In Mold (IMF) Keypad Artwork
Graphics can be applied to the top surface or the subsurface of the keypad. By printing on the subsurface of the IMF film, the graphics are sandwiched in between the film and the plunger providing the ultimate protection.
The artwork is first screen-printed to a thin plastic film. By applying the graphic ink to the subsurface, the graphics are encapsulated within the keypad to better protect from abrasion and chemical wear over the lifetime of the product. After the artwork cures, the film is then embossed (via a high-pressure forming machine) to achieve the keypad shape. High-precision registration pins ensure the graphics on the keypad are aligned accurately and consistently during each forming process. After the film is embossed, the plungers for each key are injected. The injected plungers can be permanently bonded to either a plastic or rubber keypad base.
The last process step is for the keypad to be punched to meet peripheral dimensions. In a secondary operation, IMF keypads can be modified for a custom die-cut profile to meet your design specification.
Materials used in IMF keypads vary as needed to meet our customer’s requirements. We use Polycarbonate (PC) and Thermoplastic Polyurethane (TPU) materials. Each material has properties or characteristics that make it more suitable for certain conditions.
Vacuum Metalizing ( VM ) Keypad Materials
Vacuum Metalizing (VM), also known as Thermal Evaporation or Physical Vapor Deposition, is another means that Top Bound USA offers to obtain the metalized look that is so desired in today’s handheld devices. The products produced in this manner will be Nickel free, thus making them more environmentally friendly. Metals used in the VM process are typically aluminum and chrome.
The VM process applies a thin, uniform metalized coating to the surface of films and plastics used in the manufacture of our keypad products. A primer is sprayed on the surface of the material prior to the VM process. After the VM process, a hard coat is applied which makes the surface more chemical and abrasion resistant. This process is excellent for coverage on flat and vertical surfaces.
Metals are heated to the point of evaporation which allows them to migrate to the colder surface of the film or plastic being coated. This process is performed in a vacuum so the vaporized metal does not oxidize in the oxygen in the air.
We can also supply the keypads manufactured by the “sputter” method. This method yields slightly thicker layers of metal and is therefore more abrasion resistant. However, a hard coat is still applied to the surface.
Non-conductive vacuum metallization ( NCVM) may be provided if there is a requirement. For example: The need to pass RF through coated material.
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Light Guide Film ( LGF )
Light Guide Film (LGF) is another option that Top Bound USA can offer to back light keypads and other products. This is the thinnest product for backlighting keypads currently available. These films are thin (0.125mm), flexible, and light weight. These films can be bent but not creased.
LGF has light scattering ability. This allows for uniformity and brightness. Hot spots are not an issue with this material. LGF typically is designed for side view LEDs, but top view LEDs may be used in some situations. The use of LGF can reduce the number of LEDs in a unit, thus reducing the cost of materials and also reducing the power drain on the unit.
Sheet Metal Keypads ( SMK )
Sheet Metal Keypads (SMK) are widely used in today’s thin hand held devices. These keypads offer some of the thinnest keypads on the market and yet are extremely strong. The graphics are chemically etched into the material which relieves the concern of graphic abrasion.
Typically, metal keypads will have silicone co-molded to the back side. This silicone can be reverse printed to provide color for graphics or for decoration. TPU plus silicone can also be used for further decoration.
Glass Keytops ( GKT )
Glass, as a keytop material is one of the latest developments in decoration and graphic protection. It provides exceptional clarity with its polished surfaces. Both flat and 3D (multi-faceted diamond cut) surfaces are available. The glass is hardened both by baking and chemical processes so it is very strong. The second surface printing of graphics or decoration assures that they will never wear off. These keytops can be adhered to both silicone and TPU materials, and since we can make the keytops with a minimum thickness of 0.5mm, they will work for ultra thin keypads. Cut outs are even available so secondary decoration can be added to enhance the look.
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Ultra Thin Polycarbonate ( PC ) / Acrylic Keytops
(Ultra-Thin Hard Top Keypads)
The minimum thickness of PC keytops is 0.5mm in consideration of the limitation in injection molding. The side wall should have a minimum thickness of 0.35mm excluding the radius on the corner on the keytop. This dimension is to assure the de-gating is not seen from the top view of the button. The radius at the edges of the keytops is recommended to be a minimum of 0.1mm. If a “step” is going to be molded into the keytop the minimum step height should be 0.3mm. The gating of the tooling must have a minimum of 0.2mm.
These low profile keytops are second surface printed to prevent graphic abrasion. However when dark colors are printed on PC material, scratches on the surface of the material itself will begin to show with use. Hard coating is possible to increase the surface hardness. If scratching is a major concern acrylic material should be considered. If acrylic material is used the minimum thickness will increase from 0.5mm to 0.8mm. Acrylic has lower heat resistance than PC.
In keeping with the ultra thin concept, Top Bound USA can supply metal dome or polycarbonate dome assemblies to give excellent reliability and tactile feel simulating that of mechanical switches
Silicone Rubber Compression Molded Keypads / Mobile Phones
Silicone Rubber Keys
Draft angle should be 1.0º minimum (2.0º to 3.0º preferred for ease of removal from the tool)- Typical Durometer is 60-70 Shore A, (although a custom Durometer may be blended for your application) Minimum interior base radii between keys to be 0.3mm to prevent tearing of web.
Minimum exterior edge radii to be 0.2 – 0.3mm.- Clearance between individual keys and housing to be 0.1mm minimum. Spacing between keys to be 1.8mm minimum.
Typical actuation force to be between 150-180g depending on domes and keypad Durometer.
Typical curvature of the key face should not vary by more than 0.5mm to ensure a best quality printing/etching process. Printing should not be closer than 0.3mm to the edge of the key top radius.
Hard Caps
Standard plastic injection molding tolerances apply.
Draft angle should be 1.0º minimum (2.0º preferred for ease of ejection from the tool, or if surfaces are textured).
Spacing between keys within key clusters to be 0.1 – 0.2mm minimum.
For clear keycaps, the bottom surface should be flat to allow for screen printing.
Screen printing border to be 0.10mm minimum from edge of screen printed keys.
Keys may be press fit onto the silicone base (with a constraining flange) or attached with adhesives.
A number of textures and cosmetic options are available including laser etched chrome.
Keypad Base ( Thickness )
Typical base thickness to be 0.5 – 1.2mm (0.8 to 1.0mm is preferred).
Minimum wall thickness between features is 0.5mm, and 0.3mm at perimeter of keypad.
0.3mm thick sections allowed above LED’s and required recesses.
Actuation Plungers / PCB Interface
Typical plunger to have flat base with a recommended diameter of 2.0mm (plunger diameter may increase depending on dome size).
A generous draft (30º) will improve key stability.
Plunger should touch domes line to line at nominal condition.
Base-web
The base-web surrounding the keys should be 0.2mm to 0.3mm to prevent tearing and maximize tactile feel of the domes.
Air Channels
Air channels are required under the keypad base to prevent suction when the keys are actuated (typical air channel are 2.0mm wide by 0.3mm deep).
Polished Surfaces / Backlighting
To increase light transmission of the LEDs, the rear surface of the keypad and LED recesses may be high-polished within the tool to improve or balance backlighting.
Dimensional Tolerances for Silicone Keypads
Dimension (mm) Tolerance (+/-)
0.0 - 10.0 0.10 mm
10.1 - 20.0 0.15 mm
20.1 - 30.0 0.20 mm
30.1 - 40.0 0.25 mm
40.1 - 50.0 0.30 mm
50.1 - 100.0 0.35 mm
100.1 and up 0.5%
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