Membrane Switch

Membrane switch is a new type of high-tech switch with decorative function & 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. Favor of technology products.
The membrane switch uses screen printing as the main process method. The main production process is as follows:

Membrane Switch Production Process

01. Engineering Drawing

02. Design & Film Making

03. Material Cutting

04. Color Matching / Ink adjustment

05. Silkscreen Making

06. Silkscreen Printing

07. Drying

08. Positioning & SMT

09. Assembly

10. Outline Making

11. Functional testing

12. Packaging

13. Shipment

01 Engineering Drawing

According to the product parameters of the order and the original drawings of the customer, then engineering will draw the CDR original (vector high-definition drawing). At the same time, we need to make corresponding adjustments according to our process capability. We will send the drawings and related EQs to the customer for confirmation. If the production drawings and EQ are finally confirmed to be ok, 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 the production will officially enter.

02 Design & Film Making

JRPanel uses silkscreen printing, and each color needs to be printed separately. Therefore, before silkscreen printing, different colors need to be separated to make each color film. In addition, according to the drawing, if it is a membrane switch, it is also necessary to make circuit film, and the drawing design of the surface adhesive layer, interlayer 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 finished, 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.

03 Material Cutting

The engineering designer will make panel according to the product size, quantity, material, etc. and also it need to consider the spacing between the panels and the relevant margin. Finally, the final imposition dimensions are given to the cutting staff. The cutting worker will select the materials and cut the materials according to the production panel size and material; after the cutting is completed, it will also be rechecked and confirmed to be correct, and then the cutted material will be transferred to the silkscreen printing process.

04 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 He will adjust the colors one by one; before the formal silkscreen, it is necessary to repeat the printing materials. After printing, it is repeatedly compared 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 the finished ink will be transfered to the silkscreen printing department for silkscreen printing. After the colorist adjusts, he will also make a record and compile the proof number to facilitate subsequent order adjustment and selection. [Note: Color-adjustement is done by the professional colorists, who have rich experience and proficient in the adaptability of inks to the printing materials, and he can adjust the colors closest to the customer's needs relatively faster. Because the colors are all adjusted according to the principle of three primary colors, they can only be relatively closer to the color card, and it cannot be exactly the same as the color card. Please understand this point. it is best to provide actual samples and this can be closest to your color needs, as the color difference can be minimized.]

05 Silkscreen Making

The platemaker will accord to the color/ circuit film of a single order provided by the drawing engineer and make silkscreens one by one. The silkscreen production adopts the direct plate-making method of photosensitive paste. The platemaker coats the stretched screen with a fixed thickness of photosensitive paste (usually a diazonium salt 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 silkscreen printing screen. After the screen printing is completed, and check it again with the film, and after the check is correct, it will be transferred to the silkscreen printing process. [ The quality of the scsilkscreenreen 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 high-quality screen templates. ]

06 Silkscreen Printing

The basic principle of silkscreen printing is to use the basic principle that the silkscreen printing plate's graphics and text parts are ink-permeable, and the non-graphic parts are not ink-permeable. 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 silkscreen printing plate. The ink is squeezed onto the substrate by the squeegee from the mesh of the graphic part while 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 screens, materials, and color inks are ready, the silkscreen 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 printing 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. After the error is correct, go to the next process. At the same time, the first piece is strictly submitted for inspection and 100% self-inspection. After the silk screen process is completed, the semi-finished product is sent to the quality inspection department for semi-finished product inspection. After passing the inspection, complete the product silk screen of all order quantities.

07 Drying

Because the silkscreen 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 silkscreen printing processes are completed, a baking treatment is required in an oven until the ink is completely dried and cured. After drying, the finished Graphic overlay will be transferred to the process of drilling positioning holes.

08 Positioning & SMT

Before assembling, it is necessary to make positioning holes on each layer, and assembling through the positioning holes can ensure that the layers of the membrane switch can be well aligned, this can reduce deviation, and at the same time, it can improve the yield of assembly and reduce the scrap rate.
Embossed buttons: Because the membrane switch is mainly used for buttons, the buttons are often embossed. This can enhance the touch feeling of the switch, and at the same time, it can enhance the function of customers to quickly locate the buttons. Custom molds are required for embossing. The mould can be reused for the re-orders or punches with the same embossed key position. The embossing process has cold embossing and hot embossing. For the cold embossing, which is usually for the conventional buttons.For the ,hot embossing, it is mainly used for remote control buttons or high requirements for button feeling. The hot embossing mould cost is higher. The operating pressure of embossing is mainly controlled by the time, temperature and air pressure of embossing.
Metal Dome: Customers choose gold-plated and nickel-plated dome, as well as silver-plated dome. The customer chooses the switch with the metal dome button, the mounter will select the appropriate metal dome according to the production drawing, They first glue it with the lower circuit with the fixed layer, and then fix the metal dome on the lower circuit pad.
Solder LED: If there is an LED design in the customer's design, after the circuit is completed, the mounter will select the LED colors according to the requirements of the drawing design.the LED is soldered to the lower circuit After dispensing. After the LED is soldered, it also needs to be dried. And it will do the lighting test. After the LED test is correct, the circuit layers will transfer to the assembly process.
Die presssing: Through the "pressing convex" process, the silver paste disc of the button on the circuit is pressed out with a mold to form a embossing key. The embossing of the silver paste requires the mold, especially for batch orders, which need to customize the embossing mold, This can greatly improve the production efficiency and the stability of product quality.
The rear adhesive is 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.

09 Assembly

The membrane switch is composed of multiple layers, and each layer is made separately. Usually, the membrane switch is composed of 6 layers, such as: Graphic overlay (graphic layer), upper adhesive layer, upper circuit (silver paste raised layer), lower Circuit (lower circuit with silver paste or lower circuit layer with metal dome or LED mounted), Rear adhesive layer, etc.,
Finally, all layers need to be positioned through positioning holes, and stacked in the order of each layer, and aligned from up to down, then assembled and glued together.

10 Outline Making

The size of the panel 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 cutters, laser cutting machines and other equipment to cutout the membrane switch panels. The 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 accurate and consistent, the cutting edge will be flatter, and the batch size Orders, allocated to a single cost will be very low. The cutting mold can be reused, as long as the order is returned or the order of the same shape/slot hole, the cutting mold (shape mold) can be shared, which can also save costs.

11 Functional testing

For each product, JRPanel will conduct 100% functional testing before packaging. First, Visual checking is to see if there are deviations in appearance and poor silkscreen, and then use the detector to detect each button one by one according to the principle of the circuit to see if there are problems such as open circuit, short circuit, excessive resistance, etc., and it also will pay attention to the sensitivity of the buttons ( for metal dome, it need to check whether there is a double dome), whether the detection lamp with LED is on or is always on and the brightness is not good, Also it need to check with the sample, each product should be sampled continuously for life testing (usually it can be confirmed as qualified if it is tested to 500,000 times ).

12 Packaging

After the membrane switch/panel test is completed, the packaging department will count and pack the products according to the order quantity. For each product, the packer will match it with a suitable and stable package according to the product design. After packing, they put a label (the label contains the order number, production date, quantity, etc.), and then scan the code and put it in the warehouse, and wait for delivery.

13 Shipment

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 number will be printed through the system and the waybill number will be entered into the system at the same time. A shipping email will be sent automatically to notify that the product has been shipped.
We will cooperate with DHL to ensure the fastest and safest transportation method for customers, and to be sure that products can reach customers fast and safety. For the delivery, JRPanel choose DHL as default. And also it is ok to choose: EMS, Fedex, UPS, HK Post.

In each process of membrane switch manufacturing, rigorous operations are required, 
and each process is inseparable from quality inspection to ensure the perfect presentation of the finished product.
JRPanel has been continuously improving production efficiency and process capability to 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.