JRPanel Tells You How A Membrane Switch Is Produced

 

Membrane switch is a new type of high-tech switch with decorative function and marking function; besides the switch and manipulation function of switch element, membrane switch also has switch connection and lead wire (that is, Switch circuit) function, with transparent window for reading display and transparent window for indicator light. Because the membrane switch has the characteristics of simple structure, beautiful appearance, excellent environmental resistance, long service life, light, thin, short, small, etc., it conforms to the development direction of modern electronic instruments with high integration and high intelligence, therefore favored by high technology products.

 

The membrane switch uses screen printing as the main process method. The main production process is as follows:

 

Engineering drawing--color separation/ film production--material cutting--color matching/ink adjustment--silk print screen making--screen printing--drying-positioning holes/metal shrapnel, LED, etc.--assembly--punching and forming--functional testing- packaging-delivery

 

Engineering drawing

 

According to the product parameters of the system order and the original drawings of the customer, we draw the CDR silk screen originals (vector high-definition drawings). At the same time, according to our process capability, we need to make corresponding adjustments, and send the drawings and related EQs to the customer for confirmation. If the production drawings and EQs are finally confirmed to be okay, they will be handed over to the factory engineer for document color separation and related film production, and the operation technology and processing requirements of each process will be compiled, and next comes the production.

 

Color separation/ film production

 

JRPanel uses screen printing, and each color needs to be printed separately. Therefore, before silk screen printing, different colors need to be separated to make film of each color. In addition, according to the drawing, if it is a switch, it is also necessary to make circuit film, as well as the drawing design of surface adhesive layer, inter layer adhesive, and back adhesive. After all the drawings are completed, they are handed over to the film production department for film production. After the film is completed, the engineer needs to recheck with the drawing, and after confirming that it is correct, it will be handed over to the production department for production.

Material cutting

 

The engineering designer will make the imposition according to the product size, quantity, material, etc. of the order, and also need to consider the spacing between the panels and the relevant margin to give the cutting personnel the final imposition dimensions.

 

The cutting staff will select materials and cut the materials according to the production imposition size and material; after the cutting is completed, it will also be reviewed, and after confirmation, it will be transferred to the screen printing process.

 

Color matching/ink adjustment

 

After the production drawings are confirmed by the customer, the color grading engineer will compare the Pantone color card or RAL color card or CMYK color according to the color number on the final confirmation drawing, and color them one by one; before the formal silk screen, it is necessary to repeat the printing materials. After printing, repeat the comparison with the color card until the color is adjusted to the color closest to the customer's requirement (compare Pantone color card or RAL color card or CMYK color), and then transfer it to the screen printing department for screen printing.

 

After the colorist adjusts, he will also make a record and compile the proof number to facilitate subsequent order adjustment and selection. [Note: Toning is performed by professional colorists, who have rich experience and proficient in the adaptability of inks to printing materials, and will relatively quickly call out the colors that are closest to the customer's needs. Because the colors are all adjusted based on the principle of three primary colors, they can only be relatively closer to the color card, and cannot be exactly the same as the color card. Please understand this point. The color closest to your needs, it is best to provide actual samples, so that the color difference can be minimized.

 

Silk print screen making

 

Screen production staff, according to the color/line film of a single order provided by the engineer, make film screens one by one. The screen production adopts the direct plate-making method of photosensitive paste. The plate maker coats the stretched screen with a photosensitive paste of a fixed thickness (usually a diazonium photosensitive paste), then it is dried and then plate-making The film is attached to it and placed in the exposure machine for exposure, and after development, washing, and drying, it becomes a screen printing screen. After the screen printing is completed, check it again with the film, and after the check is correct, it will be transferred to the screen printing process.

 

The quality of the screen printing screen directly affects the quality of the subsequent screen printing. According to the requirements of the plate making process, the plate maker will strictly control the drying, exposure, development and other links in order to obtain a high-quality screen template.

 

Screen printing

 

The basic principle of screen printing is to use the basic principle that the screen printing plate's graphic part has a mesh through ink, and the non-graphic part is impervious to ink. When printing, pour ink on one end of the screen printing plate, and use a squeegee to apply a certain pressure on the ink position on the screen printing plate while moving toward the other end of the screen printing plate. The ink is squeezed from the mesh of the graphic part to the substrate by the squeegee while it is moving. After many times of printing in different colors, we get the pattern style required by the final customer. Screen printing is a very important and core step in the production of the entire membrane switch/panel layer.

 

After the screen printing screen, materials, and color inks are complete, the screen printers will print the inks one by one in the order of the color screen printing according to the production process card. Each time a color screen is completed, it needs to be dried, and then transferred to the next One color silk screen until all colors are printed.

 

After each color silk screen, a self-check will be carried out. At the same time, the first product is strictly submitted for inspection and 100% self-inspection, and the semi-finished product is sent to the quality inspection department for semi-finished product inspection after the silk screen process is completed. After the inspection is qualified, complete the product silk screen of all order quantities.

 

Drying

 

Because the screen printing ink is liquid, there is a preliminary drying process after each screen printing process, but the ink is not completely dried. Therefore, after all the screen printing processes are completed, a baking treatment is required in an oven until the ink is completely dried and cured. After drying, it will go to the process of drilling positioning holes.

 

Positioning holes/metal shrapnel, LED, etc

 

Before assembling, it is necessary to make positioning holes on each layer. Assembling through positioning holes can ensure that the layers of the membrane switch panel can be well aligned, reduce deviation, and also improve the yield rate of assembly and reduce the scrap rate.

 

Embossed buttons: Because the membrane switch mainly functions as a button switch, the buttons are often embossed. This can enhance the touch of the switch and enhance the customer's role in quickly positioning the buttons. Custom molds are required for embossing. Return orders or punches with the same bump position can be reused. The thermal bumping cost is higher. The embossing is mainly controlled by the pressing time, temperature and air pressure.

 

Metal shrapnel: Customers usually choose two types of shrapnel, gold-plated and nickel-plated, as well as silver-plated shrapnel. The customer chooses the switch with the metal shrapnel button, the mounter will design according to the order drawing, select the metal shrapnel of the appropriate size, first adhesive it with the lower circuit with the inter layer adhesive, and fix the metal shrapnel on the lower circuit pad.

 

LED sticking:In the customer's design, if there is an LED design, after the circuit is completed, the mounter will select the LED according to the color requirements of the drawing design. After the LED is soldered, it needs to be dried. And carry out the lighting test, after the test is correct, transfer to the assembly process.

 

Die-pressing Keys:Through the "pressing and convex" process, the silver paste disc of the button on the circuit is pressed out with a mold to form a convex key. The convexity of the silver paste needs to use the mold, especially for batch orders, which needs to be customized. The convex mould can greatly improve the production efficiency and the stability of product quality.

 

The bottom adhesive and back adhesive are mainly used to complete the connection with the customer's machine part. Reinforcement is divided into cable end reinforcement without terminal shells or pins, mainly to increase thickness or flatness, so that the product can be closely connected or bonded to the customer's machine.

 

Assembly

 

The membrane switch is composed of multiple layers, and each layer is made separately. Usually, the membrane switch consists of 6 layers. Finally, all layers need to be positioned through positioning holes, stacked in the order of each layer, and aligned up and down, then assembled and adhesived together.

 

Punching and forming

 

The imposition size during production is not the size of the final product. After assembly, the product will have a lot of margins. Therefore, it is necessary to use special tools and equipment such as die cutting machine, laser cutting machine and other equipment to cut the adhesive and silk-screened sheet shapes used. Cutting is the basis of assembly.

 

For sample orders, laser cutting is used by default to form the final product shape and internal slots; for batch orders (>=100pcs), die cutting is adopted, the product size will be more precise and consistent, the cutting edge will be flatter. For the batch orders, the single cost will be very low. The knife mold can be reused, as long as the order is returned or the order of the same shape/slot hole, the knife mold (shape mold) can be shared, which can also save costs.

 

Functional testing

 

For each product, JRPanel will perform 100% functional testing before packaging. First, self-check to see if there is any deviation in the appearance and the screen printing is not good, and then use the detector to test each button one by one according to the principle of the circuit to see if there are problems such as open circuit, short circuit, and excessive resistance.

 

Packaging

 

After the membrane switch/panel test is completed, the packaging department will count and pack the quantity according to the order quantity. For each product, the packer will match the product design with suitable and stable packaging. After packaging, label it (the label contains the order number, production date, quantity, etc.), scan the code, and wait for shipment.

 

Delivery

 

After the product is packaged, it is transferred to the shipping department, and the shipper will contact the relevant information of the system order again, such as the order package, the amount of the order, and the quantity of each item. After ensuring that all the information is accurate, the courier tracking number will be printed through the system and the waybill number will be entered into the system at the same time. If you have subscribed to SMS, SMS will be automatically sent to notify that the product has been shipped.

 

In each process of membrane switch panel manufacturing, rigorous operation is required, and each process cannot be separated from quality inspection work to ensure the perfect presentation of the finished product.

 

JRPanel has been continuously improving production efficiency and process capabilities to continuously meet the needs of more and more customers. We will strive to be the benchmark of industry speed and quality, and look forward to growing together with customers.