Impact absorbing system for a flat switch panel

Abstract

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

What is claimed is:  
     
         1 . A method of making an impact absorbing system, for use with a flat switch panel that has at least one pushbutton switch, comprising the steps of: 
 fabricating an impact spacer having a rigid layer with a top and bottom and an energy-absorbing layer with a top and bottom;    forming at least one isolation structure in the rigid layer;    attaching the bottom of the rigid layer to the top of the energy-absorbing layer;    installing the impact spacer onto the flat switch panel so that the energy-absorbing layer is intermediate the rigid layer and the at least one pushbutton switch of the flat switch panel.    
     
     
         2 . The method of  claim 1  wherein the step of forming an isolation structure in the rigid layer is characterized by embossing an area of the rigid layer that is above the at least one pushbutton switch of the flat switch panel.  
     
     
         3 . The method of  claim 1  wherein the step of forming an isolation structure in the rigid layer is characterized by a forming a supplemental rigid layer, the supplemental rigid layer having at least one cutout that is above the at least one pushbutton switch of the flat switch panel, the top of the rigid layer substantially covering the supplemental rigid layer and the at least one cutout.  
     
     
         4 . The method of  claim 1  further comprising the step of positioning a backer on the flat switch panel such that the at least one pushbutton switch is intermediate the backer and the impact spacer.  
     
     
         5 . The method of  claim 1  further comprising the step of forming a pip on the at least one pushbutton switch of the flat switch panel such that the pip will protrude into the energy-absorbing layer of an installed impact spacer.  
     
     
         6 . The method of  claim 1  wherein the step of installing the impact spacer is characterized by the use of a selective adhesive layer, the selective adhesive layer not adhering to areas on the flat switch panel that are substantially above a pushbutton switch.  
     
     
         7 . An impact spacer, for use with a flat switch panel that has at least one pushbutton switch, comprising: 
 a rigid layer with a top and bottom;    an isolation structure in the rigid layer;    an energy-absorbing layer with a top and bottom;    a means of attaching the bottom of the rigid layer to the top of the energy-absorbing layer; and    a means of attaching the bottom of the energy-absorbing layer to the flat switch panel.    
     
     
         8 . The impact spacer of  claim 7  wherein the isolation structure is an embossed area in the rigid layer that lies above the at least one pushbutton switch on the flat switch panel.  
     
     
         9 . The impact spacer of  claim 7  wherein the isolation structure is formed by making the rigid layer from at least a first and second sheet of rigid layer material, the first sheet of the rigid layer includes the bottom of the rigid layer and has at least one cutout where the rigid layer covers the at least one pushbutton of the flat switch panel, the second sheet of the rigid layer includes the top of the rigid layer and substantially covers the first sheet and the at least one cutout.  
     
     
         10 . The impact spacer of  claim 7  wherein the means of attaching the energy-absorbing layer to the flat switch panel is by a selective adhesive layer, the selective adhesive layer not adhering to areas on the flat switch panel that are substantially above a pushbutton switch.  
     
     
         11 . An impact absorbing system, for use with a pushbutton switch having a magnetically-coupled armature, comprising: 
 an impact spacer having a rigid layer with a top and bottom and an energy-absorbing layer with a top and bottom;    a means of attaching the bottom of the rigid layer to the top of the energy-absorbing layer;    a means of attaching the bottom of the energy-absorbing layer to a top surface of the pushbutton switch;    
     
     
         12 . The impact absorbing system of  claim 11  wherein the rigid layer includes an isolation structure.  
     
     
         13 . The isolation structure of  claim 12  wherein the isolation structure is an embossed area of the rigid layer that is at least partially above the pushbutton switch.  
     
     
         14 . The isolation structure of  claim 12  wherein the isolation structure includes at least a first and second sheet of rigid layer material; the second sheet is a supplemental rigid layer, the supplemental rigid layer having a cutout that is above the pushbutton switch; the first sheet substantially covers the supplemental rigid layer and the cutout.  
     
     
         15 . The impact absorbing system of  claim 11  wherein the magnetically-coupled armature has a crown that protrudes through an aperture in a sheet magnet coupler layer of the pushbutton switch, the crown further comprising a pip that protrudes into the energy-absorbing layer of the impact absorbing system.  
     
     
         16 . The impact absorbing system of  claim 15  wherein the rigid layer includes an isolation structure.  
     
     
         17 . The impact absorbing system of  claim 16  further comprising a backer and a means of attaching the backer to the pushbutton switch so that the pushbutton switch is intermediate the impact spacer and the backer.  
     
     
         18 . The impact absorbing system of  claim 11  further comprising a backer and a means of attaching the backer to the pushbutton switch so that the pushbutton switch is intermediate the impact spacer and the backer.  
     
     
         19 . The impact absorbing system of  claim 11  wherein the means of attaching the bottom of the energy-absorbing layer to a top surface of the pushbutton switch is by a selective adhesive layer, the selective adhesive layer not providing a means of attaching the energy-absorbing layer to an area of the pushbutton switch that is at least partially above the armature.  
     
     
         20 . The impact absorbing system of  claim 17  wherein the means of attaching the bottom of the energy-absorbing layer to a top surface of the pushbutton switch is by a selective adhesive layer, the selective adhesive layer at least not extending over an area that is above the crown of the magnetically-coupled armature.