The document outlines a webinar by Epec Engineering focusing on redesigning legacy keypads for modern technologies, covering the transition to rigid, rigid-flex, and flex printed circuit boards (PCBs). It discusses the limitations of membrane-style keypads and the benefits of using PCB alternatives, including improved reliability and design flexibility, as well as the advantages of LED and fiber optic backlighting solutions. Additionally, Epec offers support for updating user interfaces and obsolescence-related redesigns with comprehensive engineering services.

1.  DELIVERING QUALITY SINCE 1952.
Re-Designing Legacy
User Interfaces
21st Century Keypad
Technologies
08.15.14

2. 2
Introduction
 This webinar will explain how Epec can provide Design & Engineering
support to bring your Legacy or obsolete keypad assembly into the 21st
century.
 During this presentation we will show possible design changes to User
Interface assemblies to include the following technologies:
– Rigid, Rigid-Flex and Flex Printed Circuit Card (PCB)
– LED, Fiber Optic and Electroluminescent Solutions
– Keypad Re-Design Due to Obsolescence's

3. 3
Membrane Style Switch Explained
 Many Legacy keypads use a
flexible printed Membrane style
keypad assembly.
 This membrane keypad
assembly uses a silver epoxy
circuit layer that is screen
printed on two opposing
polyester sheets.
 The two printed layers are
stacked on top of each other to
form the switch circuit.
 The circuit is complete when the
two layers are pressed together.

4. 4
Membrane Design Limitations
 Membrane designs have the following limitations:
– Material Selection Issues
• Incorrect material selection can cause premature failures of the assembly
– Electronic Component Mounting Issues
• Component failures can occur if assembly is deformed due to handling, environmental
conditions or sheer stress
– Component Real Estate Limitations
• Circuit trace layers and switch buttons consume most of the assembly leaving no room for
additional components
– High Density Connector Limitations
• Membrane assemblies connectors are limited to a 1.0 mm pitch minimum

5. 5
Benefits of Using a Rigid PCB
 Benefits of using a Rigid PCB Assembly vs. Membrane Assembly
– Material Selection Issues
• Standard PCB materials and thicknesses can be used (0.010” and up)
– Electronic Component Mounting Issues
• Resilient to environmental conditions
• Self supporting by design and do not require a supporting backplate
– Component Real Estate Limitations
• Components can be soldered directly to the PCB
• Additional components can be added to the rear side of the PCB
– High Density Connector Limitations
• Connectors can be soldered directly to the PCB
• PCB can use high density connectors in various configurations (Thru-hole, locking, etc.)

6. 6
Rigid PCB Additional Benefits
 Additional benefits of using a PCB Assembly vs. Membrane Assembly
– Higher Reliable Product
– Harsh Environment Use
– Use of Higher Quality Components and Materials
– Can Meet Overall Material Stack Ups Required
– Self Supporting, Metal Back Plate Not Required
– Reduced NRE & Tooling Costs

7. 7
Flex & Rigid-Flex PCB Benefits
 Benefits of Flex & Rigid Flex vs. Rigid PCB’s
– All The Same Benefits as a Rigid PCB Design
– Unlimited Freedom of Packaging Geometry While Retaining the Precision Density
and Repeatability of Printed Circuits
– High Reliability Replacement for Wire and Cable Harness Assemblies
– Ability of Design to Fit to Your Device

8. 8
LED Benefits
 Benefits of using LED’s vs. Incandescent for Indicators/Backlighting
– Energy Efficient & Low Power Draw (80% - 90% savings)
– Minimal Heat
– Low / Thin Profile
– High Light Output & Uniform Backlight
– Long Lifetime
– Color Choices to Include RGB & Night Vision (NVIS) Compatible
– Custom Shapes
– Low Electronic Emission (EMI/EMC)
– Withstands Environmental Conditions (Shock, Vibration, Temp. Extremes)

9. 9
Fiber Optic Backlighting
 Benefits of using Fiber Optic Backlighting
– Same Benefits of Using LED Backlighting
– Ultra Thin, up to 97% Thinner Than Traditional LED’s (0.125mm – 0.45mm typ.)
– Flexible Design, Uses Flexible Optical Fibers
– Power Efficiency & Component Reduction (uses a single LED)
– Complex Geometries & Unusual Shapes

10. 10
Electroluminescent Backlighting
 Benefits of using Electroluminescent Backlighting
– Many of the Same Benefits of Using LED & Fiber Optic Backlighting
– Super Thin (.007" typ.)
– Flexible, and can be put on top of Tactile Domes
– Low Power (.5 mA per sq. in typ.)
– Available in Various Colors (White, Blue, Blue-Green, Green, etc.)

11. 11
Obsolescence's Support
 Keypad Re-Design Due to Obsolescence's
– Complete Engineering & Design Services
– Staff of Electrical and Mechanical Engineer’s
– Design, Layout and Manufacture of Rigid, Flex & Rigid-Flex PCB’s
– Support Concept – Production
– Develop Complete Design Package
– Assistance with Component & Material Specifications

12. 12
Case Study
 Customer Requirements
– Re-design Product
– Conceptual Design, Minimal Design Drawings
– Small Form Factor
• Keypad required to fit in a 0.45” deep pocket
– IP68 - Ingress Protection
– Higher Reliable Product
• Current Keypad life cycle is 8-12 months
• Uses Membrane Style Switch
– High Density Mating Connector
• Mate with 0.5mm pitch ZIF connector

13. 13
Case Study – cont.
 Value Add Design Services
– Conceptual Design, Minimal Design Drawings
• Developed Complete Design Package
• Product Renderings to Assist Customer Marketing
– Small Form Factor
• Design Flex PCB to meet Stack-up Tolerance
– IP68 - Ingress Protection
• Specify Design Features & Materials
– Higher Reliable Product
• Use of Flex PCB over Membrane Style
• Design Flex PCB with Gold Switch Contacts
– High Density Mating Connector
• Design Flex PCB with High Density Pigtail

14. 14
Summary
 Epec can support you with your Design Phase.
 Epec can support Concept – Production
 Epec can also assist with the update of Legacy User Interfaces, to
include the following:
– Membrane to Printed Circuit Card Assembly
– Update to Rigid, Rigid-Flex and Flex Printed Circuit Card (PCB)
– Update to LED, Fiber Optic and Electroluminescent Solutions
– Support Keypad Re-Design issues due to Obsolescence's

15. 15
Our Products
Battery Packs Flex & Rigid-Flex PCB’s User Interfaces
Fans & Motors Cable Assemblies Printed Circuit Boards

16. 16
Design Centers & Technical Support
 Battery Pack & Power Management – Denver, CO
 User Interfaces – Largo, FL
 Fans & Motors – Wales, UK
 PCB’s – New Bedford, MA & Shenzhen, China
 Flex & Rigid Flex – Toronto, Canada
 Cable Assemblies – New Bedford, MA
 Our Engineering and Design teams are ready to help
our customers create world class and cost effective
product solutions.

17. 17
Q&A
 Questions?
– Enter any questions you may have
in the Control Panel.
– If we don’t have time to get to it, we
will reply via email.

18. 18
Thank You
Check out our previous webinars at www.epectec.com.
For more information email sales@epectec.com.
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