Molex Corporation

Todd A Hester

Robert M Fuerst

Fred L Krehbiel

Joseph D Comerci

Robert W DeRoss

Paul Christopher Berg

Edward S Sommer

Harry N Etters

Don A Arneson

Daniel T Kreger

An electronic device includes a flat flexible dielectric substrate less than 0.050 inch thick and having a generally round hole of a given diameter. A substantially square or polygonal terminal pin is inserted into the round hole in the substrate. The pin has a given cross-dimension between opposite diametral corners thereof greater than the diameter of the round hole. The difference between the cross-dimension of the pin and the diameter of the round hole is on the order of 7% to 67% of the diameter of the hole.

Terminal pins mounted in flexible substrates

A method of fabricating an improved electronic device, along with the product of that method is disclosed. A flat flexible substrate is provided with a generally round hole of a given diameter and with a conductive film on the substrate in an area at least about the hole. A generally round terminal pin is provided with a given diameter greater than that of the hole. The difference between the diameter of the pin and the diameter of the hole is on the order of 5% to 50% of the diameter of the hole. A non-conductive adhesive is applied to a portion of the pin or the substrate surrounding the hole. The pin is inserted into the hole in the substrate such that the non-conductive adhesive is scraped longitudinally from or along the pin to an area about the hole and the pin, leaving the pin in contact with the conductive film. An improved interface is established between the pin and the conductive film of the substrate.

Method of fabricating electronic device employing a flat flexible

A normally closed electrical switch includes a first circuit board having a first switch contact thereon and an aperture therethrough near the first switch contact. A second, flexible circuit board has a second switch contact aligned with the first switch contact of the first circuit board. A spacer sheet separates the first and second circuit boards and has an aperture in registry with the aperture in the first circuit board. The switch contacts extend toward each other through the aperture in the spacer sheet such that they are in normally closed condition. A movable cover is provided on the first circuit board at least over the aperture therein. An actuator is operatively associated with the cover and extends through the aperture in the first circuit board, through the aperture in the spacer sheet and engageable with the second, flexible circuit board for flexing the second circuit board and opening the switch contacts in response to movement of the cover. At least one of the circuit boards may be embossed in the area of its respective switch contact so that the contact projects through the aperture in the spacer sheet.

Normally closed electrical switch

An electrical switch assembly is disclosed to include a housing mounting a pair of spaced switches. A rocker actuator is rockably mounted for movement relative to the housing about a rotational axis between the spaced switches, and with wing portions of the actuator on opposite sides of the rotational axis provided for alternatingly actuating the pair of switches. The rocker actuator is a one-piece component and includes a relatively stiff rocker arm rockable about the rotational axis, a connecting flange projecting outwardly from the periphery of the rocker arm, and an integral flexible intermediate wall joining the rocker arm and the connecting flange. The flexible intermediate wall supports the rocker arm in a neutral position. However, the rocker arm flexes the intermediate wall when the rocker arm is rotated about the axis in either opposite direction from the neutral position to alternate actuating positions. The flexible intermediate wall is of a material to return the rocker arm automatically to the neutral position when pressure on the rocker arm is released.

Rocker switch with improved rocker actuator

An electronic device which includes a circuit sheet having a conductive path thereon. An adhesive is deposited on the conductive path, the adhesive including a nonconductive base incorporating randomly spaced conductive particles. A circuit component is forced through the adhesive, the conductive path and the circuit sheet carrying a portion of the adhesive therewith between the circuit component and the conductive path. The carried portion of the adhesive is compressed for establishing contact between the conductive particles and thereby conductivity between the circuit component and the conductive path leaving the adhesive other than that portion in a nonconductive state.

Growing community of inventors

Montgomery, IL, United States of America

Todd A Hester