Micro-Reed Switch Liquid Metal Electrodes High Current
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Solution Overview
Problem
Conventional micro-reed switches have a limited current carrying capacity of 0.1 milliamperes, which does not meet the requirements of conventional reed switches, and existing manufacturing methods are costly and inefficient.
Innovation Solution
A micro-reed switch design featuring a first and second magnetic reed with liquid metal electrodes and non-wettable conductors, where the reeds engage via magnetic force in a magnetic field and separate due to resilience force when the field is removed, allowing for high current carrying capacity, and a manufacturing method involving forming, depositing, defining non-wettable areas, and sealing the reeds with liquid metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If semiconductor fabrication or micro-electromechanical fabrication is used to manufacture micro-reed switches, then manufacturing precision and device characteristics are improved, but manufacturing cost increases and current carrying capacity remains limited to 0.1 milliamperes
Solution Approach 1:
The patent replaces conventional semiconductor fabrication processes with a mechanical assembly approach. Magnetic reeds are formed separately using traditional metalworking techniques, then assembled with liquid metal electrodes in a sealed chamber. This substitution of fabrication methodology reduces manufacturing complexity and cost while enabling higher current carrying capacity through the use of liquid metal contacts.
Solution Approach 2:
The patent changes the state of the metal electrode from solid to liquid, allowing the liquid metal to flow and form reliable electrical contacts with the magnetic reeds. This parameter change enables higher current carrying capacity (at least 50 milliamperes) compared to conventional solid metal contacts, while simplifying the manufacturing process through easier contact formation.
2Reliability
If semiconductor fabrication or micro-electromechanical fabrication is used to manufacture micro-reed switches, then device characteristics are improved, but current carrying capacity is limited to 0.1 milliamperes
Solution Approach 1:
The patent changes the physical state of the metal electrode from solid to liquid. The liquid metal electrode can flow to ensure reliable contact with the magnetic reeds while accommodating thermal expansion and mechanical tolerances. This parameter change enables the device to carry at least 50 milliamperes, significantly exceeding the 0.1 milliamperes limitation of conventional micro-reed switches.
Solution Approach 2:
The patent uses a composite structure combining magnetic reed materials (such as nickel-iron alloy) with liquid metal electrodes. This composite approach leverages the magnetic properties of the reed materials for actuation while the liquid metal provides high electrical conductivity and current carrying capacity, achieving at least 50 milliamperes while maintaining reliable device characteristics.
3Quantity of substance
If liquid metal is used as the metal electrode, then current carrying capacity increases to at least 50 milliamperes, but manufacturing complexity increases due to the need to define non-wettable areas
Solution Approach 1:
The patent introduces a non-wettable area (such as a hydrophobic coating or protrusion) as an intermediary between the liquid metal electrode and the magnetic reed substrate. This intermediary prevents the liquid metal from spreading uncontrollably while still allowing electrical contact, simplifying the manufacturing process by enabling straightforward liquid metal dispensing without requiring complex containment structures.
Solution Approach 2:
The patent applies non-wettable properties to specific localized areas on the magnetic reed substrate rather than the entire surface. This local quality approach allows the liquid metal to be contained and controlled at the contact point while maintaining simplicity in the overall manufacturing process, enabling high current carrying capacity without excessive manufacturing complexity.
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 micro-reed switch achieves a current carrying capacity of at least 100 milliamperes, enhancing performance, applicability, and reducing manufacturing costs.
Implementation Method 1
the liquid metal electrode and the second metal electrode engage with one another via a magnetic force from the magnet field
Implementation Method 2
the liquid metal electrode and the second metal electrode are separated from one another via a resilience force generated by the first magnetic reed and the second magnetic reed
Data Source
AI summary
A micro-reed switch includes a first magnetic reed and a second magnetic reed. The first magnetic reed includes a first metal electrode and a first non-wettable area. The first metal electrode includes a liquid metal. The second magnetic reed includes a second metal electrode and a second non-wettable area. The first magnetic reed and second magnetic reed is parallel to each other and a gap is defined there between. When a magnetic field is available, the liquid metal and the second metal electrode are engaged with one another by a magnetic force of the magnet.