The back panels for membrane switches make the integral position for the users providing the back supporting surface that gives something to push against. In the back panel membrane switch, the position of membrane switches is important.

Membrane switches are momentary electrical ON/OFF switches. These switches help in either activating or deactivating the circuit associated with the device. These switches, however, require rigid support as a layer or we called them back panels.

Whilst activating the switch, the back panel hence provides users with something to support their push. Therefore, the applications of these back panels vary in great numbers. For this reason, the shapes, design as well as material for back panels are available in a variety of materials. It, nevertheless, depends upon the purpose of use.

Nonetheless, there remains the condition that these back panels must be in a flat shape. This is because turning the switch ON/OFF becomes really hard when there is an uneven surface or bumps.

Types of Back Panels for Membrane Switches

The most common material for making the back panel membrane switch is aluminum. This is because the aluminum suits the best when there is so much hardware present in it. The way the aluminum we use as back panels in membrane switches present in many forms.

It can be anodized, painted, bare-open, Alodine as well as iridized. Plastic, however, also makes its way amongst the back panels for membrane switches. Plastic molding injection is the major way to form these back panels front covers.

There nevertheless are other metals that also are famous for making the back panels for membrane switches. Stainless steel, acrylic, polycarbonate, and well as ABS plastic are the common materials for making back panels. Some of these are:

Plastic Injection Molding Cases

The plastic injection molding cases carries a molded cavity that helps the back panel membrane switch to get itself fit in it. Membrane switch in this way hence receives the membrane switch. It flushed along with the case surface.

The medical industry thereby is the most common application for the plastic molding case. These plastic injection molding cases however come in one single piece. This is because these cases exactly match the color as well as the texture of the membrane switches. Switch actuation issue however is the common problem. For this therefore it is necessary to avoid making or designing the parting lines, injector pins as well as bosses.

Metal Back Panels for Membrane Switches

On the other hand, there also are metals that are common in back panel membrane switches. These panels however are very much common in industrial applications. Corrosion, however, is a very common problem in metals.

For this reason, aluminum, as well as steel, are the most widely used metals. To avoid corrosion, hence these metals carry a protective finish to avoid such issues. Therefore, black anodized aluminum back panels are very much common in membrane switches.

This is because making them in any desired shape, thickness, as well as shape, are the achievable targets.

Circuit Boards Back Panels

Upon lacking the circuitry in printed circuit boards (PCB), these circuits are very much common in making membrane switches. This makes the circuit boards a metal panel that appears light and non-conductive.

Furthermore, this circuit board is similar to that of the hardware installed in the machines. In those instruments that must be lighter in weight, here therefore the circuit board panels are very much common. These instruments mostly are portable devices which are handy as well. This thereby includes radio controllers and telephone systems.

Things to Consider While Manufacturing the Back Panels for Membrane Switches

For making the back panel membrane switch, the leading manufacturing industries use in-house and state-of-the-art machinery. The state-of-the-art machinery is thereby very much helpful in fabricating these back panels in any shape and form.

By this it means that making it flat, creating holes, stand-offs, as well as studs, are not a difficult task. Furthermore, with the use of in-house and state-of-the-art manufacturing machinery thereby the manufacturers hence reduce the production cost to a significant level.

In this way, the cost of sub-contracting the operation and the related markup reduces to a great degree. Additionally, subcontracting the back panels for membrane switches requires abundant time. Therefore, using in-house machinery thereby reduces the cost as well.

Mechanical Dimension of Back Panels

In making or designing the back panel membrane switch it is imperative to look for the assembly tolerance factor. By this, it means that there are different mechanical dimensions that the manufacturer must follow in order to avoid any hassle.

The sub-panel is the reason that must hide behind the assembly. It therefore should not be visible from any angle. According to the standards of manufacturing the design thereby must be smaller in size to that of the membrane switch, both in height and width.

The recommended dimension must be around 0.20” shorter than that of the switch from all sides. Furthermore, the holes and the cutouts must also be according to the proper dimension. The standard figure dimension for cutouts and holes is 0.30” as larger. The cutout additionally that lies behind the window must therefore be 0.60” larger than that of the window.

Those manufacturers that are experienced in this production thereby include some special sorts of cutouts.

They however also leave subpanels and cutouts back panels’ edges free from any kind of tool marks. This because in making such instruments plastic injection molding is the most common method of production.

Special shapes are easy to make instrument by using the router machines, these machines help thereby in manufacturing contours and special edges as well. These factors ultimately make the manufacturers make their way in the competitive market.

Selection of Right Material

The selection of the right material is very much important in making the back panel membrane switch. There furthermore are a variety of materials available in making back panels for several applications.

Polycarbonate

Amongst these, polycarbonate material is the most common form of material in making the back panels. This is because these materials are easy to print stuff. Furthermore, die-cut, as well as embossing, also become very convenient and cost-effective while using polycarbonate.

However, there additionally are some disadvantages as well. It is that the material becomes wear off sooner than any other material that we use. Nevertheless, the life cycle of the polycarbonate is 100,000 cycles testing.

The polycarbonate material that doesn’t contain the coating is also prone and susceptible to damage. For outdoor applications, the hard coat must be the essential factor to protect it.

Polyester

Polyester, furthermore, is the most robust material that offers a superior lifecycle as well as strong resistance against chemicals. Even at the life cycle of 1,000,000 the material even then shows not a single chance of wear of.

However, due to its memorial properties, the polyester material thereby requires hydroforming then embossing it. The unit cost nevertheless as well as the hydroforming cost of the material is very much high. Additionally, the die-cutting of the polyester material is very difficult and not suitable as well. This is the reason the re-blading steel rule dies are not suitable for this material.

Both of these materials are available with hard coats as well as a variety of textures. However, both materials are very much common and susceptible to scratching. This is the reason the recommended option is hard coating the glossy material.

Final Thoughts

In an attempt to make a back panel membrane switch there is one thing that we must keep in mind. This is that every component of the back panel thereby must meet and exceed the exact requirement for the purpose that we design.