Market forces require that mobile phone manufacturers produce an ever- increasing variety of mobile phone. In order to benefit from economies of scale and to minimise design effort for a particular model of mobile phone, it is advantageous to mal<e use of components, wherever possible, which are common to a range of models.

With this in mind, in one aspect, the present invention provides a method of constructing assemblies for keypads with different key layouts using substrates each having the same pattern of electrical-contact regions formed thereon and domed contact elements, the method including the steps of selecting a first design of key layout; providing a first insulating layer having a plurality of apertures dependent on the first design; mounting the contact elements to confront corresponding electrical-contact regions of a first of said substrates with the first insulating layer disposed therebetween, each of said apertures being in register with a said contact element, thereby to produce an assembly having the first design key layout; selecting a second design of key layout, the second design being different to the first key layout; providing a second insulating layer having a plurality of apertures dependent on the second design; and mounting the contact elements to confront corresponding electrical-contact regions of a second of said substrates with the second insulating layer disposed therebetween, each of said apertures being in register with a said contact element, thereby to produce an assembly having the second design key layout.

This design methodology allows a substrate having a standard pattern of electrical contact regions to be used for a range of keypad designs having different key spacings. For each design, a customised insulating layer is used.

In another aspect, the present invention provides an assembly for a keypad, comprising: a substrate having a plurality of electrical-contact regions, each region being defined by a first electrical terminal and a second electrical terminal; an array of domed contact elements, the elements being mounted to confront a corresponding electrical-contact region and overlie only a portion thereof; an insulating layer disposed between the substrate and the contact elements and including a plurality of apertures, each aperture corresponding to an electrical-contact region, each element being depressible from a first natural bias position to a second distorted position in which a summit portion of the element passes through its corresponding aperture to contact its corresponding electrical-contact region, thereby to establish electrical connection between the first and second terminals of the corresponding electrical-contact region.

This structure of assembly for a keypad allows a substrate having a particular pattern of electrical-contact regions to be used for a range of keypad designs having different key spacings. It will be appreciated that this is achieved because, in one design, each contact element overlies a portion of the corresponding electrical-contact regions, whereas, in another design, each contact element can overlie a different portion of the corresponding electrical- contact region - thereby to provide for different key spacings.

Preferably, the area enclosed by the electrical-contact region is greater (preferably substantially greater) than the footprint area of the dome of the corresponding contact element. Advantageously, the former area is between 1.5 and 3 times the latter area. Preferably, the former area is approximately twice the latter area. The greater the area of the electrical-contact region relative to the footprint of the dome of the corresponding contact element, the more flexibility there is in locating the corresponding contact element.

In accordance with the invention, the eletrical connection between the first and second terminals can be achieved through 'edge connection' or 'centre connection'. In edge connection, when electrical contact between the first and second terminals is achieved, a section of the rim of a contact element and its summit portion contact the first and second terminals, respectively. In centre connection, the summit portion alone of a contact element provides contacts closely-spaced first and second terminals.

In accordance with the invention, examples of edge connection and centre connection can be included in a single keypad assembly design.

In a still further aspect the present invention provides an assembly for a keypad including an array of domed contact elements, a substrate having a plurality of electrical-contact regions, the contact elements being mounted so as to confront a corresponding electrical-contact region, each contact element being depressible so as to snap from a natural-bias position in which it does not contact the corresponding electrical-contact region to a distorted position in which a summit portion of the contact element contacts the corresponding electrical-contact region, wherein each contact element overlies only a portion of the corresponding electrical-contact region.

Exemplary embodiments of the invention are hereinafter described with reference to the accompanying drawings, in which: Figure 1 shows an exploded view of first and second constructions of the invention; Figures 2(a),(b) show cross-sectional views of part of the second construction of the invention illustrating it in use; Figure 3 shows a plan view of the domed contact element and electrical- contact region depicted in Figure 2(a); Figure 4 shows an exploded view of a third construction of the invention; Figures 5(a), (b) show cross-sectional views of part of the third construction of the invention illustrating it in use; Figure 6(b) shows a plan view of an electrical-contact region depicted in Figure 5(a) and Figure 6(a) shows an alternative configuration for the electrical-contact region; and Figures 7(a), (b) show schematic plan view of different keypads in accordance with the invention with different key spacings achieved using the same underlying circuit board.

Constructions of two alternative constructions for a keypad are illustrated in Figure 1. In both constructions, a contact membrane 50 is sandwiched between a keymat 10 having a body portion 12 on which depressible keys 16 are mounted and a circuit board 40 having electrical-contact regions 42, each region 42 corresponding to one of the keys 16. The contact membrane 50 provides an array of domed contact elements made from metal. Each contact element, designated by reference numeral 30, is arranged to lie intermediate a key 1 6 and its corresponding electrical-contact region 42. The two alternative constructions differ only in the structure of the contact membrane 50.

In the first construction, the contact membrane 50 comprises an insulating sheet 52 to which is applied a one-piece metal dome sheet 54.

In the second construction, the contact membrane 50 comprises an insulating sheet 52 to which is applied a layer of adhesive tape 56 having an array of metal contact elements 30 individually adhered thereto.

In each construction, the insulating sheet 52 includes apertures 53 which align with a corresponding contact element 30. The insulating sheet 52 serves to electrically insulate the dome sheet 54, including its contact elements 30, from the electrical-contact regions 42 in the case of the first construction, and serves to electrically insulate the contact elements 30 from the electrical- contact regions in the case of the second construction. In both cases, the apertures 53 permit the contact elements 30 to make and break electrical contact with the electrical-contact regions 42 as illustrated in Figures 2(a) and 2(b).

Figures 2(a) and 2(b) illustrate the operation of a single key 1 6 of a keypad in accordance with the second construction. The key 16 is mounted relative to the body portion 1 2 by means of a skirt region 18 which is flexible and permits the downward movement of the key 1 6 as shown in Figure 2(a) when it is depressed, but naturally biases it to occupy the position shown in Figure 2(a).

On their upper surfaces, the key 16, the body portion 1 2 and the skirt region 18 can be painted; the upper surface of the key 16 includes an indicia region 19 which is painted so as to bear an indicia serving to indicate the function of the key 16, for example, an alphanumeric character or other symbol. The key 1 6 includes a base 20 from which a depending projection or pip 22 centrally projects. The pip 22 is cylindrical and has an exposed end 24. The key 16, including the pip 22, the body portion 12 and the skirt region 18 are made from a single piece of silicon rubber. The contact element 30 is insulated from the underlying circuit board 40, as shown in Figure 2(a), by the insulating sheet 52.

(It will be appreciated that the circuit board 40 is shown separated from the contact membrane 50 only for ease of illustration.) Again, as shown in Figure 2(a), the keymat 10 is mounted such that a small spacing exists between the exposed end 24 and that part of the adhesive layer 56 covering a summit portion 32 of the contact element 30.

On the circuit board 40 in the electrical-contact region 42 beneath the key 16, a pair of electrical terminals 36a, 36b are formed. The terminals form a grid 35 of intermingled, but unconnected tracks, and are best seen (in plan) in Figure 3.

The electrical terminals 36a, 36b each comprise a plurality of parallel branch tracl<s 37a, 37b. The branch tracks 37a, 37b are arranged in an evenly-spaced row with the branch tracks of the electrical terminal 36a parallel and in alternating succession with that of the electrical terminal 36b. The electrical terminals 36a, 36b also comprise main tracks 38a, 38b which connect to an end of all of the respective branch tracl<s 37a, 37b. The main tracks 37a, 37b are spaced from and parallel to each other. Thus, any two neighbouring branch tracks 37a, 37b form part of different electrical terminals 36a, 36b.

The contact element 30 is distortable so as to snap from a first natural-bias position in Figure 2(a), in which the electrical terminals 36a, 36b are not electrically connected to each other to a second distorted position, as shown in Figure 2(b), in which the summit portion 32 of the contact element 30 provides electrical connection between adjacent branch tracks 37a, 37b of the electrical terminals 36a, 36b. In Figure 2(b), the summit portion 32 is illustrated as contacting only two adjacent branch tracl<s 37a, 37b. In other embodiments, the summit portion 32 can be larger and contact more than two branch tracks 37a, 37b when the contact element 30 is in its distorted position.

As can be seen in Figure 3, the area of the grid 35 is substantially greater than the area enclosed by the rim 33 of the base of the contact element 30. As a result and as illustrated by arrows A and B, this enables the contact element 30 to be positioned in a wide variety of mounting locations overlying a portion of the corresponding electrical-contact region 42.

In use, the user depresses the key 1 6 causing it to travel downward and thus the exposed end 24 of the pip 22 to bear against the adhesive layer 56 attached to the contact element 30. The continued travel of the pip 22 causes the continued distortion of the contact element 30, until it reaches a condition at which it snaps into the second position shown in Figure 2(b). The making of the electrical connection between the electrical terminals 36a, 36b enables external circuitry (not shown) to register the depression of the key 16. When the key 1 6 is released, the resilience of the contact element 30 propels the key 1 6 upwardly and the contact element 30 resumes its first position as shown in Figure 2(a). The resilience of the skirt region 18, then causes the key 16 to re- adopt its position in Figure 2(a).

In other embodiments, the adhesive layer 56 can include an array of apertures (not shown) which allow pips 22 to act directly on the summit portions 32 of the contact elements 30.

The operation of a keypad in accordance with the first construction is not illustrated as its performance in use is the same as the second construction.

A third construction for a keypad 5 is illustrated, in exploded form, in Figure 4.

Where similar parts of the third construction are similar to analogous parts in the first or second constructions, the same reference numerals have been used.

In this construction, a contact membrane 50 is sandwiched between a keymat 10 having a body portion 1 2 on which depressible keys 1 6 are mounted and a circuit board 40 having electrical-contact regions 42, each region 42 corresponding to one of the keys 1 6. The contact membrane 50 provides an array of domed contact elements made from metal. Each contact element, designated by reference numeral 30, is arranged to lie intermediate a key 16 and its corresponding electrical-contact region 42.

The contact membrane 50 comprises an insulating sheet 52 to which is applied a layer of adhesive tape 56 having the array of the metal contact elements 30 individually adhered thereto. The insulating sheet 52 includes apertures 53 which are arranged to align with a portion of the corresponding contact element 30.

Figures 5(a) and 5(b) illustrate the operation of a single key 16 of the keypad 5.

The key 1 6 is mounted relative to the body portion 1 2 by means of a skirt region 1 8 which is flexible and permits the downward movement of the key 1 6 as shown in Figure 5(b) when it is depressed, but naturally biases it to occupy the position shown in Figure 5(a). The key 16 includes a base 20 from which a depending projection 22 centrally projects. The projection 22 is frusto-conical and has an exposed end 24. The key 16, including the projection 22, the body portion 1 2 and the skirt region 1 8 are made from a single piece of silicon rubber. The apertures 53 in the insulating sheet 52 are shaped such that a first section 33a of the rim 33 of the base of the contact element 30 is insulated from the electrical contact regions 42 on the underlying circuit board 40 and a second section 33b of the rim 33 of the base of the contact element 30 is in contact with the electrical-contact regions 42 on the underlying circuit board 40. The keymat 10 is mounted as shown in Figure 5(a) such that a small spacing exists between the exposed end 24 and that part of the adhesive layer 56 covering a summit portion 32 of the contact element 30.

On the circuit board 40 in the electrical-contact region 42 beneath the key 16, a pair of electrical terminals or pads 36a, 36b are formed. The terminals 36a, 36b are best seen (in plan) in Figure 6(b). It will be seen from Figure 6(b) that the terminal or outer pad 36b, substantially surrounds the terminal or the inner pad 36a. Electrical connection of the inner pad to the rest of the circuitry is made possible by a conductor 37a which passes through a gap 37b formed in the outer pad.

In use, the user depresses the key 1 6 causing it to travel downward and thus the exposed end 24 of the projection 22 to bear against the adhesive layer 56 attached to the contact element 30. This causes the second section 33b of the rim 33 of the contact element 30 to make positive electrical connection with the outer pad 36b. (In the Figure 5(a) position, the second section 33b of the rim 33 of the contact element 30 may be in vague/unreliable electrical connection with the outer pad 36b or, alternatively, held slightly displaced therefrom by the adhesive layer 56). The continued travel of the projection 22 causes the further distortion of the contact element 30, until it reaches a condition at which it snaps into the second position shown in Figure 5(b), at which point the summit portion 32 mal<es positive electrical connection with the inner pad 36a. The making of the electrical connection between the pads 36a, 36b enables external circuitry (not shown) to register the depression of the key 1 6. When the key 1 6 is released, the resilience of the contact elements 30 propels the key 16 upwardly and the contact element 30 resumes its first position as shown in Figure 5(a). The resilience of the skirt region 18, then causes the key 1 6 to re-adopt its position in Figure 5(a).

Figure 6(a) shows an alternative configuration for the electrical contact region 42. This alternative configuration behaves functionally (so far as the operation of the key 1 6 is concerned) in a manner identical to that of the Figure 6(b) configuration. However, the Figure 6(b) configuration differs structurally in that the outer pad 36b, completely surrounds the inner pad 36a. Electrical connection of the inner pad to the rest of the circuitry is effected by means of vias formed in the circuit board 40.

Figures 7(a) and 7(b) illustrate how two circuit boards 40 having the same pattern of electrical contact-regions 42 formed on them can be used in the realisation of two significantly different keypad layouts.

In other embodiments, the adhesive layer 56 can include an array of apertures (not shown) which allow the projections 22 to act directly on the summit portions 32 of the contact elements 30.