Monocrystalline Diamond Element Production via Nanoparticle Seeding

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Solution Overview

Problem

Current methods for producing three-dimensional diamond elements with micrometric, submicrometric, or nanometric sizes result in polycrystalline materials with high grain boundary density, which are unsuitable for applications in optics, electronics, and other fields due to defects and property reductions, while monocrystalline diamond production through etching is costly and limited in scale.

Innovation Solution

A process involving the encapsulation of diamond nanoparticles in a coating material to control their deposition in a mold, allowing for the growth of monocrystalline diamond elements with low grain boundary density through CVD, using a 'bottom-up' approach that limits nanoparticle deposition to one or a few particles per cavity, thereby reducing polycrystallinity and improving crystalline quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If diamond nanoparticles are deposited in mold cavities to initiate CVD growth, then three-dimensional diamond elements can be produced with micrometric, submicrometric, or nanometric sizes, but the material becomes polycrystalline with high grain boundary density

Engineering Contradiction:

Improveproduction capability of 3D diamond elementsVSAvoidcrystalline quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the concentration parameter of diamond nanoparticles in the suspension from high (producing polycrystalline material) to extremely low (10^-12 to 10^-15 g/mL), enabling single-particle deposition per cavity that generates monocrystalline diamond elements while maintaining the bottom-up production approach

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of the conventional approach of depositing many nanoparticles to fill mold cavities (which produces polycrystalline material), the patent inverts the strategy by depositing a single nanoparticle per cavity, thereby producing monocrystalline diamond elements through CVD growth from one seed crystal

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If etching is used to produce monocrystalline diamond elements, then crystalline quality is improved, but production cost and time increase significantly

Engineering Contradiction:

Improvecrystalline qualityVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent inverts the conventional top-down approach (starting with thick monocrystalline film and etching away excess material) by adopting a bottom-up approach where monocrystalline diamond elements grow directly from single nanoparticles deposited in mold cavities, eliminating the need for expensive and time-consuming etching processes

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent performs preliminary action by depositing a single diamond nanoparticle in each mold cavity before CVD growth, which serves as the sole crystal seed. This preliminary placement of one nanoparticle per cavity ensures monocrystalline formation during subsequent CVD growth, avoiding the need for post-growth etching to remove polycrystalline material

Inventive Principle:

Principle #10Preliminary action

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 enables the cost-effective and time-efficient production of high-quality monocrystalline or low-grain-boundary diamond elements, overcoming the limitations of existing techniques by achieving improved crystalline quality and scalability, making them suitable for advanced applications like optics and electrochemistry.

Implementation Method 1

a) the formation of beads of nanometric, submicrometric or micrometric sizes comprising a diamond nanoparticle coated by a coating material

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

d) the formation of diamond elements in the cavities containing a nanoparticle, by growth of diamond from the nanoparticles

Methodology Applied

Scientific EffectChemical Vapour Deposition: Chemical Vapour Deposition

Data Source

PatentEP2951336B1Process for producing moulded elements made of diamond which is monocrystalline or has a very low density of grain boundaries, of micrometric, submicrometric or nanometric sizes

Publication Date: 2017.03.22 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

AI summary

The invention relates to a process for producing moulded diamond elements of nanometric, submicrometric or micrometric sizes, said process comprising the following steps: a) the formation of beads of nanometric, submicrometric or micrometric sizes, each comprising a diamond nanoparticle coated with a coating material, by bringing diamond particles of nanometric sizes into contact with a coating material; b) the introduction of a bead into cavities of a sacrificial mould, the cavities forming an impression of the elements to be produced; c) the removal of the coating material; d) the formation of the diamond elements in the cavities containing a nanoparticle, by diamond growth from the nanoparticles; e) the release of the diamond elements, by partial or total removal of the sacrificial mould.