Overlay electrical conductor for a magnetically coupled pushbutton switch

A method of making electrical contact in a magnetically coupled pushbutton switch having an overlay, a coupler magnet layer, an armature with a heel end and a toe end, and a substrate layer, comprising the steps of:

• forming a crown on the armature that is electrically conductive, the crown being a raised portion that is closest to the heel end of the armature and farthest from the toe end of the armature;
• creating a first stable position, where the armature is magnetically coupled to the coupler magnet layer in a rest position;
• creating a second stable position, where the armature is partially actuated such that the heel end of the armature has broken away from the coupler magnet layer and contacted the substrate layer, but the toe end of the armature is in contact with the coupler magnet layer;
• creating a third stable position, where the heel end of the armature and the toe end of the armature are in contact with the substrate layer, in a fully actuated position;
• creating a state of initial travel, where the armature is in a position intermediate the first stable position and the second stable position;
• creating a state of final travel, where the armature is in a position intermediate the second stable position and the third stable position;
• forming an overlay electrical conductor that electrically contacts the crown at least when the armature is in the third stable position;
• allowing a user provided actuation force to cause the armature to travel to any of the stable positions or through any of the states of travel;
• forming a first set of electrical conductors that may be electrically opened or closed by the user provided actuation force, the overlay electrical conductor being part of the first set of electrical conductors.

A method of making a set of electrical conductors for a magnetically coupled pushbutton switch of the type having a coupler magnet layer that normally holds an electrically conductive magnetic armature spaced from a substrate layer, the method comprising the steps of:

• defining a heel end of the armature that is opposite a toe end of the armature, the heel end of the armature always breaking away from the coupler magnet layer before the toe end of the armature when a user provided actuation force is applied to the pushbutton switch;
• making a top face on the armature that is electrically conductive, the top face being that part of the armature that is normally held in coupled engagement with the coupler magnet layer;
• and
• forming a toe electrical conductor on or adjacent a bottom surface of the coupler magnet layer, the bottom surface of the coupler magnet layer being able to contact the top face of the armature, and the toe electrical conductor being able to contact the toe end of the armature.