Not applicable.
Not applicable.
This invention is directed to MEMS switch devices.
The reed switch is an electrical switch actuated by an applied magnetic field. The reed switch may contain a pair (or more) of magnetizable, flexible, metal reeds whose end portions are separated by a small gap when the switch is open. These macro-sized reed switches may be hermetically sealed in opposite ends of a tubular glass envelope.
The contacts may be normally open, closing when a magnetic field is present, or normally closed and opening when a magnetic field is applied. The switch may be actuated by a coil, making a reed relay, or by bringing a magnet near to the switch. Once the magnet is pulled away from the switch, the reed switch will go back to its original position.
Reed switches are widely used for electrical circuit control, particularly in the communications field. Reed switches actuated by magnets are commonly used in mechanical systems as proximity sensors. Examples are door and window sensors in burglar alarm systems and tamper proofing methods.
The reed switch principle can be applied to switch a wide variety of loads ranging from nanovolts to kilovolts, femtoamperes to amperes, and DC to radio frequency. In contrast to Hall effect devices, which have very limited ranges of outputs and generally do not control a final device, reed sensors can withstand higher voltage than typical Hall devices.
One important quality of the switch is its sensitivity, the amount of magnetic field necessary to actuate it. Sensitivity is measured in units of Ampere-turns, (A-t) corresponding to the current in a coil multiplied by the number of turns. Typical pull-in sensitivities for commercial devices are in the 10 to 60 A-t range. The lower the A-t, the more sensitive the reed switch. Also, smaller reed switches, which have smaller parts, are more sensitive to magnetic fields, so the smaller the overall size of the reed switch, the more sensitive it is. Reeds which are smaller may also be less stiff, requiring a less energetic field to move them.
Accordingly, reed switches which were heretofore generally made of macroscopic components, and have dimensions on the order of millimeters, had relatively poor sensitivity.
Accordingly, it may be desirable to shrink the size of the reed switch in order to reduce the range of sensitivity to lower values. We describe here a reed switch device that may be fabricated using MEMS fabrication techniques, and thus may be made exceedingly small. Microelectromechanical systems (MEMS) are very small moveable structures made on a substrate using lithographic processing techniques, such as those used to manufacture semiconductor devices. MEMS devices may be moveable actuators, sensors, valves, pistons, or switches, for example, with characteristic dimensions of a few microns to hundreds of microns.
The MEMS reed device may include two flexible, permeable members that are deflected in the presence of a magnetic field. When a magnetic field is applied in the proper orientation, the permeable members are drawn towards areas of maximum field gradient. In one embodiment, as they are deflected by these magnetic forces, they may come into contact with one another, closing a circuit electrically. In other embodiments, the MEMS reed switch may be configured in a normally closed architecture, such that the switch opens rather than closes on application of a magnetic field. In yet another embodiment, the MEMS reed switch may be configured as a single pole double throw switch.
Accordingly, a microfabricated MEMS reed switch may include a first flexible, magnetically permeable member formed on a surface of a substrate, at least one additional, magnetically permeable member also formed on the same substrate and disposed in a position adjacent the first flexible, magnetically permeable member, and at least two electrical contacts that, together with the flexible, magnetically permeable members form a portion of a electric circuit.
The MEMS reed switch may be fabricated on three wafers. A lid wafer may cover the moving components, a device wafer may have the components formed therein, and the device may be supported by a third support wafer.
These and other features and advantages are described in, or are apparent from, the following detailed description.
Various exemplary details are described with reference to the following figures, wherein:
It should be understood that the drawings are not necessarily to scale, and that like numbers maybe may refer to like features.
In the systems and methods described here, a reed switch may be made from a pair of magnetically permeable, flexible members, using MEMS lithographic techniques. Accordingly, the features may be made exceedingly small, having sub-millimeter dimensions, and batch fabricated on a wafer in an economical fashion. When a magnetic field (from an electromagnet or a permanent magnet) is applied to the microfabricated, permeable, flexible members, the members may be urged to come together, thus completing an electrical circuit. The stiffness of the reeds causes then them to separate, and open the circuit, when the magnetic field is withdrawn.
Other configurations may contain a non-permeable members in addition to permeable members. Devices may be normally closed (contacts which open when the field is applied), or normally open (contacts which are closed when the field is applied). Yet another embodiment may be a microfabricated reed switch in single pole, double throw configuration. The fabrication, exemplary dimensions, and operation of these embodiments are described further below.
In any or all embodiments, good electrical contact may be obtained by plating a thin layer of highly conductive material over at least the contact portions of the permeable, flexible members. Low-resistivity silver (Ag) or corrosion-resistant gold (Au) may be used for this purpose. Accordingly, the microfabricated MEMS reed switch may have at least two electrical contacts which are plated with at least one of gold (Au) and silver (Ag).
As will be described below, the permeable, flexible members and contacts of the MEMS reed switch may be sealed away from the atmosphere, and thus protected against ambient conditions, shock and vibration. The hermetic sealing of a reed switch make them suitable for use in otherwise corrosive atmospheres. The MEMS reed switches disclosed here may be built as a three-wafer stack, with microfabricated nickel iron beams forming the permeable, flexible members on a device layer encapsulated by a lid wafer and a lower support wafer. This architectural allows a simple version of the reed switch with side leads as shown in a first embodiment, and a second embodiment using top contacts for bumping, and a third embodiment having higher directional sensitivity. Lastly, the architecture can also allow a bipolar reed switch, that is, a single pole double throw switch using the same basic MEMS architecture. The geometry described below may be made on a 2×1×1 mm cube die, allowing very economical manufacturing
The permeable material forming the flexible members may be nickel-iron Permalloy, which has a composition of between about 60% and about 90% Ni and 40% and 10% iron. The most common composition is 80% Ni and 20% Fe, which has a relative permeability of about 8,000. Of course, other permeable materials may be used as well. Accordingly, the microfabricated MEMS reed switch may have a first flexible permeable member and a second flexible permeable member comprising nickel-iron. More specifically, the nickel-iron may comprise nickel-iron permalloy, having a composition of 80% Ni and 20% Fe. A permeable material, as used herein, should be understood to mean a magnetically responsive material with a relative permeability of at least 100. A flexible member should be understood to mean a member with a length and width, which is deflected when a microNewton force is exerted at its distal end, by an amount of at least about 10% of its width.
The raised feature 120 which can function as a monorail within the bond. The purpose of the raised feature 120 is to encourage the formation of a hermetic seal around the device. The purpose of bondline 110, which may be a glass frit adhesive, is to join the plurality of substrates that is used to form this device. Other adhesive materials may also be used to bond the wafers, such as gold, metal alloys, SLID bonds, and the like. The purpose of raised feature within a bond line has been disclosed elsewhere, including U.S. Pat. No. 7,569,926, issued Aug. 4, 2009 and incorporated by reference in its entirety.
Reference number 140 refers to an electrically conductive bump, which allows electrical access from the exterior to the interior of the device. Specifically, bump 140 provides a site for electrical connection to the flexible permeable member 130 and bump 142 provides a site for electrical connection to flexible permeable member 132, both inside the bondline 110.
The dashed line shown in
These structures 110-170 together constitute reed switch device 100. The functioning of the embodiment of the MEMS-fabricated reed switch will be described next with respect to
When a magnetic field is applied in the direction shown in
When the magnetic field is withdrawn, the flexible members return to their original positions because of the spring force built into the design of the device. Before application of the magnetic field, a gap may exist between the one member 130 and the second member 132. When the magnetic field is withdrawn, the flexible members return to their original positions, such that a gap exists between the one member 130 and the second member 132. Therefore the switch may be in the closed configuration with the application of an magnetic field, and in the open circuit configuration when the field is withdrawn.
The following manufacturing process can be used to make the device shown in
For the device wafer 160 (Silicon):
Back end
Another alternative back end method may be found below.
Reference number 240 refers to an electrical bump to which an electrical connection is made, and reference number 242 refers to a second bump to which electrical connection is made.
Another difference between the second embodiment of device 200 and the first embodiment device 100 is the placement and location of the bumps 240 and 242, relative to bumps 140 and 142. In the first embodiment shown in
An exemplary manufacturing process is described below for the device 200 shown in
Lid wafer 250 (Silicon LPCVD SiNx)
Main wafer 260 (Silicon)
Reference number 340 refers to an electrical bump to which an electrical connection is made to flexible member 330, and reference number 342 refers to a second bump to which electrical connection is made to flexible member 332.
As with the other embodiments, when the magnetic field is withdrawn, the flexible members return to their original positions because of the spring force built into the design of the device. Before application of the vertical magnetic field, a gap may exist between the one member 130, 230 and 330 and the second member 132, 232 and 332. When the magnetic field is withdrawn, the flexible members return to their original positions, such that a gap exists between the one member 130, 230 and 330 and the second member 132, 232 and 332. Therefore the switch may be in the closed position with the application of an magnetic field, and in the open circuit configuration when the field is withdrawn.
Flexible member 434 may be put into a state of tension by application of a magnetic field in the horizontal direction. This field will draw flexible member 434 up and into contact with flexible permeable member 430. Tab 436 attached to flexible permeable member 434 can then enter slot 470, which may latch tab 436 into this position. In this position, contact 440 may been in electrical connection with contact 444, i.e. the circuit between 440 and 444 is closed by a magnetic field applied in the horizontal direction. Accordingly, the device shown in
If a magnetic field is then applied in the vertical direction, the reluctance may be minimized by having flexible permeable member 430 move in the upward direction and into contact with flexible permeable member 432. This will then open the circuit between 440 and 444, and close the circuit between 440 and 442. The force may be sufficient to overcome the deflection imposed by the latched flexible member 434. Accordingly, the embodiment shown in
It should be apparent that other switching mechanisms and configurations are possible based on the teachings herein. For example, double pole double throw switches may be made using these design concepts. Switches that are latching or nonlatching are contemplated.
Flexible permeable members may also be combined with nonmagnetic structures which do not respond to an applied magnetic field. They may also be combined with permanent magnets, which have a permanent magnetization associated with them. For example, the third flexible member in this embodiment may be nonmagnetic.
Alternatively, each of the dimensions shown in
Accordingly, as can be seen from the above description, a microfabricated MEMS reed switch may be formed, such that the first flexible, permeable member and the at least one additional flexible, permeable member are deflected in the presence of a magnetic field. In one embodiment, the first flexible, permeable member and the at least one additional flexible member may touch, at which point an electrical connection is formed and a switch is closed. In another embodiment, the microfabricated MEMS reed switch may be formed such that when the first flexible, permeable member and the at least one additional flexible member touch, an electrical connection is severed and a switch is opened.
In some embodiments, the microfabricated MEMS reed switch may be formed such that the two flexible, permeable members are disposed with each end directly adjacent. Alternatively, the microfabricated MEMS reed switch may be formed such that the two flexible, permeable members are disposed with each end overlapping and adjacent. Alternatively, the microfabricated MEMS reed switch may be formed such that the two flexible, permeable members are disposed as mirror images across a symmetry axis. The microfabricated MEMS reed switch may further include a locking mechanism which holds at least one of the flexible, permeable members in a predefined position when the magnetic field is withdrawn. The microfabricated MEMS reed switch may be configured as a single pole, double throw switch, as described above. A microfabricated MEMS reed switch is also contemplated wherein the three flexible members are configured as a double pole, double throw switch.
It should be understood that these embodiments are exemplary only, and many other embodiments may be contemplated, and still fall within the scope of this invention. So while various details have been described in conjunction with the exemplary implementations outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent upon reviewing the foregoing disclosure.
This is a non-Provisional U.S. patent application claiming priority to U.S. Provisional Patent Application Ser. No. 62/210,299, filed Aug. 26, 2015, and incorporated by reference in its entirety.
Number | Date | Country | |
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62210299 | Aug 2015 | US |