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Reed switch

A reed switch is an electromechanical device that operates as a switch in response to an applied , consisting of two ferromagnetic metal reeds hermetically sealed within a envelope containing an such as . When a magnet approaches, the reeds become magnetized and attract each other, flexing to make and close the ; upon removal of the field, they return to their open position due to elastic recovery. This simple, passive design enables reliable operation without external power for the switch itself, with lifespans often exceeding billions of cycles. The concept of the reed switch originated in 1922 when Russian professor Valentin Kovalenkov at proposed using flexible magnetic contacts for switching, though early versions lacked sealing. It was further developed in the late 1930s by Walter B. Ellwood at Bell Laboratories, who patented the modern hermetically sealed form in 1941 (U.S. Patent No. 2,264,746), enabling its widespread use in for compact, low-power relays in telephone exchanges. By the , reed relays had become integral to electronic switching systems, including those in early and space applications like the Apollo missions, due to their ultralow power consumption and resistance to environmental hazards. Reed switches are valued for their electrical isolation (up to several kilovolts), compatibility with high voltages and currents, and ability to function in harsh environments like explosive atmospheres or vacuums, without arcing thanks to the sealed design. Common types include normally open (Form A), normally closed (Form B), and changeover (Form C) configurations, with contact materials like or for durability. Today, they find applications in security systems (e.g., sensors), automotive components (e.g., fuel level indicators), medical devices (e.g., defibrillators and endoscopes), appliances, and industrial sensors, remaining a cost-effective despite advances in solid-state alternatives.

History and Development

Invention and Early Patents

The concept of the reed switch originated in 1922 when Russian professor Valentin Kovalenkov proposed using flexible magnetic contacts for switching, though early versions lacked hermetic sealing. The modern reed switch was invented in 1936 by Walter B. Ellwood at Bell Telephone Laboratories, where he sought to develop a compact, reliable switching device for telecommunications applications. Ellwood's design featured a pair of ferromagnetic reeds—thin, flexible metal strips—sealed within a hermetically enclosed glass tube to protect the contacts from environmental contamination and ensure long-term reliability. This innovation built upon earlier concepts of magnetic actuation but distinguished itself through its emphasis on vacuum or inert gas sealing, which minimized oxidation and mechanical wear on the contacts. Early experimental work at focused on integrating these ferromagnetic reed contacts into vacuum-sealed glass envelopes specifically for telephone relay systems, aiming to replace bulkier mechanical switches with more efficient magnetic alternatives. By 1938, prototype reed switches had been incorporated into coaxial cables for experimental telephone exchanges, demonstrating their potential for low-power, high-speed operation in signal routing. Ellwood filed a for the electromagnetic switch on June 27, 1940, which was granted as U.S. 2,264,746 on December 2, 1941, detailing a single-pole, double-throw where an external caused the reeds to flex and make or break contact. A key milestone occurred in the 1940s with the first practical demonstrations of reed switches in magnetic switching for telecommunications , enabling faster and more compact relay assemblies in early electronic exchanges. The initial batch of reed switches became available around 1940, marking the transition from laboratory prototypes to viable components for infrastructure. This design addressed limitations in prior magnetic contact ideas from the , such as those explored in early instruments, by providing superior isolation and durability essential for continuous operation in networks.

Commercialization and Evolution

Bell Telephone Laboratories played a pivotal role in the commercialization of reed switches, integrating them into electronic switching systems for telephone exchanges. Although developed earlier, the first widespread commercial deployment occurred with the No. 1 Electronic Switching System (No. 1 ESS) in 1965, where arrays of reed relays formed the core switching fabric, enabling more reliable and efficient call routing compared to traditional electromechanical systems. This marked a significant transition in telecommunications infrastructure, with millions of reed relays deployed across exchanges over the following decades. In the and , dedicated manufacturers emerged to scale production and innovate on reed switch designs. Hamlin Electronics, founded in , quickly became a key player, specializing in reed switches and relays for automotive, industrial, and applications, eventually supplying global markets with custom sensor solutions. Similarly, Coto Technology, which began producing high-performance reed relays in the early after its founding in 1917 as Coto Coil Incorporated, introduced compact and low-power variants that expanded their use beyond into and . These companies drove market growth by emphasizing reliability and customization, solidifying reed switches as a staple in electromechanical sensing. Design evolution in subsequent decades addressed cost, durability, and size constraints. Manufacturers developed plastic-molded encapsulations as alternatives to fragile envelopes, reducing expenses and enhancing resistance to environmental stresses like and . advanced further in the , yielding sub-millimeter reed switches suitable for emerging compact , such as portable devices and automotive controls, while maintaining sealing for longevity. As of 2025, reed switches continue to evolve for contemporary demands, particularly in (IoT) ecosystems where they serve as low-power magnetic sensors in smart home devices and industrial monitoring systems. Compliance with directives has led to widespread adoption of lead-free variants, eliminating hazardous materials like lead in solder and components to align with global environmental regulations.

Design and Construction

Physical Components

A reed switch consists of two ferromagnetic reeds, which serve as the primary switching contacts. These reeds are typically constructed from a -iron alloy containing approximately 52% nickel and 48% iron, known as Alloy 52, selected for its magnetic properties and compatibility with the sealing process. The ends of the reeds are flattened and widened to form overlapping contact areas, enhancing reliability and contact surface area compared to point contacts. The reeds are enclosed within a envelope, usually made of , which provides environmental protection by sealing out moisture, dust, and corrosive elements while maintaining an atmosphere or inside to prevent oxidation. In some high-temperature applications, alternative materials like ceramics may be used for the envelope. Extending from the reeds are lead wires that facilitate external electrical connections. These leads are typically formed from the same nickel-iron alloy as the reeds but are often plated with tin or a tin-over-copper layer to improve and corrosion resistance. Standard reed switches measure 10 to 50 mm in overall length, with the glass envelope portion commonly ranging from 14 to 20 mm. The reed gap in the open state is typically less than 0.025 mm (25 microns), allowing for precise magnetic actuation while minimizing mechanical stress on the contacts.

Manufacturing Techniques

The manufacturing of reed switches starts with the forming of the reed blades, which are precision-engineered ferromagnetic contacts essential for reliable magnetic actuation. Thin strips of nickel-iron alloy, such as 52 alloy, are selected for their compatible and magnetic properties, then stamped from wire stock using hydraulic presses to create the flexible, flat blades with precise dimensions. This stamping process introduces , necessitating subsequent annealing to restore optimal performance. Annealing involves rapidly heating the stamped blades above their recrystallization temperature in a controlled, non-oxidizing atmosphere, holding them at that temperature, and then slowly cooling them to relieve internal stresses from forming. This heat treatment enhances the blades' and flexibility, increases magnetic permeability, and reduces magnetic , thereby minimizing losses during operation. The resulting low- reeds exhibit improved responsiveness to , a critical requirement for switch reliability. Following forming and annealing, the blades receive a protective multi-layer , typically via magnetron in a , to ensure durable, low-resistance contacts. The coated reeds are then inserted into precision glass tubes matched for coefficients, with the tube ends fused hermetically at approximately 1000°C using radio-frequency heating, lamps, or lasers—wire-wound heaters being preferred for uniform seal shapes. During sealing, the tube is often filled with an mixture, such as or , to prevent oxidation of the contacts and maintain electrical stability in the sealed environment. Quality control is integral to the process, emphasizing integrity and electrical performance to meet standards. Post-sealing, each switch undergoes helium leak testing to verify hermeticity, detecting leaks as small as 10^{-8} scc/s to ensure protection against environmental contaminants. is measured immediately after assembly using a low-voltage , applying a test current of 10-100 to confirm values typically below 100 mΩ, identifying any misalignment or defects. Automation advancements, introduced in lines since the , have enabled high-volume in environments with robotic handling for stamping, sputtering, and sealing. These automated systems now yield hundreds of millions of units annually from major producers, achieving that enable low-cost .

Principle of Operation

Magnetic Activation Mechanism

A reed switch is activated by an external magnetic field, either from a permanent magnet or an electromagnet, applied parallel to the axis of the switch. This field magnetizes the two ferromagnetic reeds inside the hermetically sealed glass envelope, inducing opposite magnetic poles at their overlapping contact ends—one reed becoming a north pole and the other a south pole at the tips. The resulting magnetic attraction between these opposite poles generates a force that overcomes the reeds' inherent spring tension, flexing them toward each other to close the electrical contacts. The closing action is driven primarily by this magnetic attraction force, which pulls the low-mass reeds together across the small air gap, typically on the order of microns. Due to the reeds' minimal mass and the rapid nature of the magnetic pull, contact bounce—temporary separations and re-closures upon impact—is limited, usually lasting a few milliseconds and aiding in reliable operation. The ferromagnetic composition of the reeds, often nickel-iron alloys, enhances their responsiveness to the field while providing the necessary mechanical resilience. Ferromagnetic hysteresis in the reeds introduces a differential between activation and deactivation thresholds. The operate point represents the minimum external required to close the contacts, while the release point is the lower at which the contacts separate as the field diminishes. This loop, characteristic of the material's curve, prevents oscillatory switching near the threshold and ensures bistable behavior, with the gap between points often 20-50% of the operate value depending on design. The attractive force enabling closure can be approximated for the magnetized reeds as dipoles using the simplified equation for the axial force between two aligned magnetic dipoles: F = \frac{3 \mu_0 m_1 m_2}{2 \pi d^4} where \mu_0 is the permeability of free space ($4\pi \times 10^{-7} H/m), m_1 and m_2 are the induced magnetic moments of the reeds, and d is the separation distance. This inverse-fourth-power relationship underscores the sensitivity to small changes in gap distance, allowing operation with modest field strengths on the order of 10-100 ampere-turns.

Electrical Characteristics

Reed switches exhibit a range of electrical properties that determine their suitability for various switching applications, primarily governed by the contact materials and sealing. The contact rating typically specifies the maximum carry of 0.5 to 10 A and switching power of 10 to 500 , with operating voltages up to 200 to 1000 V for both and circuits, depending on the switch design and load type. Response times are notably fast due to the mechanical simplicity, with operate times ranging from 0.5 to 2 and release times similarly in the 0.5 to 2 range, including contact bounce; this enables handling of high-speed signals. The low electrostatic between contacts, typically less than 1 (often 0.2 to 0.5 ), minimizes signal in sensitive circuits. Initial is low, generally under 0.1 Ω (around 50 to 100 mΩ), which increases gradually with operational wear from arcing or mechanical cycling. In the open state, insulation exceeds 10^9 Ω, often reaching 10^10 Ω or higher, ensuring reliable isolation under normal conditions. These characteristics are influenced by factors such as contact plating (e.g., or ) and environmental sealing, which help suppress arcing during switching, particularly for inductive or capacitive loads where suppression s may be required to maintain limits.

Types and Variations

Normally Open Switches

A normally open (NO) reed switch features two ferromagnetic reeds separated by an air gap within a hermetically sealed envelope, maintaining an open in the absence of a . When an axial exceeding the switch's is applied, the reeds magnetize with opposite polarities at their ends, attracting each other to close the contacts and complete the . The design of NO reed switches incorporates flat, overlapping reed ends that form a reliable upon actuation, minimizing wear and ensuring low . Standard models exhibit a sensitivity range of 10 to 60 ampere-turns (AT), where lower values indicate higher sensitivity to weaker ; specialized high-sensitivity variants can operate below 10 AT for applications requiring detection of distant or low-strength magnets. This configuration's simplicity—lacking permanent biasing—contributes to its widespread adoption, with NO types comprising the most common reed switch variant due to ease of and . Common form factors for NO reed switches include surface-mount device (SMD) versions suited for direct () assembly, typically in subminiature sizes around 7 to 14 mm in length, and cylindrical glass-enclosed types for through-hole mounting, often ranging from 14 to 50 mm. These sizes enable versatile deployment in compact while preserving the switch's sealing and magnetic response.

Normally Closed and Changeover Switches

Normally closed (NC) reed switches maintain electrical continuity between contacts in the absence of an external , providing a default closed state that opens upon application of an opposing . This configuration is typically achieved by biasing the reeds with a permanent integrated into the assembly, which holds the ferromagnetic reeds in contact; the switch opens when an external field strong enough to overcome the bias—often exceeding 20 to 100 ampere-turns (AT)—is applied. Alternatively, some designs incorporate a mechanical spring or internal structure to bias the reeds closed without an external , ensuring reliable operation in low-power or tamper-resistant setups. Single-pole double-throw (SPDT), or , reed switches extend this functionality by enabling toggling between two positions, featuring three reeds hermetically sealed in a glass envelope: a central common reed flanked by two outer reeds that form separate normally open (NO) and normally closed (NC) gaps. In operation, a attracts the common reed to bridge one gap or the other, switching the connection from the NC position to the NO position (or ) as the field or strength changes, with typical sensitivities ranging from 15 to 80 AT for actuation. This design requires precise alignment of the three reeds during manufacturing to ensure consistent and prevent intermittent operation, which increases production complexity compared to simpler two-reed configurations. NC and changeover reed switches differ from standard normally open types primarily in their biased or multi-reed constructions, which allow for closed-default or versatile switching states suited to applications demanding behavior, such as alarms where circuit interruption signals a or power loss. These variants gained traction in the for systems, offering advantages like tamper resistance since cutting the circuit or removing power results in an open state that triggers an alert. For instance, in or sensors, an NC switch ensures the alarm activates if the is removed or the assembly is disturbed, enhancing reliability in intrusion detection.

Applications

In Relays and Switching Devices

Reed relays integrate a reed switch within an , where the coil generates a to actuate the switch contacts, all hermetically sealed in a for reliable operation in harsh environments. This design ensures the contacts remain protected from contaminants, enabling consistent performance. Variants employ a instead of or alongside the coil, providing non-volatile latching that retains the switched state without ongoing power consumption. In relay applications, reed relays offer significant advantages due to their magnetic actuation mechanism, which eliminates traditional mechanical armatures and associated wear, resulting in extended operational life often exceeding billions of cycles. They also achieve high electrical isolation, with standoff voltages commonly surpassing 10 kV, facilitating safe switching in high-voltage circuits without arcing or leakage. Historically, reed relays peaked in during the 1950s, serving as selectors in electromechanical exchanges for efficient call routing. By the 1960s, millions were deployed in crossbar systems to manage substantial daily call volumes across vast networks. In automotive applications, they supported ignition systems through the by providing precise, low-power magnetic triggering for spark control. Today, they excel in low-signal RF switching, offering minimal and high for sensitive signal paths in test and communications devices.

In Sensors and Detection Systems

Reed switches play a crucial role in magnetic proximity sensors, where they detect the presence or absence of a magnetic field generated by a paired permanent magnet. These sensors are commonly employed in security applications, such as door and window alarms, where the reed switch activates upon the magnet moving out of range, typically at distances of 10-50 mm depending on magnet strength and switch sensitivity. When the door or window is closed, the magnet aligns closely with the reed switch, keeping the contacts closed; opening the door separates the magnet, opening the circuit and triggering an alarm. This non-contact mechanism ensures reliable detection without mechanical wear, making it ideal for high-traffic entry points. In position sensing, reed switches enable precise detection of mechanical movements by registering the passage of magnets attached to rotating or linear components. In automotive anti-lock braking systems (ABS), for instance, a reed switch mounted near the wheel hub counts pulses from a toothed ring or embedded magnets to measure wheel speed and prevent skidding. This setup provides robust, contactless feedback essential for real-time vehicle control, with the switch's low power consumption and immunity to environmental noise enhancing reliability in harsh conditions. Similarly, in industrial encoders, arrays of reed switches track magnet positions on shafts or conveyor belts, facilitating accurate speed and position monitoring for automation processes. For level detection in tanks, reed switches are integrated into float-based systems where a buoyant containing a rises or falls with the liquid level, sequentially activating or deactivating reed contacts along a vertical . This configuration allows for multi-point sensing, such as low, medium, and high levels in or chemical storage tanks, enabling automated control to maintain optimal volumes. Arrays of multiple reed switches provide level indications without in the sensing path, reducing maintenance needs in corrosive or contaminated environments. In medical devices, reed switches are used for reliable, non-invasive sensing in critical applications. Implantable cardioverter-defibrillators (ICDs) incorporate reed switches to detect external magnets, allowing clinicians to switch device modes or inhibit therapy during procedures without surgery. Similarly, in endoscopes and capsule endoscopy systems, miniature reed switches activate imaging or sampling functions upon magnetic proximity, enabling precise control in minimally invasive diagnostics. In the 2020s, reed switches have seen expanded integration in smart home () devices, particularly contact sensors for systems like those from . These sensors use reed switches paired with small magnets to detect door and window states, sending wireless alerts to users' apps for intrusion monitoring. This low-cost, battery-efficient technology supports seamless connectivity in modern ecosystems, contributing to energy-efficient smart .

Performance and Reliability

Advantages and Limitations

Reed switches offer several key advantages that make them suitable for demanding applications. Their glass encapsulation provides robust protection against environmental contaminants, enabling operation in harsh conditions such as dust, moisture, and corrosive or atmospheres. This sealing also ensures no sparking during actuation, enhancing safety in potentially hazardous environments. Additionally, reed switches require no external power for operation, resulting in extremely low power consumption—typically less than 1 mW in sensing configurations—making them ideal for battery-powered devices. They provide complete between control and load circuits, with breakdown voltages often exceeding 1 kV, eliminating the need for additional isolation components. In terms of mechanical reliability, reed switches withstand vibrations up to 35-50 and shocks up to 50 without malfunction, outperforming many mechanical alternatives in dynamic settings. Under non-arcing DC conditions at low loads, they achieve exceptionally long lifespans, often exceeding 10^9 operations, due to minimal contact wear. Despite these strengths, reed switches have notable limitations that can influence design choices. The fragile glass envelope is susceptible to mechanical ; while they can withstand operational shocks up to 50-100 without malfunction, severe impacts generating thousands of -forces can cause damage, potentially leading to contact misalignment or . Current-handling capacity is restricted; while they can carry up to 10 A continuously, switching loads above 1-5 A typically induces arcing, which erodes and shortens life. Furthermore, their magnetic sensitivity can result in false activations from stray external fields, such as the Earth's or nearby magnets, requiring careful shielding or positioning in multi-device systems. Compared to alternatives like sensors or solid-state switches, reed switches excel in and zero but lag in response speed, with actuation times around 0.2-1 ms versus microseconds for devices. Versus mechanical switches, reeds provide superior environmental sealing and vibration resistance but are less tolerant of high-impact shocks and higher currents without auxiliary suppression. These trade-offs position reed switches as a reliable choice for low-power, isolated applications where integrity is paramount, though they may require solutions for high-speed or high-current needs.

Lifespan and Failure Modes

Reed switches exhibit a robust operational lifespan, typically rated for 10^6 to 10^9 switching operations under specified load conditions, depending on factors such as , voltage, and load type. At rated loads, this endurance reflects the minimal mechanical wear inherent to their hermetically sealed design, where the ferromagnetic reeds flex without external exposure to contaminants. For (DC) applications without arcing—such as signal-level or low-power switching—the lifespan can extend significantly, often reaching 10^10 operations or more, as arcing is eliminated and contact degradation is minimized. Common failure modes in reed switches primarily stem from electrical and mechanical stresses during operation. Contact occurs when inrush currents significantly exceed the device's , causing the reeds to together under excessive , leading to a permanent . Pitting of the contact surfaces results from arcing in (AC) loads, where electrical discharge erodes the metal over repeated cycles, increasing and eventually causing open circuits. Mechanical fatigue arises from the repeated flexing of the reeds, which can lead to cracking or misalignment after billions of operations, particularly in high-frequency applications. Reliability testing for reed switches incorporates standardized methods to simulate operational stresses. Mechanical integrity under shock and vibration is evaluated per MIL-STD-202, ensuring the device withstands environmental accelerations without performance degradation. Life cycling tests verify endurance under rated electrical loads to operational cycles before failure thresholds are reached. To mitigate these failure modes and enhance longevity, design practices include the use of circuits, such as networks, to suppress arcing in inductive or capacitive loads by limiting voltage transients. Additionally, operating the current below the rated value reduces on the contacts, significantly extending in demanding applications.

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