Graphic Overlays: This is the top layer that provides the visual interface. It can be made from materials like polycarbonate or polyester, chosen based on durability and environmental resistance.
Circuit Layer: The circuit can be printed using conductive inks or made from etched copper. This layer is crucial for the functionality of the keypad, allowing electrical signals to be transmitted when keys are pressed.
Adhesives: These are used to bond the layers together and attach the keypad to the device. The choice of adhesive depends on the surfaces involved and the environmental conditions the keypad will face.
Embossing: This feature can enhance tactile feedback by creating raised buttons, which can improve user experience.
Additional Features: Options like backlighting, touchscreens, and embedded components (like LEDs or sensors) can be integrated into the design for enhanced functionality and aesthetics.

Design Considerations

When designing a custom membrane keypad, consider the following:

Tactile vs. Non-Tactile Feedback: Decide whether you want the user to feel a click or feedback when pressing a key. Tactile switches often use metal domes for this purpose.Environmental Resistance: Depending on the application, the keypad may need to withstand moisture, chemicals, or extreme temperatures. Selecting the right materials and sealing methods is essential for durability.
Complexity of Design: Simple designs may only require a few layers, while complex interfaces might need multiple layers and additional components like PCBs for more advanced functionalities.

Manufacturing Options

Custom membrane keypads can be manufactured through various methods, including:

Screen Printing: Commonly used for creating the circuit layer with conductive inks.
Etching: Used for creating more precise and flexible circuits with copper.
Prototyping Services: Many manufacturers offer rapid prototyping services, allowing you to test designs quickly before full-scale production.

Specification:

1)Material (for front or face overlay)

Polyester:

1.Highly versatile for embossing

2.Highly resistant to chemicals

3.Better durability

4.For internal and external use, UV resistance

Polycarbonate:

1.Different surface(Glossy, Matt) and thickness(From 0.12mm~2mm)

2. cost-effective in price

3.For internal and external use

2) Embossing

Rim embossing/pillow embossing/dimple embossing

Graphic overlays can be embossed in order to insert domes/LED, leave space for mechanical keys/LED and provide tactile indications and better tactile feeling.

3)Windows(for display function)

1. print different colors windows, As transparent grey/Red/green window for display

2. Clear/Transparent window for LCD display

2. Matt/semi-transparent window for LED

4)Keys/buttons

Tactile keys---with metal dome or poly dome

Non-tactile--silver printing dots with flat key

5) Embeded LEDs

Small, brilliant lights only about 0.02’’ in height. Avaliable in several vibrant colors.

LED colors: white, yellow, orange, green, red, or double colors LED.

6)Cable

It is an extension of the printed circuit and is used to communicate with your device.

7)Types of connector

1.Zero insertion force (ZIF) connector; 2.Female connector; 3.male connector

8) EMI / RFI / ESD Shielding

use an aluminum foil shielding / a clear ITO electrical conductive polyester

9)Adhesive

mostly used are 3M-double-side glue

10)Backplate-

in aluminum, polycarbonate, acrylic, PCB

Product index:

Operating voltage: 35V DC

Operating current: 100mA 1W

Contact resistance: < 100 Ohms

Open circuit resistance: ≥ 10MΩ at 100V

Operating temperature: Flat/Metal dome:-20°c to +80°c

Storage temperature: Flat/Metal dome:-40°cto +80°c

Life expectancy Flat type≥5,000,000 times Tactile type≥1,000,000 times

Switch stroke: 0.1 to 0.6mm

Contact bounce: 5 to 30ms

Actuation force tolerance: +/- 20 to 45g

Tactile ratio: FC > 40%

Operating humidity: up to 95% RH

Female, male connector, solder pins and heat seal connectors are available

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