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Home Generators or Motors Free-standing-diamond-sheet-and-method-and-apparatus-for-making-same

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 Free standing diamond sheet and method and apparatus for making same

Details
Inventors: Anthony, Thomas R.; Fleischer, James F.;
Assignee: General Electric Company (Schenectady, NY)
Primary Examiner: Kunemund; Robert
Assistant Examiner: Garrett; Felisa
Attorney, Agent or Firm: Pittman; William H.

The bond strength between a diamond and the substrate onto which it is deposited by the chemical vaporization method is decreased to the point where the diamond can be removed from the substrate as a free standing monolithic sheet. The bond strength can be decreased by polishing the substrate, removing corners from the substrate, slow cooling of the substrate after deposition, an intermediate temperature delay in cooling or the application or formation of an intermediate layer between the diamond and the substrate. The free standing sheet of diamond can be used as a laser lens, metallized to form a mirror, or silver soldered to tungsten carbide to form a cutting tool.

DETAILED DESCRIPTION OF THE INVENTION The interior features of one type of a CVD diamond deposition unit that can be used in the practice of the present invention to make very large, approximately one square foot sheets of free standing CVD diamond are referred to below.
The apparatus is merely contemplated for use, and is described merely to impart an understanding of the present invention.
Substrates used had a deposition face on the order of one to one and one half inch by 10to 12 inches.
All of said features, of the apparatus and are enclosed in a reaction chamber (not shown) which is air-tight and thus capable of being maintained at reduced pressure and is fitted with a suitable gas inlet and an exhaust port.
All portions of the apparatus which are present in the reaction chamber are constructed of suitable heat-resistant materials, as necessary to withstand filament temperatures on the order of about 2000.
degree.
C.
and substrate temperatures up to about 1000.
degree.
C.
Quartz is an illustrative non conductive heat-resistant material suitable for this purpose.
The features of the apparatus and associated articles include a substrate 1 which has a planar diamond deposition surface 3.
The substrate is made of molybdenum.
The substrate 1 is maintained in position at a suitable spacing from resistance heating means for deposition to take place.
The resistance heating means comprise two electrodes and a one or more vertically extending linear, electrically conductive filaments or wires (hereinafter generically designated "filaments"), and otherwise being of conventional design and circuitry.
The material of which said filaments are comprised is not critical, any material known in the art as suitable for this purpose being acceptable.
Illustrative materials are metallic tungsten, tantalum, molybdenum and rhenium; because of its relatively low cost and particular suitability, tungsten is often preferred.
Filament diameters of about 0.
2-1.
0 mm.
are typical, with about 0.
8 mm.
frequently being preferred



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