Keyboard Keys - Technology - Key Switches

Key Switches

In the first electronic keyboards in the early 1970s, the key switches were individual switches inserted into holes in metal frames. These keyboards cost from 80–120 US dollars and were used in mainframe data terminals. The most popular switch types were reed switches (contacts enclosed in a vacuum in a glass capsule, affected by a magnet mounted on the switch plunger – from Clare-Pendar in Post Falls Idaho, which became part of General Instrument, which used reedswitch capsules made by C.P. Clare Co. in Illinois; and Key Tronic Corporation of Spokane, Washington), Hall-effect switches (using a Hall-effect semiconductor where a current is generated by a passing magnet – from Microswitch in Illinois, which became part of Honeywell), and inductive core switches (again, activated by a magnet – from Cortron, which was part of ITW/Illinois Tool Works). These switches were rated to last for 100 million cycles and had 0.187-inch (4.75 mm) key travel, compared to 0.110 inch (2.79 mm) today.

In the mid 1970s, lower-cost direct-contact key switches were introduced, but their life in switch cycles was much shorter (rated ten million cycles) because they were open to the environment. This became more acceptable, however, for use in computer terminals at the time, which began to see increasingly shorter model lifespans as they advanced.

In 1978, Key Tronic Corporation introduced keyboards with capacitive-based switches, one of the first keyboard technologies to not use self-contained switches. There was simply a sponge pad with a conductive-coated Mylar plastic sheet on the switch plunger, and two half-moon trace patterns on the printed circuit board below. As the key was depressed, the capacitance between the plunger pad and the patterns on the PCB below changed, which was detected by integrated circuits (IC). These keyboards were claimed to have the same reliability as the other "solid-state switch" keyboards such as inductive and Hall-Effect, but competitive with direct-contact keyboards. Prices of $60 for keyboards were achieved and Key Tronic rapidly became the largest independent keyboard manufacturer.

Meanwhile, IBM made their own keyboards, using their own patented technology: Keys on older IBM keyboards were made with a "buckling spring" mechanism, in which a coil spring under the key buckles under pressure from the user's finger, triggering a hammer that presses two plastic sheets (membranes) with conductive traces together, completing a circuit. This produces a clicking sound, and gives physical feedback for the typist indicating that the key has been depressed.

The first electronic keyboards had a typewriter key travel distance of 0.187 inches (4.75 mm), keytops were a half-inch (12.7 mm) high, and keyboards were about two inches (5 cm) thick. Over time, less key travel was accepted in the market, finally landing on 0.110 inches (2.79 mm). Coincident with this, Key Tronic was the first company to introduce a keyboard which was only about one inch thick. And now keyboards measure only about a half-inch thick.

Keytops are an important element of keyboards. In the beginning, keyboard keytops had a "dish shape" on top, like typewriters before them. Keyboard key legends must be extremely durable over tens of millions of depressions, since they are subjected to extreme mechanical wear from fingers and fingernails, and subject to hand oils and creams, so engraving and filling key legends with paint, as was done previously for individual switches, was never acceptable. So, for the first electronic keyboards, the key legends were produced by two-shot (or double-shot, or two-color) molding, where either the key shell or the inside of the key with the key legend was molded first, and then the other color molded second. But, to save cost, other methods were explored, such as sublimation printing and laser engraving, both methods which could be used to print a whole keyboard at the same time.

Initially, sublimation printing, where a special ink is printed onto the keycap surface and the application of heat causes the ink molecules to penetrate and commingle with the plastic modules, had a problem because finger oils caused the molecules to disperse, but then a necessarily very hard clear coating was applied to prevent this. Coincident with sublimation printing, which was first used in high volume by IBM on their keyboards, was the introduction by IBM of single-curved-dish keycaps to facilitate quality printing of key legends by having a consistently curved surface instead of a dish. But one problem with sublimation or laser printing was that the processes took too long and only dark legends could be printed on light-colored keys. On another note, IBM was unique in using separate shells, or "keycaps", on keytop bases.This might have made their manufacturing of different keyboard layouts more flexible, but the reason for doing this was that the plastic material that needed to be used for sublimation printing was different from standard ABS keytop plastic material.

Three final mechanical technologies brought keyboards to where they are today, driving the cost well under $10:

1. "Monoblock" keyboard designs were developed where individual switch housings were eliminated and a one-piece "monoblock" housing used instead. This was possible because of molding techniques that could provide very tight tolerances for the switch-plunger holes and guides across the width of the keyboard so that the key plunger-to-housing clearances were not too tight or too loose, either of which could cause the keys to bind.
2. The use of contact-switch membrane sheets under the monoblock. This technology came from flat-panel switch membranes, where the switch contacts are printed inside of a top and bottom layer, with a spacer layer in between, so that when pressure is applied to the area above, a direct electrical contact is made. The membrane layers can be printed by very-high volume, low-cost "reel-to-reel" printing machines, with each keyboard membrane cut and punched out afterwards.
3. The use of pad-printed keytops (called "Tampo printed" at the time because Tampo was the most popular equipment manufacturer). Initially sublimation ink was used (see above), but very durable clear-coats are now printed over the key legends to protect them. These coatings are also used to reduce glare, and in many cases have an anti-microbial content added for user protection.

Plastic materials played a very important part in the development and progress of electronic keyboards. Until "monoblocks" came along, GE's "self-lubricating" Delrin was the only plastic material for keyboard switch plungers that could withstand the beating over tens of millions of cycles of lifetime use. Greasing or oiling switch plungers was undesirable because it would attract dirt over time which would eventually affect the feel and even bind the key switches (although keyboard manufacturers would sometimes sneak this into their keyboards, especially if they could not control the tolerances of the key plungers and housings well enough to have a smooth key depression feel or prevent binding). But Delrin was only available in black and white, and was not suitable for keytops (too soft), so keytops use ABS plastic. However, as plastic molding advanced in maintaining tight tolerances, and as key travel length reduced from 0.187-inch to 0.110-inch (4.75 mm to 2.79 mm), single-part keytop/plungers could be made of ABS, with the keyboard monolocks also made of ABS.