An Electrostatically Actuated Stacked-Electrode MEMS Relay With a Levering and Torsional Spring for Power Applications

Abstract

This paper reports on a novel electrostatically actuated microelectromechanical systems (MEMS) relay for use in power-switching applications. It features a levering and torsional spring to enhance the stand-off voltage and contact endurance by means of an active-opening scheme. The proposed relay is based on a unique stacked-electrode structure and a soft insulating layer under the contact material that make it possible to obtain extremely low contact resistance, resulting in high current driving capability and reliable contact endurance. The fabricated relay demonstrated actuation voltages under 40 V, a switching time of 230 μs, and a maximum stand-off voltage of 360 V, which is the highest level among electrostatically actuated MEMS relays reported to date. The contact resistance was under 5 mΩ at 40 V of applied voltage, and more than 1 A could be carried. The contact reliability in a hot-switching condition was investigated for various dc current levels. At a current of 10 mA, the relay operated for more than 107 cycles before the test was stopped. In addition, the permanent contact stiction during switching operation at a 200-mA current level was overcome with a pull-off (active-opening) voltage of 90 V by the levering and torsional spring. Using this healing process, a device that failed at about 104 switching cycles in the 200-mA hot-switching mode was revived and reoperated with negligible contact resistance variation, lasting up to 4.9 ×105 cycles, constituting an order-of-magnitude enhancement in the lifetime even after failure.