Chemistry of inorganic compounds – Carbon or compound thereof – Elemental carbon
Patent
1997-07-07
1999-03-23
King, Roy V.
Chemistry of inorganic compounds
Carbon or compound thereof
Elemental carbon
427249, 427596, C01B 3106
Patent
active
058855416
ABSTRACT:
A method and system for fabricating porous polycrystalline diamond material whose volume is described by a dimension larger than 1 mm, with no upper limit on size. A net shape diamond part is fabricated by compacting small diamond particles into a mold and then performing chemical vapor deposition (CVD) growth of diamond on the particles until they are joined into a porous whole. The CVD growth of diamond is achieved by photofragmentation of vapor phase Fullerene, C.sub.60, molecules in the pores. C.sub.60 molecules are vaporized from solid C.sub.60 at a temperature of about 800.degree. C. The vapor diffuses into the voids between the diamond particles in the mold. The vapor is then subjected to intense illumination by a laser which causes the C.sub.60 molecules fragment. The deposition of these fragments causes diamond growth to occur on all surfaces around the pores between the particles. Continual replenishment of the C.sub.60 by the vapor source allows continuous deposition. The transparency of the diamond particles allows penetration of the laser illumination into the volume of the particles. After sufficient deposition and growth, diamond connections are made between the particles, making the entire mass a porous, single diamond entity.
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