Free-standing diamond structures and methods
OwnerGerald T. Mearini, James A. Dayton, Jr.inventors
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Abstract
The present invention is directed in one aspect to methods of making free-standing, internally-supported, three-dimensional objects having an outer surface comprising a plurality of intersecting facets wherein a sub-set of the intersecting facets have a diamond layer of substantially uniform thickness. The diamond layer may be formed by chemical vapor deposition (CVD) over the surface of a substrate that has been fabricated to form a mold defining the sub-set of intersecting facets. A backing layer may be formed over at least a portion of the exposed diamond layer to enhance the rigidity of the layer when the substrate is removed.
Claims34
A method of making a free-standing, internally-supported, three-dimensional object, an outer surface of the object comprising a plurality of intersecting facets, at least a sub-set of said intersecting facets having a diamond layer of substantially uniform depth, said method domprising the steps of:
- (a) providing a mold having an exposed surface defining the sub-set of intersecting facets;
- (b) growing a diamond layer of substantially uniform depth over the exposed surface;
- (c) depositing a backing layer over at least a portion of the diamond layer;
- and
- (d) removing the mold to expose the surface of the diamond layer grown immediately contiguous to the mold.
A method of fabricating a free-standing object comprising a three-dimensional structure covered by a diamond film having an exposed surface, said method comprising the steps of:
- growing a diamond film on a preselected exposed surface of a substrate;
- providing a backing on at least a portion of the grown diamond film;
- and
- removing the substrate to expose the diamond surface defined by the preselected surface of the substrate on which the diamond was grown.
A method of fabricating a free-standing, internally-supported, three-dimensional object, an outer surface of the object comprising a plurality of intersecting facets, at least a sub-set of said intersecting facets having an exposed diamond surface, said method comprising the steps of:
- growing a diamond film on a preselected exposed surface of a substrate;
- providing a backing layer covering at least a portion of the grown diamond film;
- and
- removing the substrate so that the exposed diamond surface is the surface grown immediately contiguous to the substrate.
A method of making a free-standing, internally-supported, three-dimensional object, an outer surface of the object comprising a plurality of intersecting facets, at least a sub-set of said intersecting facets having a diamond layer of substantially uniform depth, said method comprising the steps of:
- (a) fabricating a silicon substrate to provide a molding surface defining the sub-set of intersecting facets;
- (b) seeding the molding surface of the substrate with carbon;
- (c) growing a diamond layer of substantially uniform depth over the molding surface of the substrate;
- (d) forming an internally-supporting backing layer over the diamond layer;
- and
- (e) chemically etching the substrate to expose the surface of the diamond layer grown contiguous to the molding surface of the substrate.
Dependencies are inferred from the claim text.