MEMS Power Relay With Magnetic Latching and Low-Heat Contacts

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Solution Overview

Problem

Existing power relays are large and inefficient, generating excessive heat that requires large heat sinks, making them unsuitable for integration into existing circuit breakers and power distribution units in data centers.

Innovation Solution

A microelectromechanical (MEMS) power relay with a stator assembly and plunger assembly, utilizing magnetic latching and low-contact-resistance contacts, such as liquid metal wetting and micromachined flexures, to achieve small size and low resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional power relays are used, then they can switch electrical power, but they generate excessive heat requiring large heat sinks

Engineering Contradiction:

Improveheat generationVSAvoidrelay size

Core Design Contradiction:

Loss of energyVSVolume of stationary object

Solution Approach 1:

The patent replaces conventional thermal management mechanisms with a magnetically actuated mechanical switching system. The MEMS relay uses magnetic fields to actuate contacts that switch power, eliminating the need for thermal management components like heat sinks while maintaining switching capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operating parameters by using low-contact-resistance materials and optimized contact geometries in the MEMS relay, reducing resistive heating at the contacts. This parameter optimization allows the relay to handle high currents without generating excessive heat, eliminating the need for large heat sinks.

Inventive Principle:

Principle #35Parameter changes

2Power

If conventional power relays are used, then they can switch electrical power, but they are too large to fit into existing circuit breakers

Engineering Contradiction:

Improvecurrent handling capabilityVSAvoidrelay size

Core Design Contradiction:

PowerVSVolume of stationary object

Solution Approach 1:

The patent replaces bulky conventional electromagnetic relay mechanisms with a compact MEMS-based magnetic actuation system. This substitution enables high current switching capability in a miniaturized form factor that can fit within existing circuit breaker configurations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transitions from planar contact arrangements to a three-dimensional stacked configuration with multiple ferromagnetic layers and coils arranged vertically. This dimensional reorganization allows for compact integration while maintaining high current handling capability through optimized magnetic flux paths.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Loss of energy

If conventional power relays are used, then they can switch electrical power, but they require large heat sinks which increase device complexity

Engineering Contradiction:

Improveheat generationVSAvoidheat sink requirements

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent replaces thermal management subsystems with a magnetically actuated switching mechanism that inherently generates minimal heat. The MEMS relay design eliminates the need for heat sinks, thermal vias, and associated cooling infrastructure, thereby reducing overall device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs low-contact-resistance materials and surface treatments that enable the contacts to self-manage heat generation through minimized resistive losses. The optimized contact geometry and material properties allow the relay to operate without external thermal management, making the system self-sufficient.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The MEMS power relay is compact, efficient, and capable of managing high currents without heat sinks, enabling integration into circuit breakers and reducing the size of power distribution units in data centers.

Implementation Method 1

a first plurality of coils that are adjacent to the first ferromagnetic layer, a second plurality of coils that are adjacent to the second ferromagnetic layer

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a plunger assembly that is situated in the chamber of the stator assembly and, in operation, moves along the central longitudinal axis between a first position and a second position

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS20260018355A1Microelectromechanical systems power relay

Publication Date: 2026.01.15 ATOMIC MACHINES INC

AI summary

A power relay having an actuator with a microelectromechanical systems stator assembly and plunger assembly that moves along the central longitudinal axis between a first position and a second position, the plunger assembly including a plunger that includes a pair of ferromagnetic plates with a magnet situated therebetween, and a first ferromagnetic plate of the pair of ferromagnetic plates is situated between first and second ferromagnetic layers in the stator assembly and a second ferromagnetic plate of the pair of ferromagnetic plates is situated between the second and third ferromagnetic layers in the stator assembly. Contacts formed by the ferromagnetic plates and ferromagnetic layers may include an array of micromachined flexures or a stabilized liquid-solid electrical contact.