Abstract: A method for depositing material on a channel plate such that the material is registered to one or more channels formed in the channel plate includes filling at least one of the channels with a resist that is not wetted by the material; depositing the material on at least a region of the channel plate that includes at least part of the resist; and then removing the resist. The method may be used, in one embodiment, to apply an adhesive or gasket material that is used in assembling a switch.

Abstract: A method and structure for a reflective optical switch. According to the structure, a chamber is housed within a solid material. A plurality of piezoelectric elements within the chamber are coupled to the solid material. A slug within the chamber is operable to be coupled to one or more of the plurality of piezoelectric elements. A liquid metal within the chamber is coupled to the slug. One or more signals of a first one or more optical waveguides coupled to the chamber are operable to be coupled to a second one or more optical waveguides coupled to the chamber. According to the method, one or more of the plurality of piezoelectric elements are actuated, with the actuation of the one or more piezoelectric elements causing the slug coupled to the one or more piezoelectric elements to move from a first number of wetting pads to a second number of wetting pads wherein the first number of wetting pads and the second number of wetting pads are wetted by the liquid metal.

Abstract: A switch device and a method of manufacture are provided that includes providing two substrates. The two substrates collectively include a fluid conductor switch device structure and a trench surrounding the fluid conductor switch device structure. An inner seal material is deposed on one of the substrates and an outer seal material is deposited in the trench. The substrates are joined to one another using the inner seal material and a peripheral hermetic seal is formed between the substrates using the outer seal material.

Abstract: Disclosed herein is a channel plate for a fluid-based switch. The channel plate is produced by 1) depositing a photoimagable dielectric layer onto a substrate, 2) photoimaging at least one channel plate feature on the dielectric layer, and 3) developing the dielectric layer to form the at least one channel plate feature in the dielectric layer, thereby forming the channel plate. Switches using photoimaged channel plates, and a method for making a switch with a photoimaged channel plate, are also disclosed.

Abstract: An electrical relay using conducting liquid in the switching mechanism. Two electrical contacts are held a small distance apart. The facing surfaces of the contacts each support a droplet of a conducting liquid, such as a liquid metal. A piezoelectric actuator is energized to reduce the gap between the electrical contacts, causing the two liquid metal droplets to coalesce and form an electrical circuit. The piezoelectric actuator is then de-energized and the electrical contacts return to their starting positions. The liquid metal droplets remain coalesced because of surface tension. The electrical circuit is broken by energizing a piezoelectric actuator to increase the gap between the electrical contacts and break the surface tension bond between the liquid metal droplets. The droplets remain separated when the piezoelectric actuator is de-energized because there is insufficient liquid metal to bridge the gap between the contacts. The relay is amenable to manufacture by micro-machining techniques.

Abstract: Fluid-based switches and methods for producing the same are disclosed. In one embodiment, a method for producing a switch comprises depositing a first alignment pad on a first substrate, depositing a second alignment pad on a second substrate, depositing solder on at least one of the alignment pads, depositing a switching fluid on the first substrate, and mating the first substrate to the second substrate by aligning the alignment pads and heating the solder, the substrates defining therebetween a cavity holding the switching fluid, the cavity being sized to allow movement of the switching fluid between first and second states.

Abstract: The number of LIMMS devices in an assembly is increased by stacking multiple layers of LIMMS devices on top of one another, and interconnecting those device layers at an array of solder pads using solder balls. Each device layer uses vias to bring the needed conductors to the array of solder pads. All signals for the entire multi-layer assembly can be routed through the bottom LIMMS device layer to pass, through another array of solder pads onto a “mother substrate” of ceramic or other material that carries the multi-layer assembly. Alternatively, signals may enter or leave the upper LIMMS device layer by way of a flexible printed circuit harness. Vias may pass, either directly or by “dog legs” on interior surfaces, completely through the bottom LIMMS device layer, and through other device layers as needed.

Abstract: The multi-pole, conductive liquid-based switch device includes an elongate passage, a first cavity, a second cavity, at least four electrodes disposed along the length of the passage, channels that extend from the passage, non-conductive fluid located the cavities and conductive liquid located in the passage. The channels are one fewer in number than the electrodes and are interleaved with the electrodes along the length of the passage. The channels are numbered in order from one end of the passage. Odd-numbered ones of the channels extend to the first cavity while even-numbered ones of the channels extend to the second cavity.

Abstract: The present invention uses a piezoelectric method to actuate a liquid metal relay. The method described here uses the piezoelectric element in an extension mode to cause the switch actuator to insert into a cavity in the static (i.e. nonmoving) switch contact structure. The cavity has sides and a pad on its end that are wettable by the liquid metal. The cavity is filled with liquid metal. Insertion of the switch actuator into the cavity causes the liquid metal to be displaced outward and come in contact with the contact pad on the switch actuator. The volume of liquid metal is chosen so that when the actuator returns to its rest position, the electrical contact is maintained by surface tension and by wetting of the contact pads on both the static switch contact structure and the actuator.

Abstract: Disclosed herein is a switch having a channel plate and a switching fluid. The channel plate defines at least a portion of a number of cavities, a first cavity of which is defined by an ultrasonically milled channel in the channel plate. The switching fluid is held within one or more of the cavities, and is movable between at least first and second switch states in response to forces that are applied to the switching fluid. Alternate switch embodiments, and a method for making a switch, are also disclosed.

Abstract: Disclosed herein is a switch having a channel plate and a switching fluid. The channel plate defines at least a portion of a number of cavities, a first cavity of which is defined by a laser cut channel in the channel plate. The switching fluid is held within one or more of the cavities, and is movable between at least first and second switch states in response to forces that are applied to the switching fluid. Alternate switch embodiments, and a method for making a switch, are also disclosed.

Abstract: A switch and method for producing the same. In one embodiment, the switch is produced by depositing a liquid switching element on a substrate, the volume of the liquid switching element being more than needed to fulfill a switching function. A channel plate is moved toward the substrate, the channel plate having a main channel with at least one reservoir fluidically connected thereto, an excess portion of the liquid switching element flowing into the least one reservoir. The channel plate is closed against the substrate.

Abstract: A volume adjustment apparatus for a switch. One embodiment of the volume adjustment apparatus may comprise a plate member sized to fit over a main channel in the switch displaces an excess of a liquid switching element from the main channel of the switch. At least one collection chamber is formed in the plate member overlapping the main channel of the switch to receive the displaced excess liquid switching element.

Abstract: A switch and production thereof. The switch may be produced by (1) depositing a liquid switching element on a substrate, (2) positioning a channel plate adjacent the substrate, (3) moving the channel plate toward the substrate, the liquid switching element wetting to the channel plate, and a portion of the liquid switching element isolated into at least one waste chamber in the channel plate; and (4) closing the channel plate against the substrate.

Abstract: Disclosed herein is a channel plate for a fluid-based switch. The channel plate is produced by 1) forming a plurality of channel plate layers in ceramic green sheet, 2) forming at least one channel plate feature in at least one of the channel plate layers, and 3) laminating the channel plate layers to form the channel plate. Switches using ceramic channel plates, and a method for making a switch with a ceramic channel plate, are also disclosed.

Abstract: Channels and cavities in a LIMMS device are formed from a layer of thick film dielectric material deposited on a substrate, which layer is then covered with a thin cover plate of ceramic or perhaps glass. The layer of dielectric material may be patterned using established thick film techniques, and good dimensional control can be achieved. The dielectric layer is itself its own hermetic seal against the substrate, and readily lends itself to the formation of the additional hermetic seal needed between itself and the cover plate. Suitable thick film dielectric materials that may be deposited as a paste and subsequently cured include the KQ 150 and KQ 115 thick film dielectrics from Heraeus and the 4141A/D thick film compositions from DuPont.

Abstract: A first resist is deposited on at least a portion of a substrate (or existing feature on the substrate) that will underlie a feature in a nonphotoimagable material that is to be deposited on the substrate. Thereafter, the nonphotoimagable material is deposited so that it overlaps at least a portion of the first resist. A second resist is then deposited on at least a portion of the nonphotoimagable material, and a feature is patterned on the second resist. Subsequently, the part is sandblasted until the first resist is exposed, and the first and second resists are then removed. In one embodiment, the nonphotoimagable material is deposited on a channel plate and used to seal at least a switching fluid between the channel plate and another substrate.

Abstract: A volume adjustment apparatus for a switch. One embodiment of the volume adjustment apparatus may comprise a plate member sized to fit over a main channel in the switch displaces an excess of a liquid switching element from the main channel of the switch. At least one collection chamber is formed in the plate member overlapping the main channel of the switch to receive the displaced excess liquid switching element.

Abstract: A polymeric switch in which a switching channel is formed in a polymer layer. The channel is formed by a micro-machining technique such as laser ablation or photo-imaging. A liquid metal switch is contained within the switching channel. The liquid metal switch operates by making or breaking an electrical circuit using a volume of liquid metal. Electrical contact pads within the switching channel are wettable by the liquid metal and provide a latching mechanism for the switch. The polymer layer may be located between two switch substrates. Solder rings are attached to the perimeters of the switch substrates. The solder rings are wettable by solder and facilitate the creation of a hermetic seal between the substrates.

Abstract: A high frequency electrical relay uses a conducting liquid in the switching mechanism. The relay uses an actuator, such as a piezoelectric element, to cause the switch actuator to insert into a cavity in a static switch contact structure. The cavity has sides and a pad on its end that are wettable by the conducting liquid. The cavity is filled with the conducting liquid, which may be liquid metal. The volume of conducting liquid is chosen so that when the actuator returns to its rest position, the electrical contact is maintained by surface tension and by wetting of the contact pads on both the static switch contact structure and the actuator.

Abstract: An electrical relay array using conducting liquid in the switching mechanism. The relay array is amenable to manufacture by micro-machining techniques. In each element of the relay array, two electrical contacts are held a small distance apart. The facing surfaces of the contacts each support a droplet of a conducting liquid, such as a liquid metal. An actuator, coupled to one of the electrical contacts, is energized in a first direction to reduce the gap between the electrical contacts, causing the two conducting liquid droplets to coalesce and complete an electrical circuit. The actuator is then de-energized and the contacts return to their starting position. The liquid droplets remain coalesced because of surface tension. The electrical circuit is broken by energizing an actuator to increase the gap between the electrical contacts to break the surface tension bond between the conducting liquid droplets.

Abstract: A switch device and a method of manufacture are provided that includes providing two substrates. The two substrates collectively include a fluid conductor switch device structure and a trench surrounding the fluid conductor switch device structure. An inner seal material is deposed on one of the substrates and an outer seal material is deposited in the trench. The substrates are joined to one another using the inner seal material and a peripheral hermetic seal is formed between the substrates using the outer seal material.

Abstract: A switch device and a method of manufacture are provided that includes providing two substrates. The two substrates collectively include a fluid conductor switch device structure and a trench surrounding the fluid conductor switch device structure. An inner seal material is deposed on one of the substrates and an outer seal material is deposited in the trench. The substrates are joined to one another using the inner seal material and a peripheral hermetic seal is formed between the substrates using the outer seal material.

Abstract: The latching switch device includes a passage, a first cavity, a second cavity, a channel extending from each cavity to the passage, non-conductive fluid located the cavities, conductive liquid located in the passage, a first electrode, a second electrode and a latching structure associated with each channel. The passage is elongate. The channels are spatially separated from one another along the length of the passage. The electrodes are in electrical contact with the conductive liquid and are located on opposite sides of one of the channels. The conductive liquid includes free surfaces. Each latching structure includes energy barriers located in the passage on opposite sides of the channel. The energy barriers interact with the free surfaces of the conductive liquid to hold the free surfaces apart from one another.

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.

Abstract: An apparatus for heating a gas in a cavity of a microcircuit. The apparatus comprises a heater. The heater is located inside the cavity of the microcircuit and is attached to the structure of the microcircuit. The attachment area of the heater to the structure of the microcircuit is substantially less than the back surface area of the heater. An add-on, suspended heater is disclosed in the embodiments described herein.

Abstract: The switch device comprises a pair of cavities, an elongate passage, a non-conductive fluid having a high electrical resistance, a conductive fluid having a high electrical conductivity and an electrical path. The passage is in fluid communication with the cavities and has a substantially elliptical cross-section over at least part of its length. The non-conductive fluid is disposed in each of the cavities. The conductive fluid is located in the passage. The electrical path is changeable between a connected state and a disconnected state by the non-conductive fluid separating the conductive fluid in the passage into non-contiguous conductive fluid portions.

Abstract: The switch device includes first and second cavities, a passage extending between the cavities, a conductive liquid located in the passage and movable therein, a conductive path that includes the conductive liquid, an actuating liquid enclosed in each of the first and second cavities and covering the inner surfaces thereof and an actuating gas enclosed in each of the first and second cavities and existing as a bubble therein. At least one of the cavities includes a constriction element shaped to constrain the expansion of the actuating gas bubble in the cavity. This limits expulsion of the actuating liquid into the passage and movement of the conductive liquid along the passage.

Abstract: A switch device and a method of manufacture are provided that includes providing two substrates. The two substrates collectively include a fluid conductor switch device structure and a trench surrounding the fluid conductor switch device structure. An inner seal material is deposed on one of the substrates and an outer seal material is deposited in the trench. The substrates are joined to one another using the inner seal material and a peripheral hermetic seal is formed between the substrates using the outer seal material.

Abstract: A gravity responsive attitude switch containing electrical contacts separated by a gap, the switch containing a bead liquid and a carrier liquid, the two liquids being immiscible and having different electric resistivity values, where the liquid bead may be disposed between the contacts by properly positioning the switch. The contacts are connected in an electronic circuit which senses the difference in resistivity dependent on whether the bead liquid or the carrier liquid is bridging the gap between the contacts, which in turn determines whether an operative electric circuit is opened or closed.

Abstract: An apparatus for separating a liquid in a liquid metal micro-switch. In representative embodiments, the apparatus comprises a heater and a sub-channel inside a structure. The heater is located inside a cavity of the structure onto which the liquid metal micro-switch is fabricated. The sub-channel inside the structure connects the cavity to a main channel. The sub-channel has a cross-sectional area. The value of the cross-sectional area at the boundary between the sub-channel and the main channel is less than the value of the cross-sectional area at the boundary between the sub-channel and the cavity. The gas permeates the cavity and the sub-channel and is capable of extending into the main channel.

Abstract: Electrical switches are described. In one aspect, an electrical switch includes a closed-loop fluid channel, multiple electrodes, and a pressure control system. The closed-loop fluid channel contains an electrically-conductive fluid and an electrically-insulating fluid. Each of the electrodes is in contact with fluid within the fluid channel at a respective location. The pressure control system is operable to change relative fluid pressure within the fluid channel at locations between adjacent electrodes to control splitting of a contiguous region of electrically-conductive fluid electrically connecting a pair of adjacent electrodes and merging of split regions of electrically-conductive fluid.

Abstract: A pressure sensing switch which prevents the crack and damage when a stress is applied. The pressure-sensing switch extended in an X-Y-direction includes pressure sensing portions arranged in an X-direction and connection portion provided between the pressure sensing portions for connecting the pressure sensing portions. The connection portion includes a straight portion extended in X-direction and a straight portion formed by inverting both ends of the straight portion. The straight portion is deformed in a Y-direction for connecting to the pressure sensing portions.

Abstract: An electrical contact breaker switch has a cavity or space that forms first and second chambers and a plurality of channels. The switch also has at least two solid electrodes formed with electrode components exposed apart from each other within the cavity. A conductive fluid held within the cavity functions as a contact for putting the electrode components of two specific solid electrodes in a “closed” state when in contiguous form and in an “open” state when in non-contiguous form. A form modification unit, which includes the first and second chambers, modifies the form of the conductive fluid.

Abstract: A flow detector includes solid state delay circuitry coupled to a flow indicating device. In response to flow being indicated, the delay circuitry is enabled. After a preset delay interval, if flow is still being indicated, an output signal can be generated. The flow indicating device can be a two-state mechanical switch. A mode setting element can be used to configure the detector for different types of installations.

Abstract: The present invention is directed to electrical devices incorporating mesoscopically conductive liquids. The devices of the present invention include switches constructed such that in one configuration a charge carrying element, such as an electrode, is insulated from a charge receiving element by a thick (super-mesoscopic) layer of a mesoscopically conductive liquid; and in another configuration, the charge carrying elements are proximate each other and the charge is conducted between the elements by a thin (sub-mesoscopic) layer of a mesoscopically conductive liquid. Preferred embodiments of the switches of the present invention are suitable substitutes for switches, relays, or other switching interfaces.

Abstract: A flow detector includes solid state delay circuitry coupled to a flow indicating device. In response to flow being indicated, the delay circuitry is enabled. After a preset delay interval, if flow is still being indicated, electrical energy can be provided by a short circuit to an output device for the duration of indicated flow. The flow indicating device can be a two-state mechanical switch. A short circuit supplying switch can be implemented as a solid state or mechanical latching relay. The flow detector circuits can be used independently to provide local alarms. Alternately they can provide alarm indicating signals to a common alarm control panel.

Abstract: A shock sensor has a mercury wetted insert for supporting a mercury mass normally spaced from a terminal or terminals. The mercury and the terminal or terminals are contained within a sealed housing. When the sensor is subjected to a shock, the mercury is redistributed and protrudes from the insert so as to make contact the terminal or terminals and complete a circuit. By providing a mercury-non-wettable surface ahead of the mercury wetted insert, a closure delay time or operation time is selectively set. Additionally, the porosity of various membranes within the housing can be pre-selected to vary the speed in which the mercury is redistributed and thus also adjust the closure delay time. Also, a constriction in the non-wettable surface ahead of the mercury wetted insert can be utilized to provide a time delay by introducing a dash-pot effect.

Abstract: A shock sensor has a mercury-wetted insert for supporting a mercury mass normally space from a terminal. The mercury and terminal are contained within a sealed housing. When the sensor is subjected to a shock, the mercury is redistributed and protrudes from the insert so as to contact the terminal and complete a circuit between that terminal and another terminal that is normally in communication with the mercury.

Abstract: A mercury switch device comprising a pool of mercury and a plurality of electrical contacts made of or coated with a non-wettable material such as titanium diboride.

Abstract: Diesel fuel tends to deposit an insulating coating on surfaces it contacts. A probe, preferably in the form of a siphon tube, is coupled to a detection circuit which is responsive to either low resistance or high capacitance between the probe and ground. The probe is initially uncoated to make a resistive coupling to a fuel container when accumulated water touches the probe. When insulating deposits from the diesel fuel or other fuel oil coat the probe, capacitive coupling will occur between the probe and the accumulated water. In either case the presence of water triggers an output signal by the detection circuit.

Abstract: A drawback device to ensure the return of a moving part to its original position, after it has been moved away from it by another force. The existing method, involving an elastic mechanical component which acts as a spring, is replaced in this invention by a quantity of liquid, placed between the moving part and a fixed part, and remaining there through the effect of capillarity. When the moving part moves away from the fixed part, surface tension is created on the surface of the liquid, tending to draw the moving part back to its original position. Such devices are used in sealed miniaturized relays with mercury-wetted contacts.

Abstract: An inclination sensitive hand controller comprises a generally cylindrical handle having liquid contact switches mounted at different angles of orientation within the handle. The switches are actuated dependent upon the tilting of the handle from a preselected position. A squeeze responsive control switch is mounted in a non-exposed position within the handle. This switch is activated or deactivated upon squeezing of the handle to control connection and disconnection of electrical power to the tilt switches. An exposed finger- depressible switch is mounted at one end of the handle which independently controls other circuits than the circuits controlled by the tilt switches and the squeeze responsive control switch.

Abstract: A freestanding multidirectional control device for use in controlling video display images in electronic game machines comprises a handle member connected by a multiconductor cable to electric circuitry in the game machine. The handle member contains two pairs of gravity switches electrically connected to separate output signal conductors in the cable. The pairs of switches are mutually normal along the vertical axis of the handle member. The switches in each pair are oppositely inclined from vertical so that tilting the handle member one way produces an output signal on one of the conductors and tilting it in the opposite direction produces such a signal on a different conductor. The pairs of switches can be either single-ended, two-position tilt switches or double-ended, three-position tilt switches. At least one of the liquid contact switches may contain at least one electrode comprising a length of electrically resistive material to form a variable resistance electrical conduction path.

Abstract: The invention relates to a device for articulating a moving blade pivoting on its base.The mobile member is constituted by a blade fixed to a float, which floats on a liquid contained in a cavity made in a base, the liquid being kept in the cavity by capillarity. The nature and dimensions of the float are adapted to the liquid density. The cavity dimensions are large enough to permit the float to move, without mechanical jamming. The mobile assembly, blade and float is prevented from escaping from the cavity by at least one bridge welded to the base towards the ends of the float.Application to switches with blades wetted by an electricity-conducting liquid.

Abstract: A mercury switch sensitive to rotations in either of two selected directions is provided for interrupting the ignition circuit of a motorcycle if the motorcycle should topple over. The switch has a Y-shaped housing with two hollow copper members joined to a hollow stem. An electrical contact is mounted by means of an insulating stopper in the hollow stem. A pool of mercury provides a contact between the electrical contact and the metal Y-shaped housing. A wire is affixed to the electrical contact and a second wire is affixed to the metal housing. A pool of mercury completes the switch between the insulated electrical contact and the metal housing. As the switch is rotated in either a first or a second selected direction, at a predetermined point, the pool of mercury will separate from the insulated electrical contact thereby causing the switch to display an open circuit condition.

Abstract: A device is disclosed which, in response to forces acting upon it, such as gravity, inertia, magnetic fields and the like, opens or closes electric circuits or otherwise generates signals which may be used to control predetermined functions.

Abstract: An omnidirectional tilt switch includes an enclosure for a gravity response conductive ball. An annular shelf surrounds a central depression where at least one switch contact passing into the housing is exposed. The shelf is operable to support the ball in a position resting against a cup-shaped portion of the switch housing, with the ball centroid located within a imaginary right cylinder having the inner shelf periphery as a base. In response to tilting of the switch, the ball is movable away from the cup-shaped housing to the depression where it engages the aforementioned contact and closes a circuit between that and another contact.A switch holder mounts the switch on a substrate located, for example, in an electro-optical display-type watch. The holder includes a base with a positioning edge or surface and tabs for securing the base to the substrate. Remote from the positioning edge or surface, the switch is supported at an angle relative to the positioning edge or surface.

Abstract: A sound or other such alarm which in practice is mounted on a fence so as to signal any attempt to surmount or bypass the fence, such attempt being an alarm condition; such alarm being characterized by its ability to distinguish said alarm condition from non-alarm conditions, thus having minimal false alarms, even though in all instances the alarm basically is triggered into operation in response to vibratory movement of the fence. This ability of the alarm to distinguish between alarm and non-alarm conditions is achieved by requiring a selected number of alarm-operating pulses (i. e. a selected number of vibrations in the fence) before the alarm operates.