Embedded Single Crystal Diamond in Polycrystalline Matrix

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Solution Overview

Problem

The industrial scalability and handling feasibility of single crystal diamonds are limited, making them less favorable for applications despite their superior properties, due to challenges in growing large sizes and the brittleness of thin-film versions.

Innovation Solution

A method is developed to grow an embedded single crystal diamond structure by disposing a single crystal diamond on a non-diamond substrate, masking its top portion, and using chemical vapor deposition (CVD) to surround it with polycrystalline diamond material, enhancing handling and scalability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If single crystal diamond is used to achieve superior properties, then performance is improved, but scalability and handling feasibility deteriorate

Engineering Contradiction:

ImproveperformanceVSAvoidscalability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent creates a composite structure where a single crystal diamond core is embedded within a polycrystalline diamond matrix. This composite approach allows the structure to exhibit both the superior performance properties of single crystal diamond and the handling feasibility of polycrystalline diamond, resolving the contradiction between performance and scalability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The single crystal diamond is nested within the polycrystalline diamond matrix, creating a hierarchical structure. This nesting allows the inner single crystal to provide performance benefits while the outer polycrystalline matrix provides mechanical robustness and ease of handling, effectively combining advantages of both material types.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If single crystal diamond is used to achieve superior properties, then performance is improved, but handling feasibility deteriorates due to brittleness

Engineering Contradiction:

ImproveperformanceVSAvoidhandling feasibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

By creating a composite structure with single crystal diamond embedded in polycrystalline diamond, the patent achieves a material that maintains the superior performance of single crystal while gaining the handling feasibility of polycrystalline diamond. The polycrystalline matrix acts as a protective shell that prevents cleavage and breakage during handling.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The polycrystalline diamond matrix serves as a protective cushion around the fragile single crystal diamond before any handling or processing occurs. This pre-protective structure prevents the single crystal from being damaged during subsequent operations, effectively cushioning it against mechanical stresses.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Productivity

If large size single crystal diamond is grown to improve scalability, then productivity is improved, but manufacturing difficulty increases

Engineering Contradiction:

ImprovescalabilityVSAvoidmanufacturing difficulty

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent segments the diamond structure into two distinct parts: a single crystal diamond core and a polycrystalline diamond matrix. This segmentation allows each part to be grown or processed separately under optimized conditions, avoiding the need to grow large single crystals which is manufacturingally difficult, while still achieving overall scalability through the easier-to-produce polycrystalline matrix.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The composite structure allows the polycrystalline diamond to serve as the primary material for scaling up production, while single crystal diamond sections are incorporated as performance-critical components. This approach bypasses the manufacturing difficulties of growing large single crystals by using polycrystalline material as the base, which is much easier to produce at scale.

Inventive Principle:

Principle #40Composite materials

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 approach allows for the creation of embedded single crystal diamond structures that are robust enough for various applications, including electronic and optical uses, while maintaining superior properties and overcoming the limitations of single crystal diamond brittleness and size constraints.

Implementation Method 1

grow polycrystalline diamond material surrounding the single crystal diamond in order to join the single crystal diamond to the polycrystalline diamond using a chemical vapor deposition (CVD) growth method

Methodology Applied

Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Data Source

PatentUS20230294994A1Embedded single crystal diamond(s) in a polycrystalline diamond structure and a method of growing it

Publication Date: 2023.09.21 IIA TECH

AI summary

A method of a growing an embedded single crystal diamond structure, comprising: disposing a single crystal diamond on a non-diamond substrate, wherein the non-diamond substrate is larger than the single crystal diamond; masking a top portion of the single crystal diamond using a masking material; and using a chemical vapor deposition (CVD) growth chamber, growing polycrystalline diamond material surrounding the single crystal diamond in order to join the single crystal diamond to the polycrystalline diamond material.