Electrically isolated liquid metal micro-switches for integrally shielded microcircuits
First Claim
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1. A liquid metal micro-switch, comprising:
- a first substrate;
a first ground plane attached to the first substrate;
a first dielectric layer attached to the first ground plane;
a conductive signal layer attached to the first dielectric layer and patterned so as to define first and second signal conductors having respectively first and second micro-switch contacts;
a second dielectric layer attached to the signal layer conductors and to the first dielectric layer;
a second ground plane attached to the second dielectric layer;
a second substrate attached to the second dielectric layer and having a cavity;
a third ground plane attached to the second substrate;
a heater positioned inside the cavity;
a main channel partially filled with a liquid metal, wherein the main channel encompasses the micro-switch contacts;
a sub-channel connecting the cavity and main channel, wherein a gas fills the cavity and sub-channel and wherein heater activation forces a change in electrical connectivity between first and second micro-switch contacts.
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Abstract
Liquid metal micro-switches. Liquid metal micro-switches and techniques for fabricating them in integrally shielded microcircuits are disclosed. The liquid metal micro-switches can be integrated directly into the construction of shielded thick film microwave modules. This integration is useful in applications requiring high frequency switching with high levels of electrical isolation.
78 Citations
30 Claims
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1. A liquid metal micro-switch, comprising:
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a first substrate;
a first ground plane attached to the first substrate;
a first dielectric layer attached to the first ground plane;
a conductive signal layer attached to the first dielectric layer and patterned so as to define first and second signal conductors having respectively first and second micro-switch contacts;
a second dielectric layer attached to the signal layer conductors and to the first dielectric layer;
a second ground plane attached to the second dielectric layer;
a second substrate attached to the second dielectric layer and having a cavity;
a third ground plane attached to the second substrate;
a heater positioned inside the cavity;
a main channel partially filled with a liquid metal, wherein the main channel encompasses the micro-switch contacts;
a sub-channel connecting the cavity and main channel, wherein a gas fills the cavity and sub-channel and wherein heater activation forces a change in electrical connectivity between first and second micro-switch contacts. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 23, 24, 25, 26, 27, 28)
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15. A liquid metal micro-switch, comprising:
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a first substrate;
a first ground plane attached to the first substrate;
a first dielectric layer attached to the first ground plane;
a conductive signal layer attached to the first dielectric layer and patterned so as to define first and second signal conductors having respectively first and second micro-switch contacts;
a second substrate;
a second ground plane attached to the second substrate;
a second dielectric layer attached to the second substrate, having a cavity, and attached to the first dielectric layer;
a heater positioned inside the cavity;
a main channel partially filled with a liquid metal, wherein the main channel encompasses the micro-switch contacts;
a sub-channel connecting the cavity and main channel, wherein a gas fills the cavity and sub-channel and wherein heater activation forces a change in electrical connectivity between first and second micro-switch contacts. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22)
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29. A method for fabricating a liquid metal micro-switch, comprising:
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attaching a first ground plane to a first substrate;
attaching a first dielectric layer to the first ground plane;
attaching a conductive signal layer to the first dielectric layer;
patterning the conductive signal layer so as to define first and second signal conductors having respectively first and second micro-switch contacts;
attaching a second dielectric layer to the first and second signal conductors and to the first dielectric layer;
patterning the second dielectric layer so as to define at least one sub-channel and a main channel;
attaching a second ground plane to the second dielectric layer;
creating a cavity in a second substrate;
attaching a third ground plane to the second substrate;
attaching a heater inside the cavity;
partially filling the main channel with a liquid metal, wherein the main channel encompasses the micro-switch contacts; and
attaching the second substrate and the third ground plane to the second ground plane and the second dielectric layer.
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30. A method for fabricating a liquid metal micro-switch, comprising:
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attaching a first ground plane to a first substrate;
attaching a first dielectric layer to the first ground plane;
attaching a conductive signal layer to the first dielectric layer;
patterning the conductive signal layer so as to define first and second signal conductors having respectively first and second micro-switch contacts;
attaching a second ground plane to a second substrate;
attaching a second dielectric layer to the second substrate;
patterning the second dielectric layer so as to define a cavity, at least one sub-channel, and a main channel;
attaching a second dielectric layer to first and second signal conductors and to the first dielectric layer;
attaching a heater inside the cavity;
partially filling the main channel a liquid metal, wherein the main channel encompasses the micro-switch contacts; and
attaching the second dielectric layer to the conductive signal layer and to the first dielectric layer.
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Specification