Wetting finger latching piezoelectric relay

Abstract

An electrical relay having two wettable electrical contacts, each supporting a conducting liquid. A wettable switch finger is moved from a non-deflected position to first and second positions by action of an actuator. In the first position the switch finger touches the conducting liquid and causes it to wet between the contacts and the switch and thereby complete an electrical circuit between the contacts. When the switch finger is in the second position, the conducting liquid cannot wet between first and second contacts and the switch finger and the electrical circuit between the first and second contacts is broken. The switch finger may be located at the free end of a beam that is deflected or bent by the action of piezoelectric elements.

Description

FIELD OF THE INVENTION

The invention relates to the field of micro-electromechanical systems (MEMS) for electrical switching, and in particular to a piezoelectrically actuated liquid metal relay.

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.

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.

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

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 array is disclosed that uses a conducting liquid in the switching mechanism. The relay uses a piezoelectric element to move an electrically conducting, wettable switch finger into contact with conducting liquid drops supported by two fixed electrical contacts. The conducting liquid wets between the fixed electrical contacts and the switch finger to form an electrical circuit. Surface tension in the liquid maintains the circuit and provides a latching mechanism. The switch finger is retracted to break the surface tension bond and open the circuit. The relay array is amenable to manufacture by micro-machining techniques.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are set forth in the claims. The invention itself, however, as well as the preferred mode of use, and further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawing(s), wherein:

FIG. 1 is a side view of a relay in accordance with certain embodiments of the present invention.

FIG. 2 is a top view of a relay in accordance with certain embodiments of the present invention.

FIG. 3 is a sectional view of a relay in accordance with certain embodiments of the present invention.

FIG. 4 is a sectional view of a relay in accordance with certain embodiments of the present invention in an open state.

FIG. 5 is a top view of a relay in an open and latched state in accordance with certain embodiments of the present invention.

FIG. 6 is a top view of a relay in a closing state in accordance with certain embodiments of the present invention.

FIG. 7 is a sectional view of a relay in a closing state in accordance with certain embodiments of the present invention.

FIG. 8 is a top view of a relay in a closed and latched state in accordance with certain embodiments of the present invention.

FIG. 9 is a top view of a relay in an opening state in accordance with certain embodiments of the present invention.

FIG. 10 is a top view of a circuit substrate of a relay in accordance with certain embodiments of the present invention.

FIG. 11 is a side view of a circuit substrate of a relay in accordance with certain embodiments of the present invention.

FIG. 12 is a top view of a relay in an open state in accordance with certain embodiments of the present invention.

FIG. 13 is a sectional view of a relay in accordance with certain embodiments of the present invention.

FIG. 14 is a top view of a relay in a closing state in accordance with certain embodiments of the present invention.

FIG. 15 is a top view of a relay in a closed and latched state in accordance with certain embodiments of the present invention.

FIG. 16 is a top view of a relay in an opening state in accordance with certain embodiments of the present invention.

FIG. 17 is a top view of a circuit substrate of a relay in accordance 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 present invention relates to an electrical relay in which the formation of a conducting liquid bridge between two fixed contacts is facilitated by action of a conducting, wettable finger. The conducting liquid may be a liquid metal, such as mercury or a gallium alloy. The finger is attached to one end of a beam, the other end of the beam is fixed to the substrate of the relay. The beam and the attached finger are moved by the action of one or more piezoelectric elements acting on the beam. The piezoelectric elements may operated to bend or deflect the beam.

FIG. 1 is a side view of an exemplary embodiment of a relay of the present invention. The relay has three layers: a cap layer 102, a piezoelectric layer 104 and a substrate layer 106. The substrate layer 106 supports electrical connections 108 to the switch, electrical connections 110 to the piezoelectric actuator and the associated circuitry. These three layers form a relay housing.

FIG. 2 is a top view of the relay in FIG. 1. The broken lines indicate hidden structure including the moveable beam 112 and the switch finger 114 that is attached to the free end of the beam 112. These elements are positioned within a switching cavity 116 in the piezoelectric layer of the relay. Also shown are two electrical contacts 118 and 120 that have wettable surfaces supporting droplets of conducting liquid. The sections 3—3 and 4—4 will be described below with reference to FIG. 3 and FIG. 4 respectively.

FIG. 3 is a sectional view through the section 3—3 in FIG. 2. The moveable beam 112 is fixed at one end to the substrate of the piezoelectric layer 104. The free end of the beam supports the switch finger 114. These elements are positioned within the switching cavity 116. The contact 120 is attached via a non-wettable pad 124 to the substrate 106. The other contact (118 in FIG. 2) is attached via a non-wettable pad 122 to the substrate 106. The electrical contacts are positioned within a recess in the switching cavity. The contacts have a wettable surface that supports a volume of conducting liquid 126. The volume of the conducting liquid is chosen such that, without the presence of the wettable finger, the liquid forms a separate droplet on each contact. The contacts are electrically connected to the connectors 108 that allow a signal to be routed through the relay. The beam 112 is moved by action of a piezoelectric actuator. Control signals are coupled to the actuator via connectors 110 that are electrically coupled to contact pads 128 in the switching cavity.

FIG. 4 is a sectional view through the section 4—4 in FIG. 2. The switch finger 114 is attached to the free end of the moveable beam 112 and is positioned in proximity to the electrical contacts and the supported liquid droplets 126. The conducting liquid 126 does not wet the non-wettable pad 124. In this embodiment, the beam 112 is moved by action of a piezoelectric element 130 attached to the side of the beam and operable to bend the beam.

FIG. 5 is a top view of a relay with the cap layer 102 removed. The switch is in an open state, since the liquid metal does not bridge the gap between the electrical contacts. In this embodiment, the moveable beam 112 is acted upon by piezoelectric elements 130 and 132 attached to the sides of the beam. Extension of the piezoelectric element 130 along the length of the beam or contraction of the piezoelectric element 132 along the length of the beam will cause the beam to bend such that the free end of the beam, and the attached switch finger, moves in the direction indicated by the arrow 134. The piezoelectric elements may be used alone or in concert. Control signals to the piezoelectric elements are provided via contact pads 128.

FIG. 6 is a top view of a relay with the cap layer 102 removed. The switch is in a closing state. The beam 112 has been bent by action of the piezoelectric elements 130 and 132, causing the switch finger 114 to touch the conducting liquid volumes 126. The conducting liquid 126 wets the surface of the wettable finger and forms a conducting bridge between the two fixed electrical contacts. This completes the electrical connection between the two electrical contacts and closes the circuit. The switch finger may be non-conductive, but a conductive switch finger reduces the electrical resistance through the connection.

FIG. 7 is sectional view through the section 7—7 in FIG. 6. The free end of the beam 112 has been displaced vertically in the figure relative to its position in FIG. 4. The switch finger 114 has been inserted into the conducting liquid volume 126, causing the two volumes to coalesce and complete the electrical connection.

FIG. 8 is a top view of a relay in a closed and latched state with the cap layer 102 removed. Once the switch finger has completed the conducting liquid connection, the piezoelectric elements 130 and 132 are de-energized and the beam 112 returns to its non-deflected position. However, surface tension in the conducting liquid 126 maintains the liquid bridge between the electrical contacts and the wettable switch finger. The electrical connection between the two electrical contacts is maintained and the switch is latched in the closed state.

In order to open the switch, the wettable switch finger is moved farther away from the electrical contacts. This is shown in FIG. 9, which is a top view of a relay in an opening state with the cap layer 102 removed. Referring to FIG. 9, the piezoelectric elements 130 and 132 are energized with a reverse polarity so that element 130 contracts and element 132 is extended to bend the beam and moves its free end 112 in a direction indicated by the arrow 134. The switch finger is moved away from the electrical connections and the surface tension bond maintaining the liquid bridge is broken. The conducting liquid breaks into two volumes 126 and the electrical circuit is broken. Surface tension in the liquid retains the liquid on the two contacts, even in the presence of body forces such as those due to motion of the whole relay. Thus, the relay is latched in the open position.

FIG. 10 is a top view of a substrate layer 106 of a relay. Two electrical contacts 118 and 120 are fixed to non-wettable pads that are in turn fixed to the substrate 106. Electrical pads 128 provide electrical connections to the piezoelectric elements. The pads and contacts may be formed on the substrate using known micro-machining techniques.

A side view of the circuit substrate is shown in FIG. 11. The electrical contacts 118 and 120 are fixed to non-wettable pads 122 and 124, respectively, which are in turn fixed to the substrate 106. The electrical contacts 118 and 120 are electrically coupled to connectors 108 on the external surface of the substrate. Alternatively, the electrical connectors may be connected, via traces on the top of the substrate, to connectors on the edge of the substrate. The electrical pads 128 provide electrical connections to the piezoelectric elements and are electrically coupled to the connectors 110 on the external surface of the substrate.

FIG. 12 is a top view of an alternative embodiment of the relay with the cap layer 102 removed. The switch is in an open state. In this embodiment, the moveable beam 112 is acted upon by a piezoelectric actuator 140 attached to a side of the switching channel 116. Extension of the piezoelectric element 140 in the plane of the layer and perpendicular to the beam moves the beam in the direction indicated by the arrow 134. In this embodiment, the piezoelectric actuator is positioned closer to the fixed end of the beam than to the free end so that the beam amplifies the motion of the piezoelectric element, thereby producing a larger displacement of the switch finger 114. Other forms of mechanical amplification may be used. Control signals are supplied to the piezoelectric element via the pads 128 and the contacts 142 and 144. The piezoelectric actuator 140 may comprise a single piezoelectric element or a stack of piezoelectric elements.

FIG. 13 is a sectional view through the section 13—13 in FIG. 13. The piezoelectric element 140 is coupled via the contact 142 to the substrate 104, and via the contact 144 to the beam 112. When a voltage is applied across the piezoelectric element it deforms in an extensional mode (the vertical direction in the figure) and acts laterally on the beam 112. This, in turn, moves the switch finger 114.

FIG. 14 is a top view of the relay in FIG. 12 showing the switch in a closing state. The piezoelectric element 140 has been energized and displaces the beam 112 laterally. This has moved the switch finger 114 to touch volume of conducting fluid 126, causing it to wet between the switch finger 114 and the two electrical contacts. This completes the electrical circuit between the electrical contacts.

FIG. 15 is a top view of a relay in a closed and latched state with the cap layer 102 removed. Once the switch finger has completed the conducting liquid connection, the piezoelectric element 140 is de-energized and the beam 112 returns to its non-deflected position. However, surface tension in the conducting liquid 126 maintains the liquid bridge between the electrical contacts and the wettable switch finger. The electrical connection between the two electrical contacts is maintained and the switch is latched in the closed state.

In order to open the switch, the wettable switch finger is moved farther away from the electrical contacts. This is shown in FIG. 16, which is a top view of a relay in an opening state with the cap layer 102 removed. Referring to FIG. 16, the piezoelectric element 140 is energized with a reverse polarity so that the element contracts and pulls the beam in a lateral direction. This moves the free end of the beam 112 in the direction indicated by the arrow 134. The switch finger is moved away from the electrical connections and the surface tension bond maintaining the liquid bridge is broken. The conducting liquid breaks into two volumes 126 and the electrical circuit is broken. Surface tension in the liquid retains the liquid on the two contacts, even in the presence of body forces such as those due to motion of the whole relay. Thus, the relay is latched in the open position.

FIG. 17 is a top view of a substrate layer 106 of the relay shown in FIGS. 10-16. Two electrical contacts 118 and 120 are fixed to non-wettable pads that are in turn fixed to the substrate 106. Electrical pads 128 provide electrical connections to the two ends of the piezoelectric element. The pads and contacts may be formed on the substrate using known micro-machining techniques.

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 enclosing a switching cavity; a first electrical contact in the switching cavity, having a wettable surface; a second electrical contact in the switching cavity spaced from the first electrical contact and having a wettable surface; a first conducting liquid in wetted contact with the first electrical contact; a second conducting liquid in wetted contact with the second electrical contact; a beam having a fixed end attached to the relay housing within the switching cavity and a free end; a wettable switch finger, attached to the free end of the beam and moveable to touch the first and second conducting liquids; and a piezoelectric actuator operable to move the beam in a lateral direction to cause the switching finger to move from a non-deflected position to a first position, where the conducting liquid wets between the first and second contacts and the switch finger and completes an electrical circuit between the first and second contacts, and to a second position where the conducting liquid cannot wet between first and second contacts and the switch finger and the electrical circuit between the first and second contacts is broken.

2. An electrical relay in accordance with claim 1, wherein the non-deflected position of the switch finger and the volume of the conducting liquid are such that movement of the switch finger from the first position to the non-deflected position does not break the electrical circuit completed by the conducting liquid.

3. An electrical relay in accordance with claim 1, wherein the non-deflected position of the switch finger and the volume of the conducting liquid are such that movement of the switch finger from the first position to the second first position breaks the electrical circuit completed by the conducting liquid.

4. An electrical relay in accordance with claim 1, further comprising: a first non-wettable pad positioned between the first electrical contacts and the relay housing; and a second non-wettable pad positioned between the second electrical contacts and the relay housing.

5. An electrical relay in accordance with claim 1, wherein the piezoelectric actuator comprises a first piezoelectric element attached to a first side of the beam, the first piezoelectric element operable to deform in a longitudinal mode parallel to the beam and thereby bend the beam.

6. An electrical relay in accordance with claim 5, wherein the piezoelectric actuator further comprises a second piezoelectric element attached to a second side of the beam, the second piezoelectric element operable to deform in a longitudinal mode parallel to the beam and in phase opposition to the first piezoelectric element.

7. An electrical relay in accordance with claim 1, wherein the piezoelectric actuator comprises a piezoelectric element acting between a wall of the switching cavity and a region of the beam between the free end and the fixed end, the piezoelectric element operable to deform in a longitudinal mode substantially perpendicular to the beam and thereby deflect the beam.

8. An electrical relay in accordance with claim 7, wherein the region of the beam acted upon by the piezoelectric element is closer to the fixed end of the beam than to the free end.

9. An electrical relay in accordance with claim 1, wherein the piezoelectric actuator comprises a stack of piezoelectric elements acting between a wall of the switching cavity and a region of the beam between the free end and the fixed end, the stack of piezoelectric elements operable to deform in a longitudinal mode substantially perpendicular to the beam and thereby deflect the beam.

10. An electrical relay in accordance with claim 1, wherein the first and second electrical contacts are positioned within a recess in the switching cavity, the recess tending to retain the conducting liquid.

11. An electrical relay in accordance with claim 1, wherein the conducting liquid is a liquid metal.

12. An electrical relay in accordance with claim 11, wherein the conducting liquid is mercury.

13. An electrical relay in accordance with claim 11, wherein the conducting liquid is a gallium alloy.

14. An electrical relay in accordance with claim 1, wherein the wettable finger is electrically conductive.

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

16. A method for switching an electrical circuit in an electrical relay between a first contact wetted by a first conducting liquid and a second contact wetted by a second conducting liquid, the method comprising: if the circuit is to completed: energizing an actuator to move a wettable finger to a first position where the wettable finger touches the first and second conducting liquids and causes them to wet between the first and second contacts and the finger; and if the circuit is to be broken: energizing the actuator to move a wettable finger to a second position where conducting liquid cannot wet between the first and second contacts and the wettable finger.

17. A method in accordance with claim 16, further comprising: if the circuit is to completed: de-energizing the actuator after the wettable finger has moved to the first position; and if the circuit is to broken: de-energizing the actuator after the wettable finger has moved to the second position.

18. A method in accordance with claim 16, wherein the relay includes a beam having a fixed end and a free end, the wettable finger being attached to the free end of the beam, and wherein energizing the actuator comprises: energizing a piezoelectric actuator attached to a side of the beam to deform in a longitudinal direction along the length of the beam, thereby bending the beam and moving the wettable finger.

19. A method in accordance with claim 16, wherein the relay includes a beam having a fixed end and a free end, the wettable finger being attached to the free end of the beam, and wherein energizing the actuator comprises: energizing a first piezoelectric actuator attached to a first side of the beam to extend in a longitudinal direction along the length of the beam; and energizing a second piezoelectric actuator attached to a second side of the beam to contract in a longitudinal direction along the length of the beam, thereby bending the beam and moving the wettable finger.

20. A method in accordance with claim 16, wherein the relay includes a beam having a fixed end and a free end, the wettable finger being attached to the free end of the beam, and wherein energizing the actuator comprises: energizing a piezoelectric actuator in contact with the beam and a housing of the relay to deform in a direction substantially perpendicular to the length of the beam, thereby deflecting the beam and moving the wettable finger.

21. A method in accordance with claim 20, wherein the piezoelectric actuator contacts the beam in a region closer to the fixed end than to the free end so as to amplify the motion of the piezoelectric actuator.