Process and apparatus for preparing a diamond substance

A process of producing a diamond substance, comprising the steps of:

• a. forming a first mixture comprised of oxygen gas and a hydrocarbon gas, wherein said hydrocarbon gas contains from about one percent to about ten percent molar excess of carbon for each mole of oxygen present in such first mixture;
• b. igniting said first mixture to produce a flame core;
• c. forming a second mixture comprised of hydrogen and oxygen, wherein:
• 1. said second mixture is comprised of a molar excess of said hydrogen over the moles of said oxygen present in the second mixture,
• 2. said second mixture contains up to about 10 volume percent of hydrocarbon gas;
• d. igniting said second mixture to produce a flame sheath;
• e. disposing said flame sheath around said flame core so that said flame sheath surrounds said flame core and shields said flame core from the atmosphere, thereby producing a composite flame;
• f. contacting said composite flame with a substrate, wherein
• 1. said substrate is comprised of a semi-conductor;
• 2. said substrate is comprised of an adhesion layer for adhering said semi-conductor to said diamond substance;
• and
• 3. said substrate comprises a material selected from the group consisting of boron, copper, nickel, tungsten, molybdenum, titanium, hafnium, silicon carbide, boron carbide, tungsten carbide, molybdenum carbide, titanium carbide, nickel carbide, hafnium carbide, boron nitride, silicon nitride, titanium nitride, hafnium nitride, aluminum nitride, quartz, alumina, silica, titanium oxide, hafnium oxide, and combinations thereof.

A process of producing a diamond substance, comprising the steps of:

• a. forming a first mixture comprised of oxygen gas and a hydrocarbon gas, wherein said hydrocarbon gas contains from about one percent to about ten percent molar excess of carbon for each mole of oxygen present in such first mixture;
• b. igniting said first mixture to produce a flame core;
• c. forming a second mixture comprised of hydrogen and oxygen, wherein:
• 1. said second mixture is comprised of a molar excess of said hydrogen over the moles of said oxygen present in the second mixture,
• 2. said second mixture contains up to about 10 volume percent of hydrocarbon gas;
• d. igniting said second mixture to produce a flame sheath;
• e. disposing said flame sheath around said flame core so that said flame sheath surrounds said flame core and shields said flame core from the atmosphere, thereby producing a composite flame;
• f. contacting said composite flame with a substrate, wherein
• 1. said substrate is comprised of a semi-conductor;
• 2. said substrate is comprised of an adhesion layer for adhering said semi-conductor to said diamond substance;
• 3. said substrate is further comprised of a first barrier layer selected from the group consisting of a diffusion barrier layer, a thermal barrier layer, a chemical reactivity barrier layer, an oxidation-reduction carrier layer, and combinations thereof, and
• 4. said substrate is further comprised of a second barrier layer selected from the group consisting of a diffusion barrier layer, a thermal barrier layer, a chemical reactivity barrier layer, an oxidation-reduction carrier layer, and combinations thereof.

An apparatus for forming a diamond substance comprising a torch assembly comprised of

• a. a first nozzle for forming a first mixture comprised of oxygen gas and a hydrocarbon gas, wherein said hydrocarbon gas contains from about one percent to about ten percent molar excess of carbon for each mole of oxygen present in such first mixture;
• b. a first igniter for igniting said first mixture to produce a flame core;
• c. a second nozzle for forming a second mixture comprised of hydrogen and oxygen, wherein:
• 1. said second mixture is comprised of a molar excess of said hydrogen over the moles of said oxygen present in the second mixture,
• 2. said second mixture contains up to about 10 volume percent of hydrocarbon gas;
• d. a second igniter for igniting said second mixture to produce a flame sheath;
• e. a torch opening for disposing said flame sheath around said flame core so that said flame sheath surrounds said flame core and shields said flame core from the atmosphere, thereby producing a composite flame.