Single-Crystal Diamond X-Ray Screening for Inclusion-Free Tool Blanks
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Solution Overview
Problem
Current methods for inspecting inclusions in single-crystal diamonds, such as visual inspection with optical microscopes, are inefficient due to the large refractive index of diamonds, leading to difficulties in precisely specifying inclusion positions and determining the extractability of diamond tool intermediates with specific shapes and crystal orientations, resulting in low yield and incorrect assessments.
Innovation Solution
A method involving X-ray imaging, where a single-crystal diamond with a specific facet plane is fixed to a support, and X-ray images are captured to specify inclusion positions and determine the extractability of diamond tool intermediates with predefined shapes, ensuring the inclusion is not within the exclusion region, thereby improving precision and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection with optical microscopes is used to inspect inclusions in single-crystal diamonds, then the inspection process is simple, but the measurement precision of inclusion positions is low due to the large refractive index of diamonds
Solution Approach 1:
The patent introduces an X-ray imaging system as an intermediary to detect inclusions in single-crystal diamonds. The X-rays penetrate the diamond and interact with inclusions, allowing precise positioning of inclusions without being affected by the diamond's large refractive index. This intermediary approach enables accurate measurement while maintaining reasonable system complexity.
Solution Approach 2:
The patent replaces the optical microscope-based mechanical inspection system with an X-ray imaging system. This substitution eliminates the refractive index problem that plagues optical methods, as X-rays interact with matter through different physical mechanisms (photoelectric effect, Compton scattering) that are not affected by the diamond's optical properties.
2Reliability
If traditional inspection methods are used to determine extractability of diamond tool intermediates, then the assessment process is quick, but the determination accuracy is low leading to incorrect assessments
Solution Approach 1:
The patent performs preliminary X-ray imaging and inclusion positioning before the extractability determination step. By obtaining precise three-dimensional information about inclusion positions, sizes, and distributions in advance, the system enables accurate assessment of whether a diamond tool intermediate can be extracted without containing inclusions in critical regions.
Solution Approach 2:
The patent transitions from two-dimensional optical surface inspection to three-dimensional X-ray volumetric imaging. This dimensional change allows comprehensive assessment of inclusions throughout the entire volume of the diamond, enabling accurate determination of extractability by evaluating inclusion positions relative to the intended tool geometry in three-dimensional space.
3Productivity
If manual inspection methods are used to specify inclusion positions, then the equipment requirement is low, but the productivity is low due to inefficiency
Solution Approach 1:
The X-ray imaging system performs automatic detection, positioning, and three-dimensional reconstruction of inclusions without requiring manual intervention. The system processes the X-ray images through algorithms that automatically identify inclusion locations, calculate their spatial coordinates, and generate extraction feasibility assessments, thereby大幅提高 inspection efficiency while managing system complexity through automation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for precise specification of inclusion positions and determination of extractable shapes, enhancing the yield of diamond tool intermediates by accurately associating crystal orientation and shape, and reducing the inclusion in the exclusion region.
Implementation Method 1
An X-ray image of the single-crystal diamond is captured, the X-ray image being an X-ray image in which a crystal orientation of the single-crystal diamond is associated with an X-ray emission direction
Data Source
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AI summary
A single-crystal diamond having a first facet plane that is a plane perpendicular to a specific crystal orientation is prepared. The single-crystal diamond is fixed to the support based on the first facet plane. An X-ray image of the single-crystal diamond is captured, the X-ray image being an X-ray image in which a crystal orientation of the single-crystal diamond is associated with an X-ray emission direction by associating the support to which the single-crystal diamond is fixed with the X-ray emission direction. A position of an inclusion of the single-crystal diamond in the single-crystal diamond is specified based on the X-ray image. It is determined whether or not a shape of the diamond tool intermediate is extractable from the single-crystal diamond with the inclusion being not included in an inclusion-excluded region. The shape of the diamond tool intermediate is extracted from the single-crystal diamond with the inclusion being not included in the inclusion-excluded region.