Fabrication of topical stopper on head gasket by active matrix electrochemical deposition

1. A method for building a three dimensional formation on a work piece through the action of electrochemical deposition using a static, generic, multi-segmented electrode array, said method comprising the steps of:

providing a plurality of anodic electrodes, each having an active end;

supporting the plurality of electrodes in an ordered array;

electrically insulating each electrode from another;

establishing an electrical circuit with each electrode to form individual anodes, each of the anodes having a width;

providing a cathodic work piece having a work surface to be built upon;

supporting the work piece with its work surface in opposing spaced relation to the active ends of the electrodes;

flowing an electrolyte rich with metallic ions through the space between the work surface and the active ends;

selectively varying the electrical energy delivered to specific electrodes to cause metallic ions in the electrolyte to deposit onto the work surface as a three dimensional formation;

supporting the active ends of all the electrodes in fixed relation to one another and in fixed relation to the work piece throughout the electrochemical deposition operation;

said step of selectively varying the electrical energy including delivering electrical energy to at least one of the electrodes while not delivering electrical energy to at least one other of the electrodes for a first time interval, delivering electrical energy to the at least one electrode not energized during the first time interval for a second time interval so that the three dimensional formation provided by the metallic ions has a thickness varying along the work surface, and wherein the following criteria are satisfied:

w max =a ·√{square root over (1+ρ −2 )}  (1)

h max =a ·√{square root over (1+ρ 2 )}  (2)

wherein w max is the maximum width of any one of the anodes, a is the profile tolerance of the three dimensional formation, ρ is the maximum profile slope of the three dimensional formation, and h max is the maximum thickness of the three dimensional formation.

2. The method of claim 1 , wherein said step of flowing an electrolyte includes maintaining an electrolyte flow rate of between 0.5 and 4 meters per second.

3. The method of claim 1 , wherein said step of selectively varying the electrical energy includes varying the amplitude of the local energy field.

4. The method of claim 1 , wherein said step of selectively varying the electrical energy includes varying the duration of the local energy field.

5. The method of claim 1 , further including the step of masking a portion of the work surface with an electrical insulator to prevent deposition of the metallic ions on select regions of the work surface.

6. The method of claim 1 , wherein said step of flowing an electrolyte includes recirculating the electrolyte and further including the step of replenishing the electrolyte with metallic ions to compensate for the loss of metallic ions deposited onto the work surface.

7. The method of claim 6 , wherein said replenishing step includes adding metallic ions to the electrolyte upstream of the space between the work surface and the active ends.

8. The method of claim 6 , wherein said recirculating step includes filtering impurities out of the electrolyte.

9. The method of claim 6 , wherein said replenishing step includes dissolving metallic ions from the anodes.

10. The method of claim 9 , wherein said step of dissolving metallic ions from the anodes includes sheltering anode pellets behind a porous membrane.

11. The method of claim 9 , wherein said step of dissolving metallic ions from the anodes includes independently moving the anodes toward the work surface.

12. The method of claim 9 , wherein the following criteria is satisfied:

h min =v·T/n   (3)

wherein T is the cycle time, v is the erosion rate of the anodes, n is the total number of deposit layers, and h min is the minimum thickness of the three dimensional formation.

13. The method of claim 1 , wherein said step of delivering electrical energy to at least one of the electrodes for the first time interval comprises delivering electrical energy to a number of the electrodes for the first time interval, the number of the electrodes being at least two, and delivering electrical energy to the number of the electrodes plus at least one more of the electrodes for the second time interval.

14. The method of claim 13 , wherein the electrodes energized for the first time interval are disposed adjacent one another, and the electrodes energized for the second time interval are disposed adjacent one another and include the electrodes energized for the first time interval.

15. The method of claim 1 , wherein the first time interval is before or after the second time interval.

16. The method of claim 1 , wherein the electrodes are arranged in a pattern corresponding to the shape of the three dimensional formation to be provided.

17. A method for building a three-dimensional formation on a work part through the action of electrochemical deposition using a multi-segmented electrode array, said method comprising the steps of:

providing a plurality of anodic electrodes, each having an active end;

supporting the plurality of electrodes in an ordered array, each of the electrodes having a width;

electrically insulating each electrode from another;

establishing an independent electrical circuit with each electrode;

providing a cathodic work part having a work surface to be built upon;

supporting the work part with its work surface in opposing spaced relation to the active ends of the electrodes;

flowing an electrolyte rich with metallic ions through the space between the work surface and the active ends;

selectively varying the electrical energy delivered to specific electrodes to cause metallic ions in the electrolyte to deposit onto the work surface as a three-dimensional formation;

said step of selectively varying the electrical energy including delivering electrical energy to each of the electrodes for a first time interval, and not delivering energy to at least one of the electrodes while delivering electrical energy to at least one of the electrodes for a second time interval so that the three dimensional formation provided by the metallic ions has a thickness varying along the work surface, and wherein the following criteria are satisfied:

w max =a ·√{square root over (1+ρ −2 )}  (1)

h max =a ·√{square root over (1+ρ 2 )}  (2)

wherein w max is the maximum width of any one of the electrodes, a is the profile tolerance of the three-dimensional formation, ρ is the maximum profile slope of the three-dimensional formation, and h max is the maximum thickness of the three-dimensional formation.

18. The method of claim 17 , wherein said step of flowing an electrolyte includes maintaining an electrolyte flow rate of between 0.5 and 4 meters per second.

19. The method of claim 17 , wherein said step of selectively varying the electrical energy includes varying the amplitude of the local energy field.

20. The method of claim 17 , wherein said step of selectively varying the electrical energy includes varying the duration of the local energy field.

21. The method of claim 17 , further including the step of supporting the active ends of all the electrodes in fixed relation to one another and in fixed relation to the work piece throughout the electrochemical deposition operation.

22. The method of claim 17 , wherein said step of flowing an electrolyte includes recirculating the electrolyte, and further including the step of replenishing the electrolyte with metallic ions to compensate for the loss of metallic ions deposited onto the work surface.

23. The method of claim 22 , wherein said replenishing step includes adding metallic ions to the electrolyte upstream of the space between the work surface and the active ends.

24. The method of claim 22 , wherein said recirculating step includes filtering impurities out of the electrolyte.

25. The method of claim 22 , wherein said replenishing step includes dissolving metallic ions from the electrodes.

26. The method of claim 25 , wherein said step of dissolving metallic ions from the electrodes includes sheltering anode pellets behind a porous membrane.

27. The method of claim 25 , wherein said step of dissolving metallic ions from the electrodes includes independently moving the electrodes toward the work surface.

28. The method of claim 25 , wherein the following criteria is satisfied:

h min =v·T/n   (3)

wherein T is the cycle time, v is the erosion rate of the electrodes, n is the total number of deposit layers, and h min is the minimum thickness of the three dimensional formation.

29. The method of claim 17 , wherein the first time interval is before or after the second time interval.

30. The method of claim 17 , wherein the electrodes are arranged in a pattern corresponding to the shape of the three dimensional formation to be provided.

31. The method of claim 17 , further including masking a portion of the work surface with an electrical insulator to prevent deposition of the metallic ions on select regions of the work surface.