to or formed on the cover. The support for the contact pad may be a contact pad base or some other layer or structure. Typically, this may be a PCB on which the contact pad is a component. The pin prevents any other layer between the actuator support and the cover and the contact pad support from being compressed against the support during use. If such compression does occur, it can affect the button's performance, such as excessive compression causing false triggering of the button, and in some cases, reducing trigger sensitivity.

[0040] The actuator can be independent of the contact pad (i.e., a component separate from the contact pad) (besides being independent of the conductive layer), or it can be linked to the contact pad and / or one or more other components. Typically, the actuator is connected to a support arranged to push the actuator away from the contact pad during use. This allows the actuator to apply minimal force to the contact pad via the conductive layer when the user is not interacting with the actuator. This means that a minimal amount of current flows through the contact pad when the actuator is not pressed by the user, which reduces the button's power consumption and also increases the dynamic range of detectable force by limiting the continuous interaction between the conductive layer and the contact pad to a minimum. Typically, no current flows through the contact pad when the actuator is not interacting with the user (or in other words, when the actuator is stationary).

[0041] The support can take any suitable form, such as a spring, hinge, or compressible element. Typically, the support includes a reflective structure and a retainer. The reflective structure is connected to the actuator and the retainer and is elastically deformable, thus providing actuation to the actuator during use. The reflective structure helps to induce movement of the actuator toward and away from the contact pad, making the button more reliable.

[0042] The reflective structure can be any suitable shape, such as a curved section or a straight section. Typically, the reflective structure is L-shaped, with one end connected to the retainer and the other end connected to the actuator. This allows the actuator to be pushed away from the contact pad and also minimizes mechanical resistance to movement, which increases the button's sensitivity because the actuator is easier to move when interacting with the user. The "L" shape is intended to indicate that the actuator is connected to, for example, the upper end of the upright portion of the "L," while the retainer is connected to, for example, the base of the "L," at the end away from the base of the upright portion.

[0043] When no force is applied to the actuator, the conductive layer can contact the contact pad. However, typically, when no force is applied by the user, there is a gap between the conductive layer and the contact pad. This increases the button's dynamic range. This is achieved by ensuring that no current flows through the contact pad before the conductive layer contacts it. This allows for the application of a maximum range of force because if current has already flowed through the contact pad, the difference between the amount of current that has flowed and the maximum current that can be output is less than the difference between no current output and the maximum current that can be output.

[0044] The actuator can be attached to a support that can be supported by a base to which the contact pad can be attached. This provides a layered structure for the button, simplifying its manufacture and limiting the complexity required for support structures used for various components.

[0045] When no force is applied to the actuator, the actuator can separate from the conductive layer through the gap between the base of the actuator and the conductive layer or any layer supporting the conductive layer. Alternatively, when no force is applied to the actuator, the actuator can be in contact with the conductive layer or any layer supporting the conductive layer.

[0046] According to a second aspect, a button array is provided, comprising a plurality of buttons according to a first aspect. This allows for the use of multiple buttons, and because each button is configured according to the first aspect, the consistency in how each button responds to a force applied by the user is increased. This improves the user experience of using the button array because each button, when pressed, reacts in a more similar manner to each of the other buttons. This is in comparison to conventional button arrays used to detect forces applied by the user.

[0047] Each button in a button array can be a separate component from every other button in the array. However, typically, multiple buttons are connected via a single base. This simplifies the manufacturing process, allowing the entire button array to be manufactured in a single process, rather than having to manufacture each button individually (which could lead to variations between buttons). Of course, multiple bases can exist, each with one or more buttons, and then buttons can be used to provide a button array using multiple bases.

[0048] The button array may have a single support structure, with all actuators of the button array connected in an array to that single support structure, or there may be multiple support structures, with one or more actuators connected to each of the multiple support structures. Attached Figure Description

[0049] This article describes in detail, with reference to the accompanying drawings, an exemplary button and an exemplary button array, wherein:

[0050] Figure 1 A cross-sectional view of an exemplary prior art button is shown;

[0051] Figure 2 A cross-sectional view of an exemplary button is shown;

[0052] Figure 3 A schematic diagram of an exemplary button array is shown;

[0053] Figure 4a A schematic diagram of an exemplary prior art PCB is shown;

[0054] Figure 4b A schematic diagram of an exemplary PCB is shown;

[0055] Figure 5a A schematic diagram of an exemplary prior art actuator array is shown;

[0056] Figure 5b A schematic diagram of an exemplary actuator array is shown;

[0057] Figure 6a A schematic diagram of an exemplary prior art contact pad is shown; and

[0058] Figure 6b A schematic diagram of an exemplary contact pad is shown. Detailed Implementation

[0059] The accompanying drawings described below detail the arrangement and configuration according to the examples of the first and second aspects. Exemplary buttons and button array arrangements are listed. As a comparison with the examples of the first and second aspects, several drawings illustrate prior art buttons and / or components thereof. For example, prior art buttons in… Figure 1 The overall value is represented by 100.

[0060] Button 100 is based on FSR. FSR is provided by contact pad 102 and conductive layer 104.

[0061] Contact pad 102 is formed on PCB 106. See below for details. Figure 6a To elaborate further, the contact pad has two contacts 108 and 110, each of which has a pattern that intersects with the pattern of the other contact.

[0062] exist Figure 1 In the example shown, when button 100 is not used (e.g.) Figure 1 As shown, the conductive layer 104 is supported above the contact pad 102, with a gap between the conductive layer and the contact pad. In other prior art examples, this gap or spacing is reduced to a smaller gap or is not present at all. In the latter case, the conductive layer rests on the contact pad even when the button is not in use.

[0063] exist Figure 1 In the example shown, the conductive layer 104 is spaced apart from the contact pad 102 due to its mounting. The conductive layer is mounted to the underside of the base layer 112. The base layer is in turn held away from the contact pad by spacers 114 located on either side (and around) the contact pad. The spacing between the conductive layer and the contact pad is thus provided by the thickness of the spacers. In prior art examples where the spacing between the conductive layer and the contact pad is reduced or absent, this is achieved by spacers with a smaller thickness or no spacers at all.

[0064] The substrate 112 is flexible to allow the conductive layer 104 to be pushed into contact with the contact pad 102 to form a complete circuit. Because this is impractical for a user to use as a button, the actuator 116 is located above the substrate, coaxial with the conductive layer and the contact pad.

[0065] The base 118 of the actuator 116 is located directly above the base layer 104, with a small gap between the base and the opposite side of the base layer on which the conductive layer 104 is mounted. The base is a flat surface with a profile parallel to the base layer.

[0066] Actuator 116 is connected to keypad 120, which supports the actuator and holds it in place. This is achieved using reflective structure 122, which extends directly from the body of the keypad to the body of the actuator.

[0067] In use, the upper surface of the actuator 116 is pushed towards the contact pad 102 by the user. Figure 1 The button 100 is interacted with. This pushes the base 118 of the actuator into contact with the base layer 104, causing the base layer to deform and push the conductive layer 104 into contact with the contact pad. This completes the circuitry that allows current to flow through the contact pad. The amount of current through the contact pad is proportional to the amount of force applied by the user actuator. This is because the larger surface area of ​​the conductive layer allows for proper contact with the contact pad, which results in a change in impedance between the two contacts and / or a change in resistance of the conductive layer when additional force is applied (since the conductive layer is a conductive polymer used in FSRs), based on the change in impedance caused by the force applied to the conductive layer.

[0068] When the user releases the actuator (i.e., when they stop pushing the actuator), the reflective structure 122 pushes the actuator away from the PCB 106. This allows the substrate layer to return to its undeformed shape, thereby disconnecting the circuitry made of the conductive layer.

[0069] Turning to the example from the first aspect, such an exemplary button is... Figure 2 The overall value is represented by 1. Similar to... Figure 1 The prior art example shown depicts a button with a PCB2 and related components located on top of it. Other components besides those shown may exist; however, those components are less relevant to the function of the button in this example.

[0070] The PCB 2 in this example includes contact pads 4 located on the surface of the PCB. Spacers 6 are mounted on the same surface of the PCB as the contact pads. In this example, the spacers are spacer ink deposited on the surface of the PCB. In other examples, the spacers may be provided by a solid material secured to the PCB using fasteners or adhesives.

[0071] The substrate layer 8 is mounted on the surface of the spacer 6 opposite to the surface of the spacer mounted to the PCB 2. The substrate layer extends over the contact pad 4, overlapping and covering the contact pad. Due to the spacer, a gap is provided between the substrate and the contact pad, wherein the substrate overlaps the contact pad.

[0072] A conductive layer 10 is mounted to a base layer 8, wherein the base layer is stacked on top of the contact pad 4. The conductive layer is mounted to the base layer on the same surface of adjacent spacers 6. The conductive layer is a conductive polymer.

[0073] In this example, conductive layer 10 is ink deposited on substrate layer 8. In other examples, the conductive layer can be a solid material, such as a conductive polymer sheet fixed to the substrate layer by fasteners or adhesives.

[0074] The thickness of the conductive layer 10 is insufficient to seal the gap between the base layer 8 and the contact pad 4. Therefore, in this example, there is a gap between the conductive layer and the contact pad. Although the gap can vary between examples, in this example, the gap between the conductive layer and the contact pad is approximately 0.062 millimeters (mm) (and therefore approximately 62 micrometers (μm)) when no force is applied by the user.

[0075] PCB 2 can be formed using any conventional method for manufacturing a PCB. Various inks used can be applied to the respective surfaces they are applied to via printing or deposition processes. For example, the FSR sheet serving as substrate 8 is a die-cut piece of PET plastic. In this example, it typically has a thickness of approximately 0.188 mm. The various inks applied to the PCB and substrate layer are each typically applied via a screen printing process.

[0076] During the manufacturing of the button, the first ink layer applied is conductive ink for the conductive layer 10. As mentioned above, in this example, this is a high-resistance ink. In this example, the ink is typically printed at a thickness of about 6 μm. In some examples, the ink is applied to the substrate layer 8 via a screen printing process.

[0077] The second printed layer is a spacer ink for spacer layer 6. In this example, the spacer ink is typically coated with a thickness of 68 μm.

[0078] The difference between the spacing ink thickness and the carbon ink thickness provides the gap between the FSR ink (and thus the ink used for conductive layer 10) and the contact pad 4; in this example, the carbon ink is the ink coated onto the contacts of the contact pad, as described above and in more detail below. In this example, the printing thickness tolerance is + / - 13 μm.

[0079] Keypad 12 is mounted on the surface of base layer 8 opposite to the surface that contacts spacer 6. The keypad, spacer, and base layer together provide a component stack for button 1.

[0080] from Figure 2As can be seen, the key pad 12, base layer 8, and spacer 6 are all mounted on the PCB2 one on top of the other. This mounting of various layers on top of each other provides a layer structure with portions of adjacent layers that, once manufactured, are in continuous contact with each other. The layer structure is laterally offset relative to the contact pad 4. By using this structure, various components that the user engages with and is moved by or responds to user engagement can be supported from the side rather than from below. This allows for separation between various components or portions of components, thus allowing the user to enjoy the advantages arising from this separation.

[0081] In this example, key pad 12 provides a support structure for actuator 14. In other examples, the support structure may be provided in the form of a frame or other structure.

[0082] Actuator 14 is located above the area where contact pad 4 is located on PCB 2. This means that in this example, the contact pad, conductive layer 10, and actuator are arranged coaxially. In other examples, these components may be arranged with offset or alternately oriented axes.

[0083] Actuator 14 is connected to keypad 12 via reflective structure 16. In this example, the reflective structure is "L"-shaped, with one end of the reflective structure connected to the actuator and the opposite end of the reflective structure attached to the keypad.

[0084] The actuator 14 is roughly cylindrical in shape. In this example, one end of the cylinder is a square with a flat end oriented approximately parallel to the surface of PCB 2, and the contact pad 4 is located on the surface of PCB 2. This is the surface that users typically interact with by applying force to the surface with one or more fingers or their hands.

[0085] Due to the height of the columnar body of actuator 14, the flat end of the actuator extends above keypad 12 away from PCB 2. Although not shown here, a housing may be used to protect the keypad by providing a barrier between the exterior and interior of a device in which buttons may be contained. In this case, the flat end of the actuator extends through a hole in the housing to allow the user to interact with the actuator. For example, the dimensions of the flat end of the actuator may be approximately 20mm × 20mm, such as approximately 20.6mm × 20.6mm. The height of the actuator from the flat end to the furthest point from the base of the actuator to the flat end may be between approximately 10mm and approximately 50mm, and preferably between approximately 15mm and 35mm or 10mm and 14mm.

[0086] To allow the reflective structure 16 to connect to the actuator 14, the side of the actuator body narrows at the point where the reflective structure connects to the actuator. This allows the tip of the "L" end connected to the actuator to be the point of connection to the reflective structure of the actuator. This allows the force transmitted from the actuator to the reflective structure to be transmitted directly along the strip of the "L," rather than being guided around the corner. This reduces wear and the connection extends the product's lifespan. In other examples, the connection may be on one side of the strip of the "L" or between any other suitable forms.

[0087] In some examples, the body of the actuator 14, which narrows at the point where the reflective structure 16 connects to the actuator, can be a gradient curve or a sloping surface. However, in this example, the narrowing is provided by the reverse steps, such that the actuator has a wider diameter above the connection with the reflective structure (i.e., closer to the flat end of the actuator) than below the connection with the reflective structure. Additionally, in this example, the walls of each section of the actuator are typically upright.

[0088] The variation in the diameter of actuator 14 also allows for variations in the actuator's shape. Above the connection to the reflective structure 16, the actuator is a square cylinder (although in various examples, the corners of this cylinder are rounded, or the portion is entirely different in shape). This means the flat end of the actuator is square. In this example, below the connection to the reflective structure, the actuator is a cylinder. This can be related to... Figure 5b The clearest view, Figure 5b A more detailed description follows.

[0089] In this example, the end of the cylinder forming actuator 14 opposite the flat end (also referred to as the base 18 of the actuator) is dome-shaped. In other examples, the base may be toroidal, conical, pyramidal, or inverted U-shaped.

[0090] In this example, the dome is convex. Another alternative is a concave shape, where the base 18 of the actuator tapers to a point.

[0091] In this example, the convex dome is provided by a smooth curve. In other examples, the convex surface can be provided by a multifaceted dome, which can have multiple flat surfaces, each of which connects to other surfaces at its edges, and each other surface can have a different orientation than the surface it connects to.

[0092] The dome provides an inclined surface that tapers away from the radial center region of actuator 14 toward the outer periphery of the cylinder providing the actuator body. Therefore, when the user is not using the button, the base of the actuator has a portion near the contact pad 4 (located in the radial center region of the actuator base 18 in this example) and a portion away from the contact pad (located in the outer periphery of the actuator base in this example). In alternative examples, the positions of the near and far portions can be reversed, these portions may not be located at the farthest points from each other on the actuator base 18, and / or multiple near and far portions may exist.

[0093] Using the term "user not using," the intention is to mean not being in active use. In other words, the intention means a situation where the user is not pushing the actuator or actively using the button.

[0094] The FSR ink of conductive layer 10 is coated onto substrate layer 8 instead of actuator substrate 18 because coating the ink onto the substrate layer is more controllable than coating it onto the actuator substrate. This allows for greater accuracy and precision in the thickness of the ink coated onto the conductive layer. Additionally or alternatively, other properties of the ink, such as the resistance of the FSR ink, can be determined more accurately and precisely. This higher level of control allows the properties of the conductive layer to be more specifically tailored to how the button is intended to be used, thereby enhancing the user experience when using the button.

[0095] At the radial center of the base 18 of the actuator, there is a hole 20 (in Figure 5b (Most clearly shown). The hole provides an opening for the recess 22 in the body of the actuator 14. The recess and hole are coaxial with the base layer 8, the conductive layer 10, and the hole 26 in the light-emitting diode (LED) 24 mounted on the PCB. In an example where there is no LED, the hole and recess may not be present. In another example, when the LED is present, the hole and recess may not be present.

[0096] In the example where the actuator 14 is not coaxial with the contact pad 4 and the conductive layer 10 (unlike the example where they are coaxial), the hole 20 and the recess 22 can be located at a position other than the radial center of the actuator. This is also the case where the LED 24 is not located at the radial center of the contact pad (again, unlike the example where the LED is located at the radial center of the contact pad) but is located elsewhere.

[0097] LED 24 is present to provide light when the button has been triggered by the user. How the LED responds to the button being triggered depends on how the circuitry and / or software driving the LED is configured and / or programmed. The LED can be a monochromatic LED or a multicolor LED, such as an LED that includes red, blue, and green LEDs, and may also include a white LED.

[0098] In this example, actuator 14 is deformable. In other examples, only a portion of the actuator, including the base 18, may be deformable. The deformable property is provided by the material used to make the deformable portion (whether all or part of the actuator).

[0099] In this example, actuator 14 is deformable to allow the base 18 of the actuator to deform when the actuator is pressed by a user. When the actuator is not pressed by the user, the portion of the base near the contact pad 4 abuts against the surface of the base layer 8 opposite the surface on which the conductive layer 10 is located. This means that due to the bending of the base, a gap exists between the portion of the base away from the contact pad and the base layer. In other examples, a gap may also exist between the portion of the base near the contact pad and the base layer, meaning that the gap between the portions of the base away from the contact pad increases, making it larger than the gap between the near portion and the base layer. This gap between the portions of the base near the base layer can be approximately 0.05 mm.

[0100] As described in more detail below, when in use, actuator 14 is pressed by the user. This causes the actuator to descend toward contact pad 4. The base 18 of the actuator pushes the base layer 8 and conductive layer 10 toward contact pad 4 by deforming the base layer, which in this example is flexible enough to allow (primarily) elastic deformation.

[0101] When the user applies sufficient force to the actuator 14, the conductive layer 10 is pressed into contact with the contact pad 4. As the force applied by the user increases, the base 18 of the actuator deforms and pushes more of the conductive layer into contact with the contact pad. When the user reduces the force applied to the actuator, the deformation of the base is partially or completely reversed, returning it to a shape closer to its undeformed state, or to its undeformed state, depending on the magnitude of the force still applied to the actuator. This allows the base layer to return to or toward its undeformed shape, thereby pulling the conductive layer partially or completely out of contact with the contact pad. When the user completely releases the force of the actuator, the components of the button 1 return to their initial arrangement, i.e., their position when not in use, also known as their "rest position".

[0102] Actuator 14 returns to its rest position due to the push exerted by reflective structure 16. The base layer 8 and conductive layer 10 return to their unused positions due to the elastically deformable nature of the material forming the base layer. This also applies to the deformable portion of the actuator, as in this example, the deformable portion is also made of an elastically deformable material.

[0103] exist Figure 2In the example shown, button 1 has a cover 60 located above keypad 12. The cover has a hole through which actuator 14 is positioned. The cover has pins 62 that pass through holes in each of the keypad 12, base layer 8, and spacer 6. These pins are in the form of (upright) legs. The pins abut against PCB 2 to support the cover and prevent it from pressing against the stacked keypads, base layer, and spacers. Therefore, in this example, the pins are located on either side of the actuator.

[0104] exist Figure 2 In the example shown, there is a gap between the upper surface of the keypad 12 and the lower surface of the cover 60. In other examples, this gap may be of a different size or may not exist.

[0105] In various examples, cover 60 is a plastic panel, but it can be made of other materials. In use, it is mounted on keypad 12.

[0106] In some examples, there are multiple buttons 1 forming an array of buttons. Such examples are... Figure 3 The total number is shown in 50. Each button in the button array corresponds to the one shown above. Figure 2 The example button 1 described is formed and functions in the same way.

[0107] exist Figure 3 In the example shown, there is a single keypad 12 having multiple reflective structures 16, each of which is attached to a corresponding actuator 14 as described above. In other examples, there may be multiple keypads, each having at least one reflective structure and one or more corresponding actuators.

[0108] In addition, Figure 3 In the example shown, there is a single support layer 8 and a spacer layer 6 (such as a single support layer and / or a single spacer layer). While alternatives are possible, in Figure 3 In the example shown, these layers are in conjunction with Figure 2 The same method is provided in the example shown. A single support layer makes manufacturing simpler because the conductive layer 10 for each button can be applied to a single support layer, for example, in a single application or via a single (printing) process.

[0109] Multiple actuators can be used individually or in combination to provide a single response (individually or in any possible combination, where the use of each actuator causes a different response and / or where the use of different combinations of actuators provides a single response) or a combination of responses. This is determined by the circuitry and / or software used in the components using the button array 50. (This is related to the above regarding...) Figure 2 As in the example described, the button array can have a housing, through which the actuator can be accessed due to the holes in the housing.

[0110] When multiple actuators are present, the "L" shape of the reflective structure offers advantages over known reflective structures. This is because, while allowing for low mechanical resistance to movement, the reflective structure, individually and / or in combination, improves the mechanical isolation of each actuator from each other. This reduces mechanical crosstalk. This is because the reflective structure absorbs motion propagated through the key pads due to its low mechanical resistance to movement, meaning a reduced amount of motion propagates to the respective actuator supported by each reflective structure.

[0111] Despite Figure 3 Not shown in the image, but such as Figure 2 The cover 60 shown in the example is capable of sitting on the keypad 12 and performing the same function. In such an example, the cover has a pin that passes through holes in the keypad, the base layer 8, and the space 6, and abuts against the PCB 2 to perform the same function as described above. Figure 2 The same functions are described. These actuators are typically located between adjacent actuators 14. The position of the cover relative to the key pad can also be the same as described above.

[0112] Figure 4 shows two example arrays of contact pads. Figure 4a A prior art contact pad array on PCB 106 is shown. Each contact pad 102 shown in this figure is associated with... Figure 1 The existing technology button 100 shown is used in conjunction with it. Figure 4a In this diagram, each contact pad is approximately square in shape, with a square hole at its center. The hole provides space for the LED. Spacers 114 are positioned around each contact pad and between adjacent contact pads. (See also: Regarding...) Figure 1 As described, the space provides support for the other components of the button.

[0113] Figure 4b Examples based on the description in this article (such as those above regarding) are shown. Figure 2 and Figure 3 Various components of one aspect of the described example. The figure shows a PCB 2 on which an array of contact pads 4 are positioned.

[0114] A spacer 6 is provided between adjacent contact pads 4. Figure 4b In the example shown, there is a square array of contact pads. In other examples, there may be only a single contact pad, or the array may be of different shapes, such as a hexagonal array or a hexagonal close-packed array. In the example with only a single contact pad, spacers are still arranged in a similar manner to that shown in this figure to provide support for components mounted on the PCB. In other words, spacers are placed around each contact pad, regardless of whether there is only a single contact pad or multiple contact pads.

[0115] Additionally, there is a gap between each contact pad 4 and the spacer 6, or in the space surrounding the contact pad. (See also: Regarding...) Figure 5b To describe in more detail, this separation allows airflow around the component.

[0116] exist Figure 4b In the example shown, each spacer 6 is provided with a free spacer ink. In this example, the contact pad 4 is also provided with conductive ink coated on the copper contacts. Typically, the conductive ink is carbon ink or carbon-based ink. In other examples, the contact pad may be simply a copper contact (although this is unlikely due to the reactivity of copper with air and the oxidizing properties of copper), or it may be a coated copper contact coated with any suitable material (such as gold).

[0117] When carbon ink or carbon-based ink is used as a coating on contact pad 4 in this example (such as on the contacts of the contact pad), the ink is applied to the contacts on the PCB via a screen printing process. This process results in the ink having a dome-shaped cross-section, also known as a dome profile. This dome profile allows the conductive layer 10 to form around the contact as the force applied by the user increases. This increases the amount of surface area of ​​the conductive layer in contact with the contact. Furthermore, the amount of conductive layer forming around the ink changes with the force applied by the user. This means that small changes in the applied force can be detected because the amount of surface area of ​​the conductive layer in contact with the contact pad varies due to the forming around the ink and because the surface area changes through a larger or smaller total area being contacted. This also improves reliability by making the contact between the conductive layer and the contact pad more defined due to the forming that occurs. This will reduce the amount of false or accidental force detection.

[0118] exist Figure 4b In the example shown, spacer 6 has a hole 64 located at the center of each spacer. This hole is provided to allow… Figure 2 The pin 62 of the cover 60 shown passes through the space to abut against the PCB 2.

[0119] exist Figure 4b In this diagram, each contact pad 4 is circular and has a hole 32 in its center. This hole provides space for an LED (not shown in the figure) to be mounted to PCB 2.

[0120] Figure 4b The circular shape of the contact pad 4 in the middle is similar to that of... Figure 5b The base 18 of the actuator shown is shaped to match. Figure 5 shows the underside of the keypad, where... Figure 5a The keypad of the prior art is shown, while Figure 5b The key pad shown is used as an example of a component as described above with respect to one aspect of the disclosure herein (e.g., in relation to...). Figure 2 , Figure 3 and Figure 4b (as described in the example).

[0121] Figure 5a A key pad 120 is shown, which has a plurality of actuators 116 (the upper part of the actuators is not shown in the figure). Figure 5a Each actuator shown has a flat, square base 118. An aperture 140 is also present in the base, providing a recess through which light from the LED can pass.

[0122] Each actuator 116 is connected to the keypad 120 via a reflective structure 122. Channels 126 are also provided in the keypad 120 and the edge of the keypad between each actuator and each adjacent actuator.

[0123] according to Figure 5b The actuator 16 shown in the example has a circular base 18 instead of a square base. As mentioned above, in this example, the circular base is not flat, but rather a convex dome.

[0124] The dome in this example also has a hole 20 that provides an opening in the base recess 22. As described above, in use, light from the LED can shine into the recess through the hole.

[0125] Figure 5b The base 18 of the actuator provides an end to the cylindrical portion of the actuator 14. The cylindrical portion forms the body of the actuator having a square column portion. The square column portion is... Figure 5b It is not visible in the image. However, the reflective structure 16 is connected to the square column portion, where the actuator body changes from a square column to a cylinder. Therefore, in this example, the reflective structure is square to conform to the shape of the portion of the actuator to which it is connected.

[0126] Given that the reflective structure 16 is square, the frame provided by the key pad 12 is also square, and the reflective structure is also connected to this frame. The frame is the portion of the key pad that is adjacent to the spacer 6 where the key pad is located.

[0127] Because the actuators are capable of movement when force is applied, this means that the cavity created between the PCB 2, substrate 8, keypad 12, and actuator 14 will change in volume during use. To prevent air from being trapped and forced through unintended paths when pushed out or pulled from its location, the frame provided by the upright wall 28 has openings 30 between each actuator and one or more adjacent actuators, and between each actuator and the edge of the keypad (if the actuator is located on one side of the keypad). This allows air to pass easily between locations within the button array 50, between the keypad and... Figure 5b The multiple actuators shown are used in conjunction with the button array 50.

[0128] exist Figure 5bIn the example keypad 12 shown, there is also a hole 66 formed through the keypad. In this example, the hole is located at the joint of the upright wall 28. The hole allows the above-mentioned... Figure 2 The described cover pin passes through the key pad.

[0129] Figure 5b The keypad 12, multiple actuators 14, and corresponding reflective structure 16 shown are manufactured using a compression molding process. This allows for the repeatable and precise formation of various desired shapes. When manufacturing only a single button (such as those mentioned above), this is possible. Figure 2 This process can also be used when describing an exemplary button. More specifically, the keypad is made of silicone material, for example, by compression molding. The raw material is placed in a single block or multiple blocks within a tool. The tool is then closed and the material is compressed into the shape of the part.

[0130] exist Figure 2 , Figure 3 , Figure 4b and Figure 5b In the example shown, the keypad 12 (along with one or more actuators 14 and one or more reflective structures 16) is made of silicone rubber. Typically, the keypad and other connecting components have a Shore A50 material hardness. In other words, using a Type A hardness tester, the material typically has a Shore hardness of 50.

[0131] exist Figure 2 , Figure 3 , Figure 4b and Figure 5b In the example shown, the silicone material typically contains coloring additives. This gives the material a "milky" appearance and helps diffuse light from the LED.

[0132] As described above, in use, the actuator is used to push the conductive layer into contact with the contact pad. Figure 6 shows two types of contact pads. Figure 6a The prior art contact pad is shown, while Figure 6b Examples of contact pads according to one aspect described herein, such as those according to... Figure 2 , 3 Examples described in 4b and 5b.

[0133] Figure 6a A contact pad 102 according to the prior art is shown. As described above, the contact pad has a square shape. The contact pad itself has two contacts 108, 110, each contact having fingers that intersect with the fingers of the other contact.

[0134] The figure shows contacts 108 and 110 having connections to a PCB circuit at opposite corners of contact pad 102. Each contact has a strip 126 extending along one side of the contact pad from the corresponding connection to the PCB circuit. This strip has six fingers 128 extending from the side of the strip away from the contact pad (from which the strip extends) toward the strip of another contact, whose strip is positioned along the opposite side of the contact pad. Three of these fingers are located at the end of the strip away from the connection to the PCB circuit and intersect with the three fingers of the other contact. At the end of the strip near the connection to the PCB circuit, there are three additional fingers that intersect with the three fingers of the other contact. These additional three fingers are the three fingers that intersect with the three fingers at the distal end of the strip of the other contact. Each of the six fingers extends away from the strip in an orientation perpendicular to the strip.

[0135] The fingers 128 extending from the strip 126, away from and close to the PCB circuit connection, each occupy an area spanning approximately one-third of the strip's length. The remaining third of the strip's length extends over the area where the holes 124 for the LEDs are located in the contact pad 102.

[0136] Because of the orifice, the fingers of each contact 108, 110 cannot extend from the strip of one contact to the strip of another. Therefore, each contact has a finger 128 that provides an edge to the orifice. Each of these fingers has six fingers 130 extending from it perpendicular to the corresponding finger (and therefore parallel to the strip of the corresponding contact). These fingers intersect with corresponding fingers of another contact and are approximately one-third the length of the strip of the corresponding contact. These shorter fingers fill the remaining area of ​​the contact pad not filled by the orifice or the other fingers of the contact pad 102.

[0137] One of the short fingers 130 of each contact 108, 110 provides the other side of the hole 124, thereby giving the hole a square shape. For each corresponding contact, the short fingers providing the side of the hole from each corresponding contact are located on the proximal side of the hole to the strip.

[0138] Although the fingers 128, 130 of each contact 108, 110 intersect with the fingers of another contact, there is no connection between the fingers of one contact and the fingers of another. There is a continuous gap 132 between the two contacts. This results in a break in the circuit in which the contact pad 102 is a part. To close the circuit, an electrical connection must be made between the two contacts of the contact pad 102. This is achieved by bringing the conductive layer 104 into contact with the contacts.

[0139] In the prior art, the conductive layer 104 contacts the contacts 108, 110 of the contact pad 102 by the user applying force to the actuator 116 to deform the base layer 112. If the user presses the actuator anywhere other than at the center of the flat end presented to them, the contact between the conductive layer and the contacts will be uneven because a specific portion of the actuator base 118 is pushed into contact with the base layer before the rest of the actuator base contacts the base layer. As described above, this reduces the reliability and consistency of the connection across the contacts, which allows current to flow variablely from one contact to another through the contact pad. This reduces the ability to accurately detect the correct force and the wide range of forces applied by the user.

[0140] Conversely, this problem is mitigated by providing contact pads for components that represent one aspect of the present invention, examples of which are shown in Figure 6b The figure shows a contact pad 4, which in this example is circular. This corresponds to the shape of the base 18 of the actuator. In other examples, the contact pad can be a different shape, such as an ellipse.

[0141] A hole 32 is present in the center of the contact pad 4. The hole is circular and provides space in the contact pad for the LED to be mounted onto the PCB.

[0142] The periphery of the hole 32 provides the radial central region of the contact pad 4. The contacts 34 and 36 of the contact pad are located between the periphery of the hole and the outer periphery of the contact pad in the radial central region of the contact pad.

[0143] Contacts 34 and 36 each have fingers that intersect with the fingers of the other contact. The fingers are oriented such that the longitudinal axis of each finger, extending along its length, is aligned with the radius of the circle of the contact pad. In other examples, the orientation and shape of the fingers may be different.

[0144] The orientation of the fingers at each contact 34, 36, and the intersecting arrangement of the fingers with those at another contact, mean that the fingers alternate between the fingers at one contact and those at another around the circumference of the contact pad 4. In examples with more than two contacts, the arrangement of the fingers at each contact can be different.

[0145] exist Figure 6b In the example shown, the fingers of one contact 34, which may be referred to as the "first contact," are connected to the PCB circuit at the outer periphery of the contact pad 4, and the fingers of another contact 36, which may be referred to as the "second contact," are connected to the PCB circuit at the periphery of the hole 32. In other examples, the contacts may be connected at either the outer periphery of the contact pad or the periphery of the hole.

[0146] To avoid any short circuits during the manufacturing process, a gap 38 is maintained between the fingers of the first contact 34 and the periphery of the hole 32, and between the fingers of the second contact 36 and the outer periphery of the contact pad 4. Due to the connection at the respective locations, this means that the fingers of the first contact extend radially outward more than the fingers of the second contact, and the fingers of the second contact extend radially inward more than the fingers of the first contact. This is achieved in various examples through linear extensions of the respective fingers or connections to conductive portions. These are not described in detail... Figure 6b As shown in the image.

[0147] exist Figure 6b In the example shown, each finger of contact 34, 36 has a protrusion. These may not be present in other examples. In this example, the protrusion extends laterally outward from the longitudinal axis of the corresponding finger. In this example, the protrusion extends laterally in a direction perpendicular to the longitudinal axis of the corresponding finger. In other examples, the protrusion may extend in other directions.

[0148] The protrusions on the fingers of the first contact 34 are complementary to the protrusions on the fingers of the second contact 36. In this example, this results in the fingers of the first contact having three protrusions on either side of each respective finger, and the fingers of the second contact having two protrusions on either side of each respective finger. In alternative examples, the fingers may have a different number of protrusions than in this example, and / or may have a different number of protrusions on opposite sides of each respective finger.

[0149] In this example, the protrusions on either side of each corresponding finger are aligned, thus giving the fingers a reflective axis of symmetry along the longitudinal axis of each finger. Given this, and the number of protrusions and fingers for each contact 34, 36, the finger of the first contact 34 has a protrusion extending outward on either side of each corresponding finger at the outer periphery of the contact pad 4. The next radially inward protrusion is located on the finger of the second contact, at the end region of the corresponding finger. This gives the radially outward end of the finger of the first contact a capital "T" shape, and the radially outward end of the finger of the second contact a lowercase "t" shape (i.e., the appearance of the top portion of the lowercase "t" (the portion protruding above the horizontal bar with a horizontal bar and a handle)).

[0150] As described above, the radially outward protrusions of the fingers of each contact 34, 36 are radially inward, and the protrusions on each finger alternate with the protrusions on each adjacent finger. The length of the protrusion (i.e., the distance the protrusion extends away from the longitudinal axis of the corresponding finger) increases as the corresponding protrusion is positioned closer to the outer periphery of the contact pad 4. Figure 6bAs shown, in this example, this means that the finger of the first contact 34 has the longest protrusion.

[0151] In this example, the protrusions on each finger have a curved shape. In an alternative example, the curves could be replaced with straight edges. However, the curved shape simplifies the manufacturing process. This is also why the curves are continuous, resulting in the fingers having no vertices and only smooth curves for the corners. The continuous curved shape makes the protrusions on each finger give the outer perimeter of the corresponding finger a wavy shape.

[0152] As described above, there is a gap of 38 between each finger and its corresponding adjacent finger. In this example, the gap has a consistent and constant width. In other examples, the width of the gap may vary along the length of the gap.

[0153] Figure 6b A dashed line 40 is also shown around the innermost circle, which intersects all the fingers of the first contact 34 and all the fingers of the second contact 36. This dashed line indicates the location where initial contact is made between the conductive layer 10 and the contact pad 4 when the user applies sufficient force to the actuator 14.

[0154] As the user increases the amount of force applied to the actuator 14, a larger surface area of ​​the conductive layer 10 comes into contact with the contacts 34, 36 of the contact pad 4. Typically, the increase in contact surface area extends radially outward from the initial contact position. Due to the convex dome shape of the actuator base 18, this increase in contact surface area is relatively uniform in all radial directions, regardless of the position on the surface provided by the flat end of the actuator under the pressure applied by the user.

[0155] Of course, the radial increase in contact surface area may vary as the user increases the amount of force applied to actuator 14. This means that a larger surface area of ​​conductive layer 10 can contact contact pad 4 in a portion of the contact pad relative to another portion of the contact pad. However, the circular shape and convex dome shape of the base 18 of the actuator minimize this variation.

[0156] As the surface area of ​​the conductive layer 10 in contact with contacts 34, 36 of the contact pad 4 increases with the increase of the force applied by the user to the actuator 14, the proportion of the portion with conductive connections between the contacts increases. This allows for an increase in the current flowing through the contact pad. Therefore, as the amount of force applied by the user to the actuator increases, the current through the contact pad increases proportionally.

[0157] The curved path followed by the spacing 38 between the fingers of the first contact 34 and the second contact 36, generated by the protrusions of the fingers of each contact, increases the path length compared to a straight path between adjacent fingers that radially passes from the center of the contact pad 4 to the outer periphery. This increases the connection length of the contacts when a specific force is applied, compared to using a straight path. This provides a greater connection length over the entire contact range, from the position where the conductive layer 10 first contacts the contact to the position where the conductive layer contacts the initial contact position and the outer periphery of the contact pad. This means that small adjustments to the force applied by the user are more likely to result in an increase or decrease in the amount of contact surface area, which increases the precision achievable by the user. This is due to the ability to achieve a greater “resolution” between the minimum force that can be applied to allow current to flow and the maximum force that can be applied to allow maximum current to flow.

[0158] Compared to existing technology systems, the reliability of button triggering (i.e., the contact made by the conductive layer 10 across the contacts 34, 38 of the contact pad 4 with at least a minimum current) is improved. This is because the initial contact is formed by a very small area of ​​the conductive layer relative to the maximum possible contact of the conductive layer (which occurs under the maximum detectable force). This means that all the force applied by the user at the trigger point reaches the contact pad only through this small area via the actuator 14 and the conductive layer. This makes the pressure applied at this small area higher than the pressure when the same pressure is applied over the entire surface area of ​​the contact pad. Therefore, this increases the likelihood of forming a conductive connection between at least one finger of the first contact pad 34 and at least one finger of the second contact pad 38.

[0159] The increased accuracy at minimum force also extends to providing increased accuracy in the smaller force portions of the entire range of forces detectable by the button. This is because the gradient of the ramp of the convex dome of the actuator base 18 is lower toward the center of the actuator base compared to the gradient toward the outer periphery of the actuator base. This means that for a relatively small increase in the force applied by the user, the amount of surface area of ​​the actuator base that is pushed into contact with the conductive layer 10 of the contact pad increases faster at lower forces than at higher forces. Therefore, the current increase for a specific increase in force at lower forces is greater than the current increase for the same specific increase in force at higher forces.

[0160] As further evidence, the convex dome shape of the actuator base 18 also provides lower accuracy under higher forces. This is due to the increased gradient of the actuator base towards its outer periphery. The lower accuracy is beneficial in this respect, given the magnitude of the force applied by the user and the upper limit of the force detectable by the button.

[0161] In comparison to existing technology systems such as the Novation Launchpad Pro, available prior to October 2019, existing buttons typically detect a minimum force of approximately 80 gf and have a force detection range between approximately 80 gf and 200 gf. However, the trigger force (i.e., the minimum detectable force) varies between different buttons, ranging from approximately 80 gf to approximately 160 gf. Using buttons according to the aspects described herein, for example regarding... Figure 2 , Figure 3 , Figure 4b , Figure 5b and Figure 6b The described button has a minimum detectable force of approximately 50 gf to 60 gf and a maximum detectable force of at least 200 gf, for example, up to approximately 2000 gf or up to approximately 4000 gf. We also found that reliability was improved between different buttons to limit the minimum detectable force to the range of 50 gf to 60 gf given above.

[0162] In use, to push the conductive layer 10 into contact with the contact pad 4 and to increase the surface area of ​​the conductive layer in contact with the contact pad as the force increases, similar to that applied to a button, the actuator 14 deforms such that the dome shape of the actuator base 18 flattens and conforms to the shape required to push the base layer 8 with the conductive layer and the contact pad. This movement of the actuator also causes the reflective structure 16 to deform to allow the movement of the actuator.

[0163] When the user selects to reduce the amount of force applied to actuator 14, the deformation of the actuator is reversed, causing the actuator to return to its natural shape when not in use. If the user only partially releases the force and the actuator, the deformation is reduced only by the amount allowed by the applied force. If the user releases all the force on the actuator, the actuator returns to its undeformed state. The reflective structure 16 also pushes the actuator away from the contact pad to return to its unused rest position. In some examples, this pushing can also be assisted by tension in the base layer 8 pushing the base layer back to its undeformed shape. This pushing by the reflective structure gives the actuator a rest position in which it is held in a position that does not cause deformation of the actuator or the base layer.

[0164] Based on the various aspects described herein, such as button 1 and button array 50, such as regarding Figure 2 , Figure 3 , Figure 4b , Figure 5b and Figure 6bThe described button 1 and button array 50 can be used as part of a controller. One use of this controller is to cause components connected to it to produce sound. Alternative uses of the buttons and button arrays described herein can be found in computer keyboards, for example, where multiple button combinations are needed to achieve a specific effect, which can be replaced by a user pressing a single button, where the action produced by the button press depends on the amount of force applied by the user to the button. Furthermore, the buttons and button arrays according to the aspects described herein can be used to detect typing errors on a keyboard, such as when a key is accidentally pressed (which typically results in a lighter button press than normal). Such a lighter button press can be detected using the described buttons and button array.

Claims

1. A button for changing an output based on an applied force, the button comprising: A contact pad having at least two contacts arranged in a complementary pattern of intersecting fingers with a gap between them; as well as An actuator and a conductive layer, the conductive layer being located between the base of the actuator and the contact pad and independent of the actuator and the contact pad, the base of the actuator being shaped to increase the surface area of ​​the conductive layer in contact with the contact when the actuator is pushed toward the contact pad, thereby increasing the current flow between the contacts as the force applied to the actuator increases during use; Wherein, the longitudinal axis of each finger of the contact is radially oriented, and Wherein, at the radial center of the base of the actuator, there is a coaxial hole in the contact pad, the conductive layer and the base of the actuator.

2. The button according to claim 1, wherein, At least a portion of the actuator is deformable, the at least a portion including the base of the actuator, the portion being arranged to deform when a force is applied to the actuator by the user and the conductive layer contacts the contact pad.

3. The button according to claim 2, wherein, When in a non-deformable state, the base of the actuator has a cross-sectional profile having at least one portion close to the contact pad and at least one portion away from the contact pad, and a slope between the at least one portion close to the contact pad and the at least one portion away from the contact pad.

4. The button according to claim 3, wherein, The at least one portion near the contact pad is radially inside the at least one portion away from the contact pad.

5. The button according to claim 4, wherein, The at least one portion that is away from the contact pad is located at the outer periphery of the base of the actuator.

6. The button according to claim 4 or 5, wherein, The at least one portion near the contact pad is located in the radial central region of the base of the actuator.

7. The button according to any one of claims 3 to 5, wherein, The inclined plane is a convex inclined plane.

8. The button according to claim 1, wherein, The base of the actuator is circular.

9. The button according to claim 8, wherein, The contact pad is circular.

10. The button according to claim 1, wherein, Each of the fingers has one or more protrusions extending transversely to the longitudinal axis of the corresponding finger.

11. The button according to claim 1, wherein, Each finger has a plurality of protrusions extending transversely to the longitudinal axis of the respective finger, the protrusions being radially spaced apart along the longitudinal axis of each respective finger.

12. The button according to claim 11, wherein, The protrusions are arranged symmetrically along the longitudinal axis of each corresponding finger.

13. The button according to any one of claims 10 to 12, wherein, The length of the protrusion increases based on the proximity of the protrusion to the outer periphery of the contact pad.

14. The button according to claim 1, wherein, The contact pad has a first contact and a second contact, each contact having fingers that intersect with the fingers of the other contact, the fingers of the first contact being connected to circuitry at the outer periphery of the contact pad, and the fingers of the second contact being connected to circuitry at the inner periphery of the contact pad.

15. The button according to claim 14, wherein, The spacing between the intersecting fingers is curved.

16. The button according to claim 15, wherein, The bend is a continuous curve.

17. The button according to any one of claims 14 to 16, wherein, The spacing between the intersecting fingers has the same width along the length of each spacing.

18. The button according to claim 1, wherein, Each contact point of the contact pad has a carbon ink coating, and the contact between the conductive layer and the contact point is provided through the contact between the conductive layer and the carbon ink coating.

19. The button according to claim 1, wherein, The conductive layer is held between the actuator and the contact pad.

20. The button according to claim 1, wherein, The conductive layer is suspended between the actuator and the contact pad.

21. The button according to claim 1, wherein, The conductive layer is attached to a substrate, which is supported radially outward of the contact pad.

22. The button according to claim 21, wherein, The substrate is supported on a surface on which the contact pad is provided.

23. The button according to claim 21, wherein, The actuator is connected to a support member arranged to push the actuator away from the contact pad during use.

24. The button according to claim 23, wherein, The support includes a reflective structure and a retainer, the reflective structure being connected to the actuator and the retainer and being elastically deformable to provide actuation to the actuator during use.

25. The button according to claim 24, wherein, The reflective structure is L-shaped, connected at one end to the retainer and at the opposite end to the actuator.

26. The button according to any one of claims 23 to 25, wherein, The actuator is connected to a support member that is supported by the substrate to which the conductive layer is attached.

27. The button according to any one of claims 23 to 25, further comprising a cover arranged to provide a housing for the button in use, the cover having an opening that allows access to the actuator.

28. The button according to claim 27, wherein, The cover has a pin arranged to protrude from the cover into a support for the contact pad during use, thereby holding the cover at a minimum distance from the support.

29. The button according to any one of claims 1-5, 8-12, 14-16, and 18-25, wherein, There is a gap between the conductive layer and the contact pad when no force is applied by the user.

30. A button array comprising a plurality of buttons according to any one of claims 1 to 29.

31. The button array according to claim 30, wherein, The plurality of buttons are connected via a single base.

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