Integrating Windows in Membrane Switches

Integrating Windows in Membrane Switches​

Graphic Overlays with Display Windows

It is very common for our membrane switches to be applied above a display.  When this is the case, our graphic overlays can be designed and manufactured with a transparent or translucent window for viewing the display from the front of the panel. The window design is typically contingent on the type of display being used in order to maximize the visibility and readability of the display.

LCD displays require clear windows therefore typically utilize windows with minimal filters with a gloss finish. Anti-glare can also be used if required. LED segment displays require less clarity and typically utilize windows with optical filtering to maintain readability in brighter settings. VFDs usually accept a matte finish.

Graphic overlays with windows are typically manufactured using the following:

    • Gloss
    • Hard-coat
    • Scratch-resistant polyester
    • Polycarbonate

The first surface (or top surface) is typically selectively textured leaving the windows glossy while offering a secondary matte surface finish. 

Windows can also be smoked and printed color dyes can be added to produce red, green, yellow, etc. to produce filters or tints.

Additionally, the LCD windows can be manufactured with alternative gloss levels for anti-glare if the membrane switch is used outdoors in a bright environment.

Optically bonded windows can also be integrated into the window design which adds thickness and durability to the window to make up air gaps between the display and window to prevent window damage.

Opti Bonded Membrane Switch

What are the Differences Between Screen Printing, Digital Printing & Pad Printing?​

What are the Differences Between Screen Printing, Digital Printing & Pad Printing?​

Screen Printing:

Membrane switches have always utilized screen printing to print circuits and graphic overlays. 

Screen printing is a process that uses a woven mesh stencil to transfer ink to the material underneath or substrate. The stencil contains the actual design or artwork. The screen sits atop the product that will receive the image and a squeegee is moved across the screen to fill the open mesh apertures with the ink to create the design on the substrate.

The process was known as silkscreening because silk was originally used as the material. Nowadays, synthetic materials are used in the screen printing process typically polyester, nylon, or stainless steel materials. 

 

Digital Printing:

Digital printing is the process of sending information from a device, typically a computer, to the printer using digital files created by graphics software. The information is reduced to binary code for storage and reproduction. 

Digital printing is ideal for membrane switch designs that are more complex than the traditional artworks such as 3D graphics, textures, fading, half-tones and other effects that cannot be screen printed.

Pad Printing:

Pad printing is a process that transfers a 2D image onto a 3D object. Pad printing is typically used to print images on to more difficult products or surfaces. It involves three main components: an etched plate, a silicone pad to transfer the image, and the substrate. An image is etched into the flat printing plate which is then filled with ink. The silicone pad has a very smooth surface with chemical resistances which is then used to carry the ink from the plate and transfer it onto the object. The silicone material is ideal because it does not absorb the ink and can adapt to irregular shaped surfaces.

Membrane Switch Overlay Material Guide

Membrane Switch Overlay Material Guide

Due to the customized nature of membrane switch designs, it can be somewhat challenging to choose the proper overlay material. There are a few major factors that must be considered when choosing the overlay material including but not limited to the finish, thickness, and environment. CSI has outlined the materials in the guide below to make this process easier and less daunting.

Pantone Color Matching for Graphic Overlays

Pantone Color Matching for Graphic Overlays

What is the Pantone Color Matching System?

The Pantone Color Matching System or PMS is a common industry standard for color reproduction. It is regularly used in graphic overlays design, publishing, and printing companies. Instead of asking for just the color “green”, Pantone can give you the exact shade of green and allow you to communicate that red to others in a standardized, no-nonsense, uncomplicated, communicative way.

Why is the Pantone Color Matching System used?

Pantone Color Matching System is used to help clearly communicate specific and standardized colors and prevent confusion or a problem with manufacturing and printing. It allows special colors to be used and produced from metallics to fluorescents. PMS allows businesses and customers to reference and match colors no matter the media: ink or online. It allows a consistency and uniform base that will not cause a mix up in the final product.

How does PMS Work?

There are several different ways of using PMS, one of which is called the CMYK process which only uses four primary colors: cyan, magenta, yellow and black. You may recognize this as the colors that are used in your printer at home. Guidelines are used to provide the correct cyan, magenta, yellow and black colors – since there are several “versions” and shades. These colors are then mixed in specific amounts to create other colors that are calculated and communicated through the amount of each of the four colors distributes. There are, however, several colors that cannot be created with this process and instead uses 14 colors that are mixed in specific amounts. Pantone colors are given a specific number and that number is then communicated to produce a consistently based color among media.

What kinds of PMS tools are available?

The Pantone Formula guide is a three-guide set of 1,114 solid Pantone specified colors that come in coated, un-coated and matte coated. There are several different books, each for a different industry but each is similar in that it shows the corresponding formula for each color.

There are “chip” books that can be used for quality control. Manufacturers use these chips in order to make sure that the color on the product matches with the chip chosen so that the end product is exactly what the customer asked for. Pantone also provides chips and guides that have colors produced by the four-color process. There are also other color reference guides that include metallics, pastels, tints, duotones, film and foil. There are also online Pantone guides which can be used to reference colors on a computer or design program. Caution should be used when viewing and choosing colors on a computer screen, as each monitor has a different color output, and most are not calibrated for consistency.

What affects the accuracy of PMS?

The three main things that effect the accuracy of PMS is lighting, colors sent via computers and the material of the surface the ink will be printed on. It is best to color match under a controlled daylight viewing for a more accurate reading. In order to make a final decision on the color, it is also a good idea to look at the color under different kinds of light/in different lighting such as natural, fluorescent, UV, and incandescent. This is typically done with a Color Viewing Booth.

Computers may not show you the correct color because each computer screen is different. Your computer may have a higher or lower contrast than that of the customer’s, and most monitors are not calibrated to the same standard output.

Different materials can cause different results when using the same color on them. Each can react differently based on absorption and finish with the colored ink. Some surfaces absorb the ink more than others and will therefore give the color either a glossier or more subdued appearance. Because of this, it is important to note that different finishes on overall products and using the same color, will look different and many times not match well. This can sometimes be controlled by using different coating methods and techniques, however, to get the right look that the customer is looking for. Consideration must be taken towards the materials and finishes being used in combination with all colors of a product.

How is the Pantone Color Matching System used at CSI Keyboards?

There are many other color matching systems out there besides Pantone: Munsell, RAL and Federal Standard Color System. CSI typically uses the Pantone Color Matching System in order to consistently control products for our customers exactly the way they want them. We use it as a common reference to clearly communicate with our customers without the problem of inconsistent colors. As screen printers, CSI finds the Pantone Color Matching System one of the crucial tools we use as it provides us with a standard that our printers can live by and we have found it to be reliable throughout our years of service.

The Importance of the Graphic Overlay in a Membrane Switch

The Importance of the Graphic Overlay in a Membrane Switch

A membrane switch is the interface that connects the user to a machine, device, or other types of equipment. It is the control panel, facilitating functionality and enabling the user to control the product.

The graphic overlay is one of the most important aspects of the membrane switch. The graphic overlay is the faceplate to the membrane switch and often the product itself. The graphic overlay defines a product’s identity and is the visual layout and design of the interface that determines how easy or difficult a device is for the average user to operate. 

CSI Keyboards is in a class of its own when it comes to the design and production of high quality Graphic Overlays, Labels, and Nameplates. We have been manufacturing overlay products for a wide array of customers and industries for over 35 years. A graphic overlay not only enhances the aesthetic appearance of a product or device, but it can also provide environmental protection. A graphic overlay can also be applied to an assembly using discrete switches or laminated to a membrane or rubber switch depending on the design. CSI offers both silk screened and digitally printed overlays and labels in wide range of shapes, sizes, colors and finishes.  

Critical Features of the Graphic Overlay:

Environmental Conditions

You likely know what type of environment your product is going to end up in. Are there going to be some obvious environmental concerns? If so, it is critical that the right graphic overlay material is designed into your product, since different materials offer different environmental advantages.

Enhancing Usability

Usability is the ultimate goal of a user interface. The features of the graphic overlay can be used to enhance the overall usability of your product. By making the graphic overlay easier to feel, operate, and understand, raised buttons and embossed features can dramatically enhance its functionality. 

Building Your Brand

The visual impact of the graphic overlay cannot be underestimated. The graphic overlay is the faceplate to the membrane switch and often the product itself. The graphic overlay defines a product’s identity and is the visual layout and design of the interface that determines how easy or difficult a device is for the average user to operate. Based on our 35 plus years of experience, we can choose the ideal ink technologies and materials to deliver specialized textures, finishes, and colors. This allows you to create on-brand graphic treatments, powerful visual differentiation, and market-appropriate design cues. With specialized inks, we can match proprietary brand colors. With the right material, we can deliver the right texture and finish, from matte to high gloss. Add in transparent qualities and vibrant base colors, and you can start to see how may options you really have.

Digital printing gives us even more design freedom, in a very cost-effective way. With these technologies, we can reproduce photographs onto the graphic overlay, allowing you to specify any type of background pattern. Brushed aluminum or carbon fiber patterns for more sophisticated applications

Graphic Overlay Capabilities:

Surface Finishes:

  • Velvet
  • Gloss
  • Anti-reflective
  • Anti-microbial
 

Printing:

  • Screen printing 
  • Digital printing
 

Window Options:

  • Clear LCD or LED
  • ITO using optical clear lamination
  • Dead front
  • Smoked as well as translucent colors for backlighting
 

Embossing & Forming:

  • Finger guide, LED, braille, rim, pillow either as a standalone or combination of
  • Cold and hot embossing
  • Hydroforming
 

Cutting:

  • Laser traced steel rule dies
  • Tinplate high precision tools
  • Laser and CNC cutting