Abstract:
Apparatus for defining patterns electrochemically on conductive materials by forming the patterns as conductive features of a tool, providing insulative properties about the conductive features so the patterns are defined; then providing an immersive medium including an etchant or plating material for defining the pattern on a workpiece, providing an electric direct current so that the immersive medium is concentrated at desired locations defined by the conductive features on the conductive materials; and etching the conductive materials by applying the electric current in a quantity and for an elapsed time to etch or plate patterns in or on the conductive materials.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    The present application claims priority to Provisional Application 60/088,126 filed Jun. 4, 1998 by McLeod et al., which is incorporated herein by reference. 
     
    
     
       FIELD  
         [0002]    This invention relates to electrochemical machining (ECM), and particularly to the ECM of fluid dynamic bearing and race surfaces.  
         PRIOR ART  
         [0003]    In the prior art, microfeatures on surfaces, such as the fluid dynamic grooves on bearing and race surfaces, were formed by machining or casting.  
           [0004]    Microfeatures on surfaces in many applications involve the machining of very hard materials, such as ceramics or hard metals. These materials are difficult to work with, and often the result of machining the features was undesirable displacement of the material, resulting in “lips” or “spikes”, also called “kerf” by many machinists; small eruptions of materials along the edges of the grooves or other features. Removing the undesired material often meant polishing or deburring, while great care is required to avoid damage to the surface with microfeatures.  
           [0005]    For example, shallow trenches with a contoured cross-section are often made by pressing on the material with a ball of hard material. This type of manufacture is known to preferentially pile up material along the edge of the trench. Since the edge of the trench may meet the original surface at a shallow angle, the pile up of material can be very difficult to remove.  
           [0006]    Another method of machining which may comprise a machined surface, grooves involves electrochemical machining. In electrochemical machining, an electrode is applied to a work which may comprise a machined surface piece where it is desired to form a feature. Both the electrode and the work piece are in an aqueous electrolyte containing a salt usually NaNO 3  or NaCl. A current from the electrode to the work piece causes the ions of the workpiece to dissolve in solution.  
           [0007]    In the following discussion, etching or removal of material is assumed, but it will be obvious that similar results would be achieved in electrodepositing material, such as in electroplating materials onto a medium.  
           [0008]    Etching occurs where the current reaches the work piece. This effect is pronounced enough to allow microfeatures to be etched in the work piece with only the effect of a cleaning operation elsewhere; which is often independently desirable.  
           [0009]    Electrochemical etching avoids the problem of material pile up, since there is no physical pushing action to cause a rearrangement of the material, but creates problems of its own. One problem introduced by electrochemical machining is that the electrode requires a finite time for material removal. The electrode is often complex and difficult to make; in one prior art approach to making grooves for a bearing. This insulation is placed on the surface to be grooved. This makes for slow, tedious work, and greatly increases costs while limiting productive throughput.  
           [0010]    The present invention addresses the above problems, and introduces benefits not discussed in the interests of brevity and clarity in the discussion above.  
         SUMMARY OF THE INVENTION  
         [0011]    The present invention overcomes the problems of the art as previously known by providing an electrode which covers the entire surface of a fluid dynamic bearing, whether a thrust bearing or journal bearing, on which grooves are to be formed. The electrode has grooves machined or otherwise formed in it and lands between these grooves which define the pattern of the bearing grooves which are to be formed on the bearing surface. By then connecting the bearing element and the electrode element across an appropriate current supply, and causing electrolyte to flow between the two materials, the desired groove pattern is quickly and efficiently formed. The present process and apparatus of this invention allows for complete sets of grooves to be formed on a shaft, a sleeve surrounding a shaft, a thrust plate or counter plate, or either the male or female section of a conical bearing, simply by changing the shape of the surface electrode and forming the appropriate pattern of grooves and lands thereon. 
       
    
    
     BRIEF DESCRIPTION  
       [0012]    [0012]FIG. 1 is an embodiment of the prior art with an idealized view showing an electrode of a type often used.  
         [0013]    [0013]FIG. 2 200  is an embodiment of the invention showing a section of a bearing race with two fluid dynamic bearing surfaces included. In the prior art, detail such as this within a bore would be difficult or even impractical, but with the present invention can be done with a shaft-shape insertable tool.  
         [0014]    [0014]FIG. 3 300  is an embodiment of the invention showing a conical end bearing surface combined with a cylindrical bearing surface in a race for a shaft support.  
         [0015]    [0015]FIG. 4 400  is an embodiment of the invention showing how multiple bearing surfaces may be incorporated into a tool comprising a shaft with provisions for forming a bearing end surface for lateral bearing support on the finished part being built.  
         [0016]    [0016]FIGS. 5A and 5B are embodiments of the invention showing a tool end for forming an internal bearing surface, with a section view in FIG. 5B showing the insulation between the electrodes on the tool.  
         [0017]    [0017]FIG. 6 is an embodiment of the invention showing how a conductive tool is built up, in this case with brass. The tool will then be coated with an insulator and polished, forming the cross-section of FIG. 5B.  
         [0018]    [0018]FIG. 7 is an embodiment of the invention showing an application in which microfeatures are to be introduced to a conical depression by a tool with an external conical shape for fitting therein.  
         [0019]    [0019]FIG. 8 is an embodiment of the invention showing a bore in a tool for forming microfeatures on an included shaft.  
         [0020]    [0020]FIG. 9 is an embodiment of the invention in which a pattern on a flat tool has been configured in order that the pattern may be electromechanically machined on a flat surface.  
         [0021]    [0021]FIG. 10 is an embodiment of the invention showing a cross sectional view of the flat tool of FIG. 9 demonstrating how an insulator may be used in defining a pattern of microfeatures. 
     
    
     DETAILED DESCRIPTION  
       [0022]    Electrochemical machining (ECM) has many advantages over the conventional mechanical machining. Material displacement, resulting in “bumps”, “spikes”, also called “kerf” in machining, which are common with mechanical machining, is avoided by electrochemical machining. ECM is also well suited to machining microfeatures, where mechanical tools may be too fragile, or if not fragile, too large. However, ECM as it was practiced in the prior art introduces other problems. One problem is that ECM has involved using an electrode to essentially “paint” microfeatures, a slow and expensive process.  
         [0023]    In FIG. 1 a prior art embodiment of ECM  100  is illustrated in an idealized view. The electrode or tool for ECM  103  is shown inside a conceptual direct current (DC) circuit; where the electrode  103  is to be connected to the cathode, and the workpiece  105 , in this case a ferrous material, is illustrated in a blow up of the work area  107 . In this embodiment a salt solution plus electrical flow is being used to etch ferrous material (Fe), with ferrous hydroxide resulting. As illustrated the ferrous hydroxide is discharged in a flow of the etchant.  
         [0024]    The theory of operation is that negative hydroxyl (OH) ions will be repelled from the negative cathode, while ferric (Fe) ions will be repelled by the positive anode, which is the workpiece. The ferric and hydroxyl ions are thereby encouraged to associate. As a practical matter, since the hydroxyl ion is very mobile, while the ferrous ion is more tightly bound, the hydroxyl ion is often considered as “attacking” the ferrous ion and etching it out of the workpiece under the influence of the electric field.  
         [0025]    As the electric current increases, the hydroxyl ions, which may be considered to be the conductors of the DC current, also increase, and as they attack the ferrous ions, giving up their excess electric charge in the process, they “rip” ferrous ions out of the workpiece. The current essentially causes the ions of the workpiece to dissolve in solution.  
         [0026]    [0026]FIG. 2 is an embodiment of an ECM machine  200  of either the prior art or of the invention; the method of practicing ECM is not affected at this level. The electrode or tool  203  is typically a sharp pointed object in the prior art, but is larger with the invention since it must be capable of supporting a master imprint of an entire section of a fluid bearing. The invention has the effect of simultaneously applying multiple parallel electrodes, compared to the prior art. The workpiece  205  is disposed to rotate in this embodiment, with an electrolyte dispenser  207  to apply a constant flow of etchant to the interface between the electrode and the workpiece, but it will be appreciated that any embodiment that brings the tool  203  proximal to the workpiece  205  with an electrolyte dispenser  207  or other means for providing a flowing intermediary between the workpiece  205  and the tool  203  for modifying the workpiece is anticipated hereby. A means for providing a DC current between the tool  203  and the workpiece  205  through the electrolyte or other intermediary herein provided by electrolyte dispenser  207 , thereby using ECM to modify the workpiece, is provided, but not shown. Any of the many means for providing a negative or positive DC voltage and current to the workpiece  205  and a positive or negative DC voltage and current to the tool  203  is within the purview of this invention.  
         [0027]    [0027]FIG. 3 is an embodiment of the ECM workpiece  300  prior art or the invention, and in a completed state. Bearing  303  having microgrooves machined therein, which are emphasized here for clarity, resides in a race  305 , with a shaft  307  being attached to bearing  303 . ECM might be used to provide grooves inside race  305  as an alternative or in addition to grooves on bearing  303 . It is normal for either bearing  303  or race  305  to be stationary, with the other moving at high speeds, in this case rotating. The grooves will typically be provided on at least the one that is moving, bearing  303  or race  305 . The purpose of the grooves is to encourage a fluid dynamic fluid, such as air, toward the center of the bearing when the bearing is in use. Thereby a high pressure area is induced, holding bearing  303  away form race  305  with very little friction, but as much force as practical.  
         [0028]    As the speed of the moving part, bearing  303  or race  305 , increases, it is desired that the amount of fluid dynamic fluid pressurized be minimized, since energy is used in pressurizing the fluid or gas involved. It is therefore desired that both the spacing between parts, such as the bearing  303  and race  305 , and the grooves, such as in bearing  303 , be minimized. This requires that the grooves in, for example, bearing  303 , be very shallow, and that no “kerf” or “lips” be introduced by the manufacturing thereof; meaning imperfections rising above the surface of the workpiece. The particular shape or placement of the grooves is not part of this invention; only the apparatus and method by which they are achieved.  
         [0029]    [0029]FIG. 4 shows a fluid dynamic bearing incorporating a shaft  10  rotating inside a bushing or sleeve  12 . One of the two opposing surfaces, in this case the shaft, carrying cylindrical sections of spiral grooves. A thrust place  14 , rotating in a recess in the sleeve  12 , is also provided with concentric spiral groove sections as shown. The relative rotation of the shaft and sleeve combination pumps the fluid as a function of the direction and angle of the grooves with respect to the sense of rotation of the shaft  10  and thrust plate  14 . Pumping action builds up multiple pressure in zones along the journal and thrust plate, maintaining a fluid film between the relatively rotating parts, and providing stiffness for the bearing. The grooves are of the type which are readily formed by the electrodes used in the present invention. The grooves must be very clean and well-formed, but with no “kerf” on the edges due to the manufacturing process. Also, since this is a common application, the manufacturing process requires high volumes with high quality of the grooved parts. This in turn requires precision tooling as is taught by the invention, and operation on as large an area of a workpiece as practical, so that the time spent on each workpiece may be minimized.  
         [0030]    [0030]FIG. 5 is an embodiment of a cylindrical tool of this invention shown in cross section  500 . In this embodiment, grooves or slots  503  were formed between teeth  505 . It is recognized, of course, that grooves will be formed in the workpiece opposite the teech or lands  503 . An insulator  507  was then provided in grooves  503 , for example, by applying a material such as epoxy or acrylic material to cover both the teeth and intermediate slots, then polishing the outside of the tool surface. Rotating the tool  500  and applying a spaced polishing tool will cause the applied material to be removed outside the slots, but left in the slots, as shown.  
         [0031]    In use, the cylindrical tool  500  has teeth  505  in the shape of a pattern of the slots or grooves to be formed on the surface of the bearing race, which in this case would be a bearing sleeve. By providing electrolyte between the cylindrical tool and surrounding sleeve, material will be removed from the sleeve in the pattern of the teeth  505 , but not the intermediate slots. The tool can be the length of all bearings to be formed on a complementary shaft or sleeve, so that all the grooves of a shaft supporting fluid dynamic bearing can be formed at once. The tool can also be used to form grooves for a bearing on the inner surface of a bearing sleeve.  
         [0032]    [0032]FIG. 6 is a partial view of an embodiment of a cylindrical tool of this invention  600 ; in this case a bore machining tool for introducing grooves into a bore hole in a workpiece. Section A-A illustrates where the view of FIG. 5 might have been taken.  
         [0033]    Raised tooth, also called “kerf”, might occur with the prior art methods, as shown herein at  603 . One method of the prior art for providing grooves, especially when an arced groove rather than the square groove of FIG. 5 is desired, is to use a hard ball under pressure against the workpiece, whereby the hard ball is made to sink into the workpiece. Since the displaced material is not removed, it “flows” outward from the ball, and some of it becomes a raised tooth or “kerf” as discussed before. Such kerf must be removed before the shaft could be used as an electrode; however, once the electrode can be reused many times to form corresponding grooves on multiple sleeves, the issue of key removal is dramatically simplified.  
         [0034]    [0034]FIG. 7 is an embodiment of the invention  700 . A conical tool for providing grooves for one surface of a conical bearing is disclosed. Conical bearings are becoming more common, especially in disc drives, as they provide both radial and lateral stability, thereby saving space. Such bearings are difficult to form in mass production machining. However, by utilizing the electrochemical machining approach of the present invention, single or limited number of conical elements can be machined or otherwise formed according to the invention, and each used to make a large number of conical grooved surfaces. For example, FIG. 7 shows such a male cone  700 , with lands or raised segments  702  corresponding to the groove pattern desired to be etched on a female cone.  
         [0035]    [0035]FIG. 8 is an embodiment of the invention comprising a perspective view of a sleeve  803  having features  805  on the interior surface corresponding to the grooves to be formed on the surface of a shaft for a fluid dynamic bearing such as shown above. A cylindrical tool  803  for providing grooves on a shaft or rod introduced into a bore in tool  803  using the pattern  805  is shown.  
         [0036]    [0036]FIG. 9 is an embodiment of the invention  900  where a pattern in accordance with the invention is shown on a flat tool surface  902 . Here the lands  902  are defined so that a groove pattern such as on a thrust plate shown above can be established.  
         [0037]    [0037]FIG. 10 is an embodiment of the invention  1000  illustrating how the tool of FIG. 9 is prepared. In this embodiment, the tool conductive part is left flat, and an insulating layer is adhered to the tool surface and patterned as shown. This is a lower cost, faster way of providing the tool of this invention, since adding an insulator is a simpler task that cutting or etching the tool surface. As will be seen by view A-A taken of the tool cross section, a metal electrode  1003  forming a tool conductive part has a pattern defined by a patterned insulator  1005  on the surface. Thereby no machining of the metal of the tool is required.  
         [0038]    While the examples given are intended to be as complete and instructive as practical, clarity dictates keeping the disclosure to a reasonable size. However, other embodiments that will use this invention will be clear to those in the art, and this invention applies to all such other embodiments as if they were specifically detailed herein.