High pressure superabrasive particle synthesis
First Claim
1. A method for controlling nucleation sites during superabrasive particle synthesis, comprising the steps of:
- a) forming a raw material layer including a raw material;
b) forming a particulate catalyst layer adjacent the raw material layer to form a crystal growth layer, said particulate catalyst layer including a catalyst material; and
c) placing crystalline seeds in a predetermined pattern at least partially in at least one of the catalyst layer and the raw material layer to form a growth precursor.
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Abstract
An improved method for controlling nucleation sites during superabrasive particle synthesis can provide high quality industrial superabrasive particles with high yield and a narrow size distribution. The synthesis method can include forming a raw material layer, forming a particulate catalyst layer adjacent the raw material layer, and placing crystalline seeds in a predetermined pattern at least partially in the catalyst layer or raw material layer to form a growth precursor. Alternatively, the raw material and catalyst material can be mixed to form a particulate crystal growth layer and then placing the crystalline seeds in a predetermined pattern in the growth layer. Preferably, seeds can be substantially surrounded by catalyst material. The growth precursor can be maintained at a temperature and pressure at which the superabrasive crystal is thermodynamically stable for a time sufficient for a desired degree of growth. The crystalline seeds can be placed in a predetermined pattern using a template, a transfer sheet, vacuum chuck or similar techniques. The superabrasive particles grown using the described methods typically have a high yield of high quality industrial particles and a narrow distribution of particle sizes.
118 Citations
35 Claims
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1. A method for controlling nucleation sites during superabrasive particle synthesis, comprising the steps of:
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a) forming a raw material layer including a raw material;
b) forming a particulate catalyst layer adjacent the raw material layer to form a crystal growth layer, said particulate catalyst layer including a catalyst material; and
c) placing crystalline seeds in a predetermined pattern at least partially in at least one of the catalyst layer and the raw material layer to form a growth precursor. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
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- 28. A growth precursor, comprising at least one crystal growth layer having a raw material layer and a particulate catalyst layer, said catalyst layer having a plurality of crystalline seeds placed in a predetermined pattern.
Specification