High frequency push-mode latching relay

Abstract

An electrical relay that uses a conducting liquid in the switching mechanism. In the relay, a pair of moveable switching contacts is positioned between a pair of fixed electrical contact pads. A surface of each contact supports a droplet of a conducting liquid, such as a liquid metal. An actuator is energized to move the pair of switching contacts, closing the gap between one of the fixed contact pads and one of the switching contacts, thereby causing conducting liquid droplets to coalesce and form an electrical circuit. At the same time, the gap between the other fixed contact pad and the other switching contact is increased, thereby causing conducting liquid droplets to separate and break an electrical circuit. The actuator is then de-energized and the switching contacts return to their starting positions. The volume of liquid metal is chosen so that liquid metal droplets remain coalesced or separated because of surface tension in the liquid. The relay is amenable to manufacture by micro-machining techniques.

Description

FIELD OF THE INVENTION

The invention relates to the field of micro-electromechanical systems (MEMS) for electrical switching, and in particular to a latching relay with liquid metal contacts and piezoelectric or magnetorestrictive actuators.

BACKGROUND

Liquid metals, such as mercury, have been used in electrical switches to provide an electrical path between two conductors. An example is a mercury thermostat switch, in which a bimetal strip coil reacts to temperature and alters the angle of an elongated cavity containing mercury. The mercury in the cavity forms a single droplet due to high surface tension. Gravity moves the mercury droplet to the end of the cavity containing electrical contacts or to the other end, depending upon the angle of the cavity. In a manual liquid metal switch, a permanent magnet is used to move a mercury droplet in a cavity.

Liquid metal is also used in relays. A liquid metal droplet can be moved by a variety of techniques, including electrostatic forces, variable geometry due to thermal expansion/contraction and magneto-hydrodynamic forces.

Conventional piezoelectric relays either do not latch or use residual charges in the piezoelectric material to latch or else activate a switch that contacts a latching mechanism.

Rapid switching of high currents is used in a large variety of devices, but provides a problem for solid-contact based relays because of arcing when current flow is disrupted. The arcing causes damage to the contacts and degrades their conductivity due to pitting of the electrode surfaces.

Micro-switches have been developed that use liquid metal as the switching element and the expansion of a gas when heated to move the liquid metal and actuate the switching function. Liquid metal has some advantages over other micro-machined technologies, such as the ability to switch relatively high powers (about 100 mW) using metal-to-metal contacts without micro-welding or overheating the switch mechanism. However, the use of heated gas has several disadvantages. It requires a relatively large amount of energy to change the state of the switch, and the heat generated by switching must be dissipated effectively if the switching duty cycle is high. In addition, the actuation rate is relatively slow, the maximum rate being limited to a few hundred Hertz.

SUMMARY

An electrical relay is disclosed that uses a conducting liquid in the switching mechanism. In the relay, a pair of moveable switching contacts are positioned between a pair of fixed contact pads. The surface of each contact supports a droplet of conducting liquid, such as a liquid metal. An actuator is energized to move the pair of switching contacts, closing the gap between one of the fixed contact pads and one of the switching contacts, thereby causing conducting liquid droplets to coalesce and form an electrical circuit. At the same time, the gap between the other fixed contact pad and the other switching contact is increased, thereby causing conducting liquid droplets to separate and break an electrical circuit.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself however, both as to organization and method of operation, together with objects and advantages thereof, may be best understood by reference to the following detailed description of the invention, which describes certain exemplary embodiments of the invention, taken in conjunction with the accompanying drawings in which:

FIG. 1 is a side view of a latching relay consistent with certain embodiments of the present invention.

FIG. 2 is a top view of a latching relay with the cap layer removed consistent with certain embodiments of the present invention.

FIG. 3 is a sectional view of a latching relay consistent with certain embodiments of the present invention.

FIG. 4 is a top view of a circuit substrate of a latching relay with the cap layer removed consistent with certain embodiments of the present invention.

FIG. 5 is a further sectional view of a latching relay consistent with certain embodiments of the present invention.

DETAILED DESCRIPTION

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail one or more specific embodiments, with the understanding that the present disclosure is to be considered as exemplary of the principles of the invention and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in the several views of the drawings.

The electrical relay of the present invention uses a conducting liquid, such as liquid metal, to bridge the gap between two electrical contacts and thereby complete an electrical circuit between the contacts. Two moveable electrical contacts, which will be referred to as switching contacts, are positioned between a pair of fixed contact pads. A surface of each contact supports a droplet of a conducting liquid. In an exemplary embodiment, the conducting liquid is a liquid metal, such as mercury, with high conductivity, low volatility and high surface tension. An actuator, which is a piezoelectric element in the exemplary embodiment, is coupled to a contact carrier that supports the two switching contacts. In a further embodiment, a magnetorestrictive element, made of Terfenol-D for example, is used. In the sequel, piezoelectric elements and magnetorestrictive elements will be collectively referred to as “piezoelectric elements”. When energized, the actuator moves the contact carrier so that a first switching contact moves towards a first fixed contact pad, causing the conducting liquid droplets on the contacts to coalesce and complete an electrical circuit between the first switching contact and the first fixed contact pad. The relative positioning of the contacts is such that as the first switching contact moves towards the first fixed contact pad, the second switching contact moves away from the second fixed contact pad. This is achieved by placing the switching contacts between the fixed contact pads. After the switch-state has changed, the actuator is de-energized and the switching contacts return to their starting positions. The conducting liquid droplets remain coalesced in a single volume because the volume of conducting liquid is chosen so that surface tension holds the droplets together. The electrical circuit is broken again by energizing the piezoelectric actuator to move the first switching contact away from the first fixed contact pad to break the surface tension bond between the conducting liquid droplets. The droplets remain separated when the piezoelectric actuator is de-energized provided there is insufficient liquid to bridge the gap between the contacts. The relay is amenable to manufacture by micro-machining techniques.

FIG. 1 is a side view of an embodiment of a latching relay of the present invention. Referring to FIG. 1, the relay 100 comprises three layers: a circuit substrate 102, a switching layer 104 and a cap layer 106. These three layers form a relay housing. The circuit substrate 102 supports electrical connections to the elements in the switching layer and provides a lower cap to the switching layer. The circuit substrate 102 may be made of a ceramic, polymer or silicon, for example, and is amenable to manufacture by micro-machining techniques, such as those used in the manufacture of micro-electronic devices. The switching layer 104 may be made of ceramic or glass, for example, or may be made of metal coated with an insulating layer (such as a ceramic). The cap layer 106 covers the top of the switching layer 104, and seals the switching cavity 108. The cap layer 106 may be made of ceramic, glass, metal or polymer, for example, or combinations of these materials. Glass, ceramic or metal may be used in an exemplary embodiment to provide a hermetic seal.

FIG. 2 is a top view of the relay with the cap layer and the conducting liquid removed. Referring to FIG. 2, the switching layer 104 incorporates a switching cavity 108. The switching cavity 108 is sealed below by the circuit substrate 102 and sealed above by the cap layer 106. The cavity may be filled with an inert gas. An extendible piezoelectric or magnetorestrictive element 110 is attached to the switching layer and is operable to move a rigid contact carrier 112. The contact carrier 112 supports switching contacts 114 and 116. In an exemplary embodiment, an electrical signal may be routed to the switching contacts through additional moveable contacts 118 and 120 on the contact carrier 112, which are electrically coupled to the switching contacts 114 and 116. The additional moveable contacts are coupled to an electrical pad 126 on the circuit substrate via a droplet of conducting liquid, such as a liquid metal, that wets between the additional moveable contacts and the pad 126. The surface between the contacts 118 and 120 and the contact 114 and 116 is non-wettable, to prevent migration of the conducting liquid and allow the correct liquid volumes to be maintained. In an alternative embodiment, an electrical signal to the switching contacts 114 and 116 is supplied through circuit traces or conductive coatings on the carrier 112 and the actuator 110. Fixed contact pads 122 and 124 are attached to the circuit substrate. The exposed faces of the contacts are wettable by a conducting liquid, such as a liquid metal. The external surfaces separating the electrical contacts are non-wettable to prevent liquid migration. In operation, the length of the actuator 110 is increased or decreased to move the switching contacts 114 and 116 between the fixed contacts 122 and 124. For low-frequency switching, the contact pads 122, 124 and 126 may be connected to a mother substrate through suitable circuit routing together with pads and solder balls on the bottom of the circuit substrate. For medium and high frequency, the switching contact pads 122, 124 and 126 are electrically connected through circuit traces 134, 136 and 128, respectively, which may be connected with short ribbon wirebonds at the edge of the circuit substrate 102. Also, for high frequency switching, ground traces 130 may be included on the top of the circuit substrate 102, either side of the signal traces. These are discussed below with reference to FIG. 4.

FIG. 3 is a sectional view through section 3—3 of the latching relay shown in FIG. 2. The view shows the three layers: the circuit substrate 102, the switching layer 104 and the cap layer 106. The contact carrier 112 is supported from the free end of the actuator 110 and is moveable within the switching channel 108. Electrical connection traces (not shown) to supply control signals to the actuator 110 may be deposited on the upper surface of the circuit substrate 102 or pass through vias in the circuit substrate. The surfaces of the contacts support droplets of conducting liquid that are held in place by the surface tension of the liquid. Due to the small size of the droplets, the surface tension dominates any body forces on the droplets and so the droplets are held in place even if the relay is moved. The liquid between contacts 114 and 122 is separated into two droplets 140, one on each of the contacts 114 and 122. The liquid between contacts 116 and 124 is coalesced into a single volume 142. Thus, there is an electrical connection between the contacts 116 and 124, but no connection between the contacts 114 and 122.

When the actuator 110 is contracted, the first switching contact 114 is moved towards the first fixed contact 122, and the second switching contact 116 is moved away from the second fixed contact 124. When the gap between the contacts 116 and 124 is great enough, the conducting liquid is insufficient to bridge the gap between the contacts and the conducting liquid connection 142 is broken. When the gap between the contacts 114 and 122 is small enough, the liquid droplets 140 coalesce with each other and form an electrical connection between the contacts. The liquid volume is chosen so that when the actuator is de-energized and returns to its undeflected position, the coalesced droplets 140 remain coalesced and the separated droplets 142 remain separated. In this way the relay is latched into the new switch-state. The switch state can be returned to that shown in FIG. 3 by extending the actuator 110 to break the liquid connection between contacts 114 and 122 and cause the liquid droplets 142 to coalesce again.

The use of mercury or other liquid metal with high surface tension to form a flexible, non-contacting electrical connection results in a relay with high current capacity that avoids pitting and oxide buildup caused by local heating.

A top view of the circuit substrate 102 is shown in FIG. 4. Signal traces 128, 134 and 136 connect to fixed contact pads 126, 122 and 124 respectively. The traces are covered with a material that the conducting liquid does not wet, so as to prevent unwanted transfer of conducting liquid. Upper ground traces 130 are positioned on either side of the signal traces to provide electrical shielding. Vias 150 provide electrical connections from the upper ground traces 130 to lower ground traces 132 so that ground currents can surround the signal currents upstream and downstream of the switching structure. All bends in the traces are no more than 45° to minimize reflections. Additional circuit traces (not shown) to supply control signals to the actuator may also be formed on the circuit substrate. Alternatively, the actuator may be connected through suitable circuit routing, pads and solder balls on the bottom of the substrate.

FIG. 5 is a sectional view through the section 5—5 shown in FIG. 2. The conducting liquid droplet 152 fills the gap between contacts 118 and 120 and fixed contact pad 126 and completes an electrical circuit between them. The liquid volume is chosen so that motion of the contact carrier 112 will not break this liquid connection. Upper ground traces 130, on either side of the contact pad 126, are coupled through vias 150 to lower ground traces 132 so as to provide electrical shielding.

In one mode of operation, the contact pad 126 serves as a common terminal and a signal connected to the terminal is switched to either contact pad 122 or contact pad 124 by motion of the actuator 110.

While the invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, permutations and variations will become apparent to those of ordinary skill in the art in light of the foregoing description. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variations as fall within the scope of the appended claims.

Claims

1. An electrical relay comprising: a relay housing containing a switching cavity; first and second fixed contact pads, each attached to the relay housing in the switching cavity and having a wettable surface; first and second switching contacts positioned between the first and second fixed contact pads, each of the first and second switching contacts having a wettable surface; a moveable contact carrier supporting the first and second switching contacts; a first conducting liquid volume in wetted contact with the first switching contact and the first fixed contact pad; a second conducting liquid volume in wetted contact with the second switching contact and the second fixed contact pad; and an actuator in a rest position, coupling the contact carrier to the relay housing and operable to move the contact carrier in a first direction, to decrease the distance between the first switching contact and the first fixed contact pad and increase the distance between the second switching contact and the second fixed contact pad, and a second direction to increase the distance between the first switching contact and the first fixed contact pad and decrease the distance between the second switching contact and the second fixed contact pad, wherein: motion of the contact carrier in the first direction causes the first conducting liquid volume to form a connection between the first switching contact and the first fixed contact pad and causes the second conducting liquid volume to separate into two droplets, thereby breaking a connection between the second switching contact and the second fixed contact pad; and motion of the contact carrier in the second direction causes the first conducting liquid volume to separate into two droplets, thereby breaking the connection between the first switching contact and the first fixed contact pad and causes the second conducting liquid volume to form a connection between the second switching contact and the second fixed contact pad.

2. An electrical relay in accordance with claim 1, wherein the actuator is a piezoelectric actuator.

3. An electrical relay in accordance with claim 1, wherein the actuator is a magnetorestrictive actuator.

4. An electrical relay in accordance with claim 1, wherein the first and second conducting liquid volumes are liquid metal droplets.

5. An electrical relay in accordance with claim 1, wherein the first and second conducting liquid volumes are such that connected volumes remain connected when the actuator is returned to its rest position, and separated droplets remain separated when the actuator is returned to its rest position.

6. An electrical relay in accordance with claim 1, further comprising electrical connections to the first and second fixed contact pads and the first and second switching contacts.

7. An electrical relay in accordance with claim 6, wherein the electrical connections to the first and second fixed contact pads and the electrical connections to the first and second switching contacts are electrically shielded by ground conductors.

8. An electrical relay in accordance with claim 6, wherein the electrical connection to the first and second switching contacts comprises: a first moveable contact supported by the contact carrier and electrically coupled to the first and second switching contacts; a third fixed contact pad positioned in proximity to the first moveable contact and having a surface wettable by conducting liquid; and a third conducting liquid volume in wetted contact with and forming an electrical connection between the first moveable contact and the third fixed contact pad,

9. An electrical relay in accordance with claim 1, wherein the relay housing comprises: a circuit substrate supporting electrical connections to the actuator, the first and second switching contacts and the first and second fixed contact pads; a cap layer; and a switching layer positioned between the circuit substrate and the cap layer and having the switching cavity formed therein.

10. An electrical relay in accordance with claim 9, wherein at least one of the electrical connections to the first and second fixed contact pads and the first and second switching contacts passes through the circuit substrate and terminates in a solder ball.

11. An electrical relay in accordance with claim 9, wherein at least one the electrical connections to the first and second fixed contact pads and the first and second switching contacts terminates at an edge of the switching layer.

12. An electrical relay in accordance with claim 9, wherein at least one of the electrical connections to the first and second fixed contact pads and the first and second switching contacts is a trace deposited on the upper surface of the circuit substrate.

13. An electrical relay in accordance with claim 12, further comprising a first plurality of ground traces deposited on the upper surface of the circuit substrate either side of the at least one electrical connection.

14. An electrical relay in accordance with claim 13, further comprising a second plurality of ground traces deposited on the lower surface of the circuit substrate, the first plurality of ground traces being electrically connected to the second plurality of ground traces by one or more vias passing through the circuit substrate.

15. An electrical relay in accordance with claim 9, manufactured by a method of micro-machining.

16. A method for switching between a first electrical circuit, between a first switching contact and a first fixed contact pad, and a second electrical circuit, between a second switching contact and a second fixed contact pad, in a relay, the first and second switching contacts being supported on a contact carrier and positioned between the first and second fixed contact pads, the method comprising: if the first electrical circuit is to be selected: energizing an actuator to move the contact carrier in a first direction, thereby moving the first switching contact towards the first fixed contact pad so that a first conducting liquid volume, supported by at least one of the first switching contact and the first fixed contact pad, wets between the first switching contact and the first fixed contact pad and completes the first electrical circuit; and if the second electrical circuit is to be selected: energizing the actuator to move the contact carrier in a second direction, thereby moving the second switching contact towards the second fixed contact pad so that a second conducting liquid volume, supported by at least one of the second switching contact and the second fixed contact pad, wets between the second switching contact and the second fixed contact pad and completes the second electrical circuit.

17. A method in accordance with claim 16, wherein: motion of the contact carrier in the first direction moves the second switching contact away from the second fixed contact pad, so that the second conducting liquid volume cannot wet between the second switching contact and the second fixed contact pad, thereby breaking the second electrical circuit; and motion of the contact carrier in the second direction moves the first switching contact away from the first fixed contact pad, so that the first conducting liquid volume cannot wet between the first switching contact and the first fixed contact pad, thereby breaking the first electrical circuit.

18. A method in accordance with claim 16, further comprising: if the first electrical circuit is to be selected: de-energizing the actuator after the first conducting liquid wets between the first switching contact and the first fixed contact pad; and if the second electrical circuit is to be selected: de-energizing the actuator after the second conducting liquid wets between the second switching contact and the second fixed contact pad.

19. A method in accordance with claim 16, wherein the first actuator is a piezoelectric actuator and wherein energizing the first actuator comprises applying an electrical voltage across the piezoelectric actuator.

20. A method in accordance with claim 16, wherein the first actuator is a magnetorestrictive actuator and wherein energizing the first actuator comprises applying a magnetic field across the magnetorestrictive actuator.