Patent ID: 7977137

Claim:
A method of making a zip-mode actuated, mono wafer self-latching MEMS electrical switch comprising the steps of: placing a fixed position metal electrical contact and coplanar surrounding metal on an electrically insulating substrate member; forming a first layer of electrical charge retention-capable dielectric material over said fixed position metal electrical contact; overlaying said layer of electrical charge retention-capable dielectric material, and said fixed position metal electrical contact with a first layer of sacrificial material; providing a low spring constant, elongated, flexible, thin, cantilever, metallic switch wiper member over said first layer of sacrificial material and a selected portion of said electrically insulating substrate member, a free end of said wiper member residing contiguous said fixed position metal electrical contact; covering said metallic switch wiper member, said first layer of sacrificial material, said first layer of electrical charge retention-capable dielectric material, said selected portion of said electrically insulating substrate member with a second shaped mass of said sacrificial organic material; adding a second layer of said electrical charge retention-capable dielectric material over said second shaped mass of sacrificial organic material; supplying a sealable metallic cap member over all of said second layer of electrical charge retention-capable dielectric material, said second shaped mass of said sacrificial organic material, said metallic switch wipe member, said first layer of sacrificial organic material, said first layer of electrical charge retention-capable dielectric material and said selected portion of said electrically insulating substrate member; and releasing said metallic switch wiper member from captivity in said sacrificial organic material in a releasing sequence accomplished within switch wiper member protecting confines for said sealable metallic cap member; whereby said released switch wiper member is susceptible to receiving an opposing curvature s-shaped stable profile contour in at least one of a said electrical contact adjacent and a said sealable cap layer adjacent transiently energized switch wiper member operating positions.