Abstract:
An optical switch assembly for a two-way radio has electrical and mechanical subassemblies. The electrical portion consists an IR emitter (12) and a pair of IR receivers (14,16) strategically positioned upon a printed circuit board (10). The mechanical portion consists of a rotatable interposer mechanism (20) interconnected to a knob (35) on the radio via a shaft (28). The interposer has inner (22) and outer (24) concentric cylindrical walls. The outer wall controls the light transmitted between the emitter and one of the receivers (16), ultimately controlling the On-Off state of the radio. The inner wall has an integrated gray-scale graphic which controls the transmission of light between the emitter and the other IR receiver (14), ultimately controlling the audio output of the radio.
Abstract:
A rapid method for fabricating a precision electrical discharge machining (EDM) electrode (71). A set of master parts (31, 32) in the shape of the EDM electrode is formed using stereolithography or other rapid prototyping techniques (106). The master parts are assembled and a flexible material is molded (109, 56, 57) in them to form a flexible mold (111, 61). The flexible mold is then filled (115) with electrically conductive powder and the powder is cold isostatically pressed (117) to solidify it and form the EDM electrode.
Abstract:
A method of fabricating an elastomeric keypad having a hard key cap over the elastomeric key. A sheet (50) containing a key cap (24) with graphics (26) is placed onto a first plate (52) of a molding tool (54). A second plate (58) is then attached to the first plate, covering the graphic film. The first plate and the second plate interact in a manner such that the key cap containing the graphic is excised out of the film and retained in the molding tool assembly. The waste material (60) surrounding the key cap is displaced away from its original position. A third plate (64) is then attached to the assembled first and second plates. The assembled molding tool creates a cavity (66) that is representative of the keypad assembly, and an elastomeric material is molded into that cavity. Afar the elastomeric material (12) solidifies, the tool is opened, the molded keypad assembly (10) containing the integrally attached rigid key caps is removed.