Liquid switch production and assembly

• US 20050000784A1
• Filed: 07/27/2004
• Published: 01/06/2005
• Est. Priority Date: 12/12/2002
• Status: Active Grant

• Current Assignee: Marvin Glenn Wong
• Original Assignee: Marvin Glenn Wong
• Inventors: Wong, Marvin Glenn
• Granted Patent: US 6,909,059 B2
• Time in Patent Office: Days
• US Class Current: 200/182
• CPC Class Codes: H01H 1/0036 Switches making use of microelectromechanical systems [MEMS] for electromagnetic relays H01H50/005; for electrostatic relays H01H59/0009
• CPC Class Codes: H01H 2029/008 using micromechanics, e.g. micromechanical liquid contact switches or [LIMMS]
• CPC Class Codes: H01H 2061/006 Micromechanical thermal relay
• CPC Class Codes: H01H 29/28 with level of surface of contact liquid displaced by fluid pressure
• CPC Class Codes: H01H 61/02 wherein the thermally-sensitive member is heated indirectly, e.g. resistively, inductively

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.

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.