Multi-Layer Integral Keypad

A keyboard having a multilayer keypad, comprising:

• a keyboard circuit;
• a mounting surface supporting a plurality of switches spaced apart from one another and in electrical communication with said keyboard circuit;
• a plurality of key tops, at least two of said key tops having a display layer, a translucent plastic layer, and an actuating structure;
• said display layer having an upwardly facing display surface and a downward facing back surface;
• said plastic layer having an upper surface coupled to said back surface of said display layer and a lower surface facing toward said mounting surface;
• said actuating structure coupled to said lower surface of said plastic layer and positioned over a one of said switches;
• a resilient key top support layer coupled to said plastic layer of at least two of said key tops and integrally connecting said key tops to one another;
• said key top support layer having a support layer arcuate leg section extending downward and away from said key tops toward a support layer base contacting said mounting surface;
• wherein said key top support layer is operable to allow a plurality of said key tops to be in a stationary position when no force is applied to said key tops and to allow a single of said key tops to be in an activation position and actuate at least one of said switches when a predetermined force is applied to said single of said key tops;
• wherein said key top support layer is free from contact with any of said switches.

A multilayer integral keypad for actuating a plurality of switches, comprising

• a plurality of key tops, each of said key tops having a metal layer and a translucent plastic layer, said metal layer of each of said key tops having a display surface and a back surface, and said plastic layer of each of said key tops coupled to said back surface of said metal layer and having an actuating structure extending in a direction downward and away from said back surface of said metal layer;
• a key top support layer, said key top support layer coupled to said plastic layer of each of said key tops and surrounding each said actuating structure of each of said key tops;
• said key top support layer having a leg section extending downward from each said plastic layer to a key top base;
• wherein the entirety of said key top support layer is downward and below said metal layer and wherein said key top support layer extends only partially underneath said key tops;
• and
• wherein said key top support layer is configured to allow a plurality of said key tops to be in a stationary position when no force is applied to said key tops and to allow a single of said key tops to be in an activation position and actuate at least one of the switches when a predetermined force is applied to said single of said key tops.

A method for producing a multilayer integral keypad, comprising the steps of:

• placing a sheet of metal over a plurality of mold cavities arranged according to a predetermined keypad layout;
• inserting at least one forming punch into said plurality of mold cavities to cut said sheet of metal into a plurality of individual metal layers;
• maintaining said plurality of metal layers in said mold cavities and depositing a plastic layer onto each of said metal layers;
• depositing a resilient material layer onto each said plastic layer so that said resilient material layer attaches each said plastic layer to any adjacent said plastic layer.