Robust electrical contacts integrating a liquid metal bridge for mechanical switches

Abstract Intrinsic roughness of solid surfaces causes a series of inevitable shortcomings in the use of mechanical electrical contacts, among which one of the most fatal is the repulsive electrodynamic force arising from high currents. A large contact force coming from a heavy holding mechanism helps to suppress the repulsive effect whereas the mechanism consumes energy and remains to be challenging for a compact switching device. Here, a liquid metal (LM) bridge is introduced to wet solid electrodes to eliminate contact issues. Four instability patterns induced by the electromagnetic pinch effect are identified to characterize LM bridge’s response to high currents. Simulation results reveal that an inner vortex caused by uneven distributions of current density and electrodynamic volume force leads to the rupture of a necked LM bridge. With a uniform structure, a cylindrical LM bridge is proved to be robust with respect to an impulse current higher than 10 kA, exceeding a commercial compact relay by a factor of more than 10 in terms of current withstand performance. Our research facilitates compact and energy-saving switch equipment and has a potential to realize arbitrary desired levels of high current withstand without the use of a holding mechanism. This paper also offers deep insights into the high current applications of LM from the perspective of fluid related physical mechanisms.