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Fortune 1000 companies depend on Monopanel for custom engineered membrane switch solutions where print houses are forced to deliver the infamous, “No Bid.” In typical membrane switch pioneer fashion Monopanel recently solved just such a complex membrane switch backlighting issue for a major industrial manufacturer.

The issue at hand; separate membrane switch display elements needing to be brightly backlit with NO bleed through from one backlit area to the next. While it sounds simple the Monopanel expert sales staff was reluctant to promise a perfect backlight display in this individual application. Once again the Monopanel team found themselves with a technically challenging project. The choices were as they have always been when it comes to breaking new ground in the membrane switch industry for Monopanel. Think like a printed circuit board manufacturer and deliver a, “No bid,” OR Monopanel could do what they have done countless times before….. Call on Monopanel’s ‘in house’ membrane switch engineering expertise.

This custom backlight membrane switch solution turned out to be simple after all. Simple that is to the head of engineering for the world standard in membrane switch technology. Monopanel’s membrane switch sales department did call on the engineering staff to deliver an economically feasible solution. On top of a great price, the requirement for bright backlighting with zero bleed through was the trick. Zero bleed through seemed to preclude film based membrane switch products from meeting the specified requirements yet Monopanel’s engineering team worked hand in hand with the various departments of the industrial manufacturer to meet the backlighting specifications. Samples representing Monopanel’s unique approach to backlighting the membrane switch assembly were produced and presented to the project managers just a week later.

Having begun to wonder if their expectations were too lofty the industrial manufacturer’s production team was shocked and delighted to see the overall brightness and the nonexistence of bleed through from one field to the next. This cutting edge LED backlighting membrane switch technology allows selective lighting of text and graphics at a price significantly less than other membrane switch backlighting strategies like fiber optics, EL (electro luminescence) and edge lens lighting. The backlighting was bright enough to be clearly visible under normal ambient light conditions.

The net result of Monopanel being involved in the engineering phase of production resulted in a design that met the customer specifications both from cosmetic and price point of view. Membrane switch technology moves forward at the hands of the innovative Monopanel engineering team again. Production on this cutting edge backlight membrane switch application with Monopanel is booked.

Technically speaking; The Backlight membrane switch solution Monopanel engineers left accepted membrane switch backlighting technology on the shelf in this instance. The custom membrane switch backlighting application started with a printed circuit board substrate. The printed circuit board substrate allows more options for surface mount device packages than film based embedded LED membrane switch lighting options.

Monopanel engineers decided to use the printed circuit board with daughter boards. The printed circuit board allowed Monopanel to backlight this membrane switch application with LED lighting soldered into place rather than glued in place with epoxy. The added benefit is soldered membrane switch assembly components have a stronger mechanical and electrical connection. It also allows for space to attach other SMD devices that may be an integral part of the switch and display. The advantages of the printed circuit board membrane switch substrate with optional daughter boards allows for the use of mounting studs and/or stand offs, mounting of seven segment LED’s, mounting of LCD or other types of displays and diffuses light thereby helping to eliminate the membrane switch backlighting problem of LED hot spots.

Monopanel is able to deliver selective backlighting of text and graphics in membrane switch assemblies at a significant cost savings over other membrane switch backlighting techniques like fiber optic, electro luminescence and edge lens backlighting. In fact, Monopanel is able to deliver the superior printed circuit board membrane switch backlighting for the same cost as printed film based membrane switch backlighting, in essence, delivering greater functional options at a base price point.

Printed circuit board membrane switch technology by Monopanel provides rigid backing eliminating the need for a second surface. Monopanel’s printed circuit board membrane switch substrate also offers better sealing capabilities in harsh industrial or medical membrane switch applications. AND Monopanel’s printed circuit board membrane switch technology allows flexibility in mixing electrical components with surface mounted devices and through holes for a completely tested front panel assembly.

This cutting edge ENGINEERED backlight membrane switch solution Monopanel has delivered may not be considered conventional; YET. In every aspect of membrane switch and membrane switch assembly, Monopanel continues to define the membrane switch industry, delivering bright advantages.

Monopanel Technologies, Inc. has formed another membrane switch manufacturing strategic alliance with Jiangsu Zhong Shan, a major manufacturer of membrane switches in China. This alliance brings to five strategic membrane switch manufacturing alliances Monopanel has with Asian membrane switch manufacturers and suppliers. These partnerships allow Monopanel to meet our customers' needs for high volume, low cost membrane switches and electronic assemblies . Monopanel's philosophy is to design membrane switches in the USA, specifying customer requirements and using the design criteria and processes that Monopanel has employed for over thirty years. Monopanel will then test the initial membrane switch products for performance requirements and add whatever is necessary to customize the membrane switch product and inventory the membrane switch products as required. These manufacturing alliances also put Monopanel in a unique position of being able to manufacture membrane switch product s domestically and overseas. The continual goal of Monopanel is to supply our customers quality membrane switches with deliveries that comply to their requirements and at the best price.

Membrane switch technology gets more complex as customer requirements expand. To keep ahead of the curve Monopanel has made a major upgrade to its automated assembly capabilities. With the addition of the Mirae model MPS-1030 pick-&-place machine, Monopanel positions itself as a premier membrane switch manufacturer. Membrane switches are no longer simply polyester layers laminated together, but rather complete pc board assemblies. Every component type can populated into a membrane switch assembly. With the addition of the MPS-1030 Monopanel can offer membrane switches produced with consistant quality and at a low cost from efficient manufacturing. The purchase is a demonstration of Monopanel's dedication to produce the highest quality membrane switch and determination to stay on the cutting edge of membrane switch technology.

Monopanel offers free custom design samples.
In an effort to introduce more companies to our high quality membrane switches and excellent service that Monopanel provides, Monopanel is offering 5 free custom designed membrane switch samples to qualified new customers. Monopanel will be giving companies their first sample run of membrane switches for free, whether it is a flex design or PC board based. This is an opportunity to have custom membrane switch samples built to your specifications for testing and evaluation at no cost. Qualifying is easy. Simply have a company web site, company email, provide a purchasing and engineering contact. Start the evaluation process by contacting a Monopanel sales professional to see if you qualify for this unique offer. Monopanel reserves the right to make the final decision on companies that qualify for this offer.

Membrane keypads are an attractive and low cost alternative to mechanical switches and other panel-mounted components in OEM applications. They offer a virtually unlimited choice of colors, graphics and materials, LED or liquid crystal displays.

At the same time, membrane switch technology is not by itself capable of replacing components that retain their state or settings, depend on analog inputs and outputs, or implement simple control loops.

Monopanel Technologies, Inc. (West Allis, WI) has been a leading manufacturer of custom membrane switch assemblies since 1974. Monopanel Technologies provides front panel assemblies that typically utilize rigid PCB substrates. The ability to provide complex value added assemblies differentiates Monopanel from other membrane switch suppliers and gives OEM customers a real competitive advantage. Their patented, tamper resistant, Endura-Switch^TM design provides a thick graphic overlay for harsh, abusive membrane switch environments.

In October 2000 Monopanel Technologies began working with a leading OEM supplier of industrial convection and infrared ovens, to provide an updated control panel for their printing plate industrial ovens. The current design utilized electromechanical switches, gauges, counters and timers manually assembled to a metal front panel. To bring the new design concept to reality Wisconsin Oven relied on the engineering resources of Monopanel and Adicon Consulting and Design (Milwaukee, WI). Adicon is a consulting and engineering firm providing electronic product development and software for industrial controls, instrumentation, data acquisition and communication products since 1986.

"Our partnership with Monopanel and Adicon on this project has proven successful" says Todd A. Schlender, Vice President, Sales & Marketing, Wisconsin Oven, "Our goals for a stylish, cost effective, and functional upgrade to our controls were all met in a timely and professional manner".

In the initial stage of the design, Adicon worked with Monopanel to provide digital, analog, and AC sensing and switching circuitry as part of an integrated front panel solution. Project goals included designing an interface between the membrane switch panel and the oven and combining various I/O functions on one controller board.

Mechanical switches were replaced with momentary membrane switches with status LED's. Speed potentiometers were removed from the panel and replaced with digital controls and isolated analog outputs to provide accurate control signals for variable-speed AC and DC drives. Four control-relays and related wiring were eliminated in favor of PCB mounted relays and incorporated into the new assembly without sacrificing dielectric isolation between AC circuits. The new design also provides programmability through the on-board processor, some enhanced control functions, and operator settings saved in non-volatile memory.

In addition to consulting and design services, Adicon supplied programming, component selection, testing and sourcing for the controller board assembly.

"Typical PCB components usually offer significant cost savings in key areas including power supply, solid state logic, and switching small loads. Combining the talents of two established providers of custom solutions simplified the specification and design process, and produced an almost seamless product with better features than traditional control panels with minimal NRE cost," said Peter Miczek, Project Manager at Adicon.

In parallel with the above efforts, Monopanel Technologies worked on the membrane switch front panel design. The new membrane switch was designed with second surface graphics and matte surface texture. This included custom embossed graphics on the function keys and embedded chip LED's for status indicators. Larger LED display modules replaced mechanical speed setting indicators for better visibility. The panel was laid out to make the controls more intuitive, so an operator can easily follow the control logic from one button to another. The new control panel replaced six electromechanical panel-mounted components and eliminated their control wiring and the associated labor cost. Terminal blocks were replaced with connectors and wire harnesses. Therefore, the final assembly of the finished unit has significantly fewer connection points and will prove to be simpler in assembly and more reliable in the field. In addition, the membrane switch was sealed from the front using an adhesive gasket around the perimeter of the overlay. This environmental seal provide improved chemical resistance while allowing easy cleaning of the front graphics.

"Taking this example one step further, the use of an integrated membrane switch solution can provide OEM customers with any combination of inputs and outputs, application specific functions such as interface to AC drives, sensors and encoders, embedded control loops and serial communication ports. Custom graphics on the panel overlay improve the appearance and ease of use of the product. Combining state-of-the-art membrane switch and display technology with I/O in one package reduces the number and cost of most components and connections, lowers the test cost of the final assembly and improves the reliability of the product," said Martin Hedrich, President and Chief Executive Officer of Monopanel Technologies.

In conclusion, teamwork between supplier and customer generated a final product with a more modern "solid state" user interface. The new panel keeps the same form factor and fits within the current oven enclosure. This synergistic approach helped Wisconsin Oven bring their new product to market in a timely fashion by utilizing engineering and design resources from Monopanel Technologies and Adicon Consulting and Design.

Monopanel and ADICON offer innovative solutions for industrial products, equipment, instrumentation, data acquisition and measurement systems. Custom control panels integrate membrane switches and I/O to mimic functions usually found in traditional electro-mechanical components and controls.

Membrane keypads are an attractive and low cost alternative to mechanical switches and other panel-mounted components. They offer a virtually unlimited choice of colors, graphics and materials, LED or LCD displays.

At the same time, membrane switch technology does not replace components that retain their state or settings, depend on analog inputs and outputs, or implement simple control loops, by itself.

An integrated control panel can support AC and DC inputs, relay contacts, analog I/O, temperature and pressure sensors, encoders, transducers, and various displays. The end product can also include application specific interfaces to electric motor drives, serial communication ports, and user-configurable control functions.

Product Features

• Overlay graphics with subsurface colors, surface textures, and embossing
• Spill-proof and washable overlays
• Backlighting, ESD/EMI shielding, optional rigid PCB substrates
• Tactile feedback options including metal/polyester domes or elastomer keys
• Endura-SwitchTM overlays for harsh membrane switch environments
• AC or DC digital inputs, relay outputs, analog inputs and outputs
• Serial communication port
• Embedded custom application software
• Supervisory and local control loop functions
• Interface to sensors, transducers, counters and timers
• LED and LCD displays

The example pictured above includes four control functions requiring eight membrane keys, multiple 7-segment LED displays, 10 isolated 120 V inputs and outputs, four relays, two analog outputs, and a temperature controller. Product design in collaboration with Monopanel Technologies Inc.

Monopanel Technologies now offers a membrane touch switch resistant to damage from pens, pencils, screwdrivers and other sharp objects. The new Endura-Switch^TM is easily actuated through a protective front surface and complies with standard membrane switch specifications.

"Endura-Switch provides unmatched durability, yet it can be actuated with a standard amount of force," said Martin Hedrich, president and CEO of Monopanel Technologies. "Depending on requirements of design, typical actuation forces of only 16 ounces are experienced."

Monopanel's Endura-Switch offers significant design flexibility. The unit's durable front surface can be constructed from a variety of materials including aluminum, stainless steel and polycarbonate. In addition, the patented switch design allows for a front surface thickness of up to .060 inches.

Endura-Switch can be customized for specific applications by applying a graphic overlay to its outer surface, or in the use of polycarbonate; outer surface or under side. The uniqueness of the design allows for the option of not having the front layer to be adhered to the actual switch, allowing for replacement without effecting the unit's functionality.

"Endura-Switch has proven to be effective in a wide variety of abusive environments," Hedrich added. "Typical applications include appliances, industrial equipment, petroleum pumps and other harsh environments."

Monopanel Technologies is a vertically integrated manufacturer of membrane touch switches. The company offers a broad spectrum of products, from simple flex switches to fully integrated, electronic switch panels. For more information about Endura-Switch, call Monopanel at (414) 256-5200.

MONOPANEL
QUALITY IMPROVEMENT SYSTEM

June 2007  

ROXANNE LAYMAN AND TERESE GATZA

You were nominated to be the recipient of Monopanel's monthly achievement award. You were recognized because of your proactive and efficient manner in which you reviewed and handled our products that contained printed circuit boards that may have contained plating issues. It was certainly disappointing that this issue came up, but because both of you "jumped" in and reviewed all our product in a quick and efficient manner we were able to resolve the issues in the existing boards we had in our inventory. The Recognition Committee recommended that both of you should receive our monthly achievement award.

The QGT concurs and selected you to be Monopanel's recipients of the June Achievement Award.