Liquid switch production and assembly

Abstract

In one embodiment, a switch is assembled by depositing a liquid switching element on a substrate. A channel plate is then positioned adjacent the substrate. The channel plate has a main channel and a waste chamber, and the main channel is positioned over the liquid switching element. The channel plate is then moved toward the substrate to cause a portion of the liquid switching element that overfills the main channel to be isolated from the main channel in the waste chamber. A method of switch production is also disclosed.

Description

BACKGROUND

Liquid metal micro-switches (LIMMS) have been developed to provide reliable switching capability using compact hardware (e.g., on the order of microns). The small size of LIMMS make them ideal for use in hybrid circuits and other applications where smaller sizes are desirable. Besides their smaller size, advantages of LIMMS over more conventional switching technologies include reliability, the elimination of mechanical fatigue, lower contact resistance, and the ability to switch relatively high power (e.g., about 100 milli-Watts) without overheating, to name just a few.

According to one design, LIMMS have a main channel partially filled with a liquid metal. The liquid metal may serve as the conductive switching element. Drive elements provided adjacent the main channel move the liquid metal through the main channel, actuating the switching function.

During assembly, the volume of liquid metal must be accurately measured and delivered into the main channel. Failure to accurately measure and/or deliver the proper volume of liquid metal into the main channel could cause the LIMM to fail or malfunction. For example, too much liquid metal in the main channel could cause a short. Not enough liquid metal in the main channel may prevent the switch from making a good connection.

The compact size of LIMMS makes it especially difficult to accurately measure and deliver the liquid metal into the main channel. Even variations in the tolerance of the machinery used to deliver the liquid metal may introduce error during the delivery process. Variations in the dimensions of the main channel itself may also introduce volumetric error.

SUMMARY OF THE INVENTION

In one embodiment, a switch is assembled by depositing a liquid switching element on a substrate. A channel plate is then positioned adjacent the substrate. The channel plate has a main channel and a waste chamber, and the main channel is positioned over the liquid switching element. The channel plate is then moved toward the substrate to cause a portion of the liquid switching element that overfills the main channel to be isolated from the main channel in the waste chamber.

In another embodiment, a switch is produced by depositing a liquid switching element on a substrate, with the volume of the liquid switching element being more than needed to fulfill a switching function. The channel plate is then moved toward the substrate such that barriers of the channel plate isolate a portion of the liquid switching element into at least one waste chamber in the channel plate as the barriers contact the liquid switching element. The channel plate is then closed against the substrate.

Yet other embodiments are also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative and presently preferred embodiments of the invention are illustrated in the drawings, in which:

FIG. 1(a) is a perspective view of one embodiment of a switch, shown in a first state;

FIG. 1(b) is a perspective view of the switch of FIG. 1(a), shown in a second state;

FIG. 2(a) is a plan view of a channel plate used to produce the switch according to one embodiment of the invention;

FIG. 2(b) is a plan view of a substrate used to produce the switch according to one embodiment of the invention;

FIG. 3 is a side view of the channel plate positioned adjacent the substrate, showing a liquid switching element deposited on the substrate;

FIG. 4 is a side view of the channel plate and substrate moved toward one another, showing the liquid switching element wet to the channel plate;

FIG. 5 is a side view of the channel plate and substrate moved closer to one another, showing the liquid switching element discharging into the waste chambers;

FIG. 6 is a side view of the channel plate and substrate, showing the liquid switching element in equilibrium;

FIG. 7 is a side view of the channel plate assembled to the substrate, shown in a first state; and

FIG. 8 is another side view of the channel plate assembled to the substrate, shown in a second state.

DETAILED DESCRIPTION OF THE INVENTION

One embodiment of a switch 100 is shown and described according to the teachings of the invention with respect to FIG. 1(a) and FIG. 1(b). Switch 100 comprises a channel plate 110 defining a portion of a main channel 120, drive chambers 130, 132, and subchannels 140, 142 fluidically connecting the drive chambers 130, 132 to the main channel 120. The channel plate 110 is assembled to a substrate 150, which further defines the main channel 120, drive chambers 130, 132, and subchannels 140, 142.

In one embodiment, the channel plate 110 is manufactured from glass, although other suitable materials may also be used (e.g., ceramics, plastics, a combination of materials). The substrate 150 may be manufactured from a ceramic material, although other suitable materials may also be used.

Channels may be etched into the channel plate 110 (e.g., by sand blasting) and covered by the substrate 150, thereby defining the main channel 120, drive chambers 130, 132, and subchannels 140, 142. Other embodiments for manufacturing the channel plate 110 and substrate 150 are also contemplated as being within the scope of the invention.

Of course it is understood that the main channel 120, drive chambers 130, 132, and/or subchannels 140, 142 may be defined in any suitable manner. For example, the main channel 120, drive chambers 130, 132, and/or subchannels 140, 142 may be entirely formed within either the channel plate 110 or the substrate 150. In other embodiments, the switch may comprise additional layers, and the main channel 120, drive chambers 130, 132, and/or subchannels 140, 142 may be partially or entirely formed through these layers.

It is also understood that the switch 100 is not limited to any particular configuration. In other embodiments, any suitable number of main channels 120, drive chambers 130, 132, and/or subchannels 140, 142 may be provided and suitably linked to one another. Similarly, the main channels 120, drive chambers 130, 132, and/or subchannels 140, 142 are not limited to any particular geometry. Although according to one embodiment, the main channels 120, drive chambers 130, 132, and/or subchannels 140, 142 have a semi-elliptical cross section, in other embodiments, the cross section may be elliptical, circular, rectangular, or any other suitable geometry.

According to the embodiment shown in FIG.1(a) and FIG. 1(b), switch 100 may also comprise a plurality of electrodes or contact pads 160, 162, 164 which are exposed to the interior of the main channel 120. Leads 170, 172, and 174 may be provided through the substrate 150 and may carry electrical current to/from the contact pads 160, 162, 164 during operation of the switch 100.

Of course the switch 100 may be provided with any number of contact pads, including more or less than shown and described herein. The number of contact pads may depend at least to some extent on the intended use of the switch 100.

The main channel 120 is partially filled with a liquid switching element 180. In one embodiment, the liquid switching element 180 is a conductive fluid (e.g., mercury (Hg)). As such, the liquid switching element 180 may serve as a conductive path between the contact pads 160, 162 or contact pads 162, 164. Alternatively, an opaque fluid may be used for an optical switch (not shown). The opaque fluid is used to block and unblock optical paths, as will be readily understood by one skilled in the art after having become familiar with the teachings of the invention.

The subchannels 140, 142 may be at least partially filled with a driving fluid 185. Preferably, the driving fluid 185 is a non-conductive fluid, such as an inert gas or liquid. The driving fluid 185 may be used to move the liquid switching element 180 within the main channel 120.

Drive elements 200, 202 (FIG. 2(b)) may be provided in drive chambers 130, 132. Drive elements 200, 202 may comprise, for example, heat-producing means (e.g., thin-film resistors) which heat the driving fluid 185 and cause it to expand. Other embodiments, now known or later developed, are also contemplated as being within the scope of the invention. For example, drive elements 200, 202 may comprise acoustic or pump means, to name only a few. In any event, the drive elements 200, 202 can be operated to force the driving fluid 185 (see FIG. 1(a) and FIG. 1(b)) into the main chamber 120, causing the liquid switching element 180 to “part” and move within the main channel 120.

By way of illustration, switch 100 is shown in a first state in FIG. 1(a) wherein the liquid switching element 180 makes a conductive path between contact pads 162 and 164. Drive element 202 may be operated to effect a change in state of switch 100, as shown in FIG. 1(b). Operation of the drive element 202 (FIG. 2(b)) causes the liquid switching element 180 to move toward the other end of the main channel 120, wherein the liquid switching element 180 makes a conductive path between contact pads 160 and 162. Similarly, drive element 200 (FIG. 2(b)) can be operated to change the state of the switch 100 back to the first state.

Suitable modifications to switch 100 are also contemplated as being within the scope of the invention, as will become readily apparent to one skilled in the art after having become familiar with the teachings of the invention. For example, the present invention is also applicable to optical micro-switches (not shown). Also see, for example, U.S. Pat. No. 6,323,447 of Kondoh et al. entitled “Electrical Contact Breaker Switch, Integrated Electrical Contact Breaker Switch, and Electrical Contact Switching Method”, and U.S. patent application Ser. No. 10/137,691 and filed on May 2, 2002 of Marvin Wong entitled “A Piezoelectrically Actuated Liquid Metal Switch”, each hereby incorporated by reference for all that is disclosed.

The foregoing description of one embodiment of switch 100 is provided in order to better understand its operation. It should also be understood that the present invention is applicable to any of a wide range of other types and configurations of switches, now known or that may be developed in the future.

Switch 100 may comprise a channel plate 110 and a substrate 150, as shown in more detail according to one embodiment in FIG. 2(a) and FIG. 2(b), respectively. Note that the channel plate 110 is shown in FIG. 2(a) as it appears from the top looking through the channel plate 110. Substrate 150 is shown in FIG. 2(b) as it appears from the side (e.g., top) that abuts the channel plate 110. In addition, the main channel 120, subchannels 140, 142, waste chambers 210, 212, and heater chambers 130, 132 are outlined in FIG. 2(b) to indicate their presence in embodiments where at least a portion of these features are provided in the substrate 150, as discussed above.

Channel plate 110 has a main channel 120 and waste chambers 210, 212 formed therein. Substrate 150 has contact pads 160, 162, 164. Contact pads 160, 162, 164 may be made of a wettable material. Where the contact pads 160, 162, 164 serve to make electrical connections, contact pads 160, 162, 164 are made of a conductive material, such as metal.

Contact pads 160, 162, 164 are spaced apart from one another. Preferably, subchannels 140, 142 open to the main chamber 120 in the space provided between the contact pads 160, 162, 164. Such an arrangement serves to enhance separation of the liquid switching element 180 during switching operations.

A liquid switching element 180 may be deposited on the contact pads 160, 162, 164, as shown according to one embodiment in FIG. 3. Preferably, the liquid switching element 180 is more than needed to fulfill a switching function. An excess portion of the liquid switching element discharges from the main channel 120 into the waste chambers 210, 212 when the channel plate 110 is assembled to the substrate 150, as will be discussed in more detail below.

The main channel 120 may be isolated from the waste chambers 210, 212 by dams or barriers 300, 302 on the channel plate 110. Barriers 300, 302 serve to isolate the liquid switching element 180 into the main channel 120 and the waste chambers 210, 212 during assembly. See for example, the illustration of FIG. 4 through FIG. 7 discussed below. Barriers 300, 302 also serve to isolate the excess liquid switching element 180 in the waste chambers 210, 212 after assembly (e.g., during operation of the switch 100). Accordingly, the waste chambers 210, 212 do not need to be separately sealed, but may be if so desired.

Seal belts 220, 222, 224 may be provided on the channel plate 110 to promote wetting of the liquid switching element 180 to the channel plate 110. Seal belts 220, 222, 224 are illustrated in FIG. 2(a) in outline form to better show their position relative to main channel 120 and waste chambers 210, 212 (i.e., overlaying the channels).

Seal belts 220, 222, 224 are preferably made of a wettable material. Suitable materials may include metal, metal alloys, to name only a few. In one embodiment, seal belts 220, 222, 224 are made of one or more layers of thin-film metal. For example, the seal belts 220, 222, 224 may comprise a thin layer (e.g., about 1000 Å) of chromium (Cr), a thin layer (e.g., about 5000 Å) of platinum (Pt), and a thin layer (e.g., about 1000 Å) of gold (Au). The outermost layer of gold quickly dissolves when it comes into contact with a mercury (Hg) liquid switching element 180, and the mercury forms an alloy with the layer of platinum. Accordingly the liquid switching element 180 readily wets to the seal belts 220, 222, 224.

It is noted that one of the seal belts (e.g., 220) preferably extends across one of the barriers (e.g., 300) into the adjacent waste chamber (e.g., 210). Therefore, the liquid switching element 180 wets to the barrier 300 and excess liquid switching element 180 is readily discharged into the waste chamber 210 during assembly (see FIG. 4).

It is also noted that one of the seal belts (e.g., 224) preferably does not extend across one of the barriers (e.g., 302) into the adjacent waste chamber (e.g., 212). The liquid switching element 180 does not readily wet to the barrier 302 without a seal belt. Accordingly, at least a portion of the liquid switching element 180 is forced into the main channel 120 toward contact pad 162 during assembly (see FIG. 5).

Following assembly, the desired amount of liquid switching element 180 remains in the main channel 120 as shown in FIG. 7 and FIG. 8. The liquid switching element 180 remaining in the main channel 120 can be used to effect a change of state in the switch 100, as described above. Excess of the liquid switching element 180 is isolated from the main channel 120 in the waste chambers 210, 212.

Preferably, waste chambers 210, 212 are isolated from the main channel 120 by barriers 300, 302. Waste chambers may also be sealed (e.g., around the outer perimeter of the switch 100). For example, seals 310, 312 (e.g., made of CYTOP®, commercially available from Asahi Glass Company, Ltd (Tokyo, Japan)) may be provided on the outer perimeter of the channel plate 110 and/or substrate 150. Excess liquid switching element 180 therefore remains in the waste chambers 210, 212. Alternatively, excess liquid switching element 180 may be removed from the waste chambers 210, 212, as desired.

Switch 100 may be produced according to one embodiment of the invention as follows. Liquid switching element 180 is deposited on the substrate 150, as illustrated in FIG. 3. In one embodiment, liquid switching element 180 is deposited on each of the contact pads 160, 162, 164. Although liquid switching element 180 need not be accurately measured, suitable volumes of deposited liquid switching element 180 may form “swells” on the contact pads 160, 162, 164, but preferably does not run over the sides of the contact pads 160, 162, 164 onto the substrate 150.

The channel plate 110 may be positioned adjacent the substrate 150. Although channel plate 110 may be positioned adjacent the substrate 150 prior to depositing the liquid switching element 180, the invention is not limited to this sequence. The channel plate 110 may then be moved toward the substrate 150.

As the channel plate 110 is moved toward substrate 150, the liquid switching element 180 on contact pads 160, 164 comes into contact with barriers 300, 302 on the channel plate 110, as shown in FIG. 4. In one embodiment, liquid switching element 180 on contact pad 160 wets to the seal belt 220 extending across the barrier 300 from the main channel 120 into the waste chamber 210. Accordingly, excess liquid switching element 180 is discharged into waste chamber 210 and is not forced into the main channel 120.

Also according to this embodiment, the liquid switching element 180 on contact pad 164 does not wet to barrier 302, as it is not provided with a seal belt 220 extending into the waste chamber 212. Instead, the hydrostatic pressure of the liquid switching element 180 increases as barrier 302 is moved against it, forcing liquid switching element 180 into the main channel 120 and into contact with the liquid switching element 180 on contact pad 162, as shown in FIG. 4 and FIG. 5. A portion of the liquid switching element 180 (i.e., excess) may also be discharged into the waste chamber 212.

Preferably, the assembly process comprises pausing or slowing movement of the channel plate 110 toward the substrate 150 for a time sufficient to allow liquid switching element 180 to equilibrate. The surface tension of the liquid switching element 180 causes the liquid switching element 180 to flow toward an area having a greater cross-sectional area (i.e., the waste chambers 210, 212). Movement of the liquid switching element 180 is enhanced by wettable areas (i.e., the contact pads 160, 164 and seal belts 220, 224).

The liquid switching element 180 is shown in equilibrium between the waste chambers 210, 212 and main channel 120 in FIG. 6. According to this embodiment, the liquid switching element 180 on contact pad 160 extends substantially perpendicular to the substrate 150 and is aligned between the edge of contact pad 160 and the edge of seal belt 220. Liquid switching element 180 on contact pad 164 has merged with liquid switching element 180 on contact pad 162. The liquid switching element 180 wets to the contact pads 162, 164 and seal belts 222, 224, and has “pulled away” from the channel plate 110 and substrate 150 between the contact pads 162, 164 and seal belts 222, 224. Excess liquid switching element 180 is discharged or otherwise removed into the waste chambers 210, 212.

The channel plate 110 may then be closed against the substrate 150, as shown in FIG. 7. Liquid switching element 180 may be forced out from under the barriers 300, 302 and into the main channel 120 and waste chamber 210, 212. The volume of liquid switching element 180 forced out from under barriers 300, 302 may bulge toward the air space between the liquid switching element in main channel 120 (as illustrated in FIG. 7), but is not forced so far into the main channel 120 that the switch is shorted.

The channel plate 110 may be connected to the substrate 150 in any suitable manner. In one embodiment, an adhesive is used to connect the channel plate 110 to the substrate 150. In another embodiment, screws or other suitable fasteners may be used. Barriers 300, 302 serve to isolate the main channel 120 from the waste chambers 210, 212.

The switch 100 may be operated as described above. By way of brief illustration, switch 100 is shown in a first state in FIG. 7 wherein the liquid switching element 180 makes a conductive path between contact pads 162 and 164. Drive element 202 (FIG. 2(b)) may be operated to effect a change in state of switch 100, as discussed above. Operation of the drive element 202 causes the liquid switching element 180 to move toward the other end of the main channel 120, wherein the liquid switching element 180 makes a conductive path between contact pads 160 and 162, as shown in FIG. 8. Drive element 200 (FIG. 2(b)) can be operated to change the state of the switch 100 back to the first state (FIG. 7).

It is readily apparent that switch 100 and production thereof according to the teachings of the present invention represents an important development in the field. The present invention allows for variance in the volume of liquid metal that is measured and delivered into the main channel 120. Excess liquid switching element 180 is removed into the waste chamber(s) 210, 212. Accordingly, the present invention corrects for volumetric errors that may be introduced during assembly of compact switching devices (e.g., LIMMS). For example, the present invention corrects volumetric errors resulting from the tolerance of the delivery tools. The present invention also corrects for volumetric errors resulting from variations in the dimensions of the main channel 120 itself.

Having herein set forth preferred embodiments of the present invention, it is anticipated that suitable modifications can be made thereto which will nonetheless remain within the scope of the present invention.

Claims

1. A method for assembling a switch, comprising: depositing a liquid switching element on a substrate; positioning a channel plate adjacent the substrate, said channel plate having a main channel and a waste chamber, and said main channel being positioned over the liquid switching element; and moving the channel plate toward the substrate to cause a portion of the liquid switching element that overfills the main channel to be isolated from the main channel in said waste chamber.

2. The method of claim 1, further comprising pausing during said moving, to allow the liquid switching element to equilibrate.

3. The method of claim 1, further comprising closing the channel plate against the substrate.

4. The method of claim 1, further comprising sealing the waste chamber from the main channel.

5. The method of claim 1, wherein the liquid switching element wets to a contact pad on the substrate and a seal belt on the channel plate when the channel plate is moved toward the substrate.

6. The method of claim 1, wherein, as the channel plate is moved toward the substrate, the liquid switching element wets to a seal belt on the channel plate, said seal belt extending between said main channel and waste chamber.

7. A switch produced by: depositing a liquid switching element on a substrate, the volume of said liquid switching element being more than needed to fulfill a switching function; moving a channel plate toward said substrate such that barriers of the channel plate isolate a portion of said liquid switching element into at least one waste chamber in the channel plate as said barriers contact the liquid switching element; and closing said channel plate against said substrate.

8. The switch of claim 7, wherein said liquid switching element is a liquid metal.

9. The switch of claim 7, wherein said liquid switching element is deposited on a plurality of contact pads on said substrate, said liquid switching element for conductively connecting at least two of said plurality of contact pads to one another.

10. The switch of claim 7, wherein moving said channel plate toward said substrate is paused to allow said liquid switching element to equilibrate.

11. The switch of claim 7, wherein moving said channel plate toward said substrate is slowed to allow said liquid switching element to equilibrate.

12. The switch of claim 7, wherein the waste chamber is sealed from a main channel in said channel plate after closing said channel plate against said substrate.

13. The switch of claim 7, wherein said liquid switching element wets to at least one seal belt on said channel plate when said channel plate is moved toward said substrate.

14. The switch of claim 13, wherein said liquid switching element wets to at least one seal belt extending between a main channel and the at least one waste chamber on the channel plate, said at least one seal belt enhancing the separation of said portion of liquid switching element into the at least one waste chamber.