Multi-layer integral keypad

A multilayer keypad for interfacing with a plurality of switches, comprising:

• a plurality of key tops, at least two key tops of said key tops having a display layer, a translucent plastic layer, said plastic layer different than said display layer;
• each said display layer having an upwardly facing display surface and a downward facing back surface;
• each said plastic layer having an upper surface coupled to said back surface of said display layer and a downward facing lower surface;
• wherein an actuating structure is formed in said lower surface of said plastic layer and positioned over one of said switches;
• a resilient key top support layer coupled to said plastic layer of said at least two key tops and integrally connecting said at least two key tops to one another;
• said key top support layer having a support layer arcuate leg section extending downward and away from said at least two key tops toward a support layer base;
• wherein said key top support layer is operable to allow said at least two key tops to be in a stationary position when no force is applied to said at least two key tops and to allow a single of said at least two 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 at least two key tops;
• wherein said key top support layer is configured to be free from contact with any of said switches in said stationary position and in said activation position;
• and
• wherein the entirety of said key top support layer is downward and below said display layer.

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 resilient 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 an arcuate 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, to form 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 resilient 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 an arcuate 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 an actuate at least one of the switches when a predetermined force is applied to said single of said key tops.