Patent ID: 9076615
Filing Date: 2015-07-07
Classification: H01F,H01H,Y10T

Abstract:
1. A method of forming an electromechanical relay, the method comprising: etching a layer of magnetic material on a substrate to foam a substrate-metal structure comprising a pattern of one or more electrically conductive contacts on a surface of the substrate; electroplating the substrate-metal structure to form an electroplated substrate-metal structure; attaching the electroplated substrate-metal structure to a surface of a multi-layered printed circuit board; and removing a portion of the electroplated substrate-metal structure to electrically decouple the one or more electrically conductive contacts; wherein the multi-layered printed circuit board comprises: a common contact terminal disposed within the multi-layered printed circuit board, wherein a first end of each of the one or more electrically conductive contacts is disposed in alignment to the common contact terminal; and one or more magnetic actuators respectively associated with the one or more electrically conductive contacts and each magnetic actuator comprising (i) a magnetic core comprising a first core part disposed within at least one via extending through one or more layers of the multi-layered printed circuit board, and (ii) an electrical coil disposed around at least a portion of the first core part of the magnetic core and within one or more layers of the multi-layered printed circuit board; wherein in performing the attaching step, each of the one or more electrically conductive contacts is disposed in alignment to a corresponding one of the magnetic actuators to enable electrical contact between the common contact terminal and a given electrically conductive contact upon activation of a given magnetic actuator associated with the given electrically conductive contact.