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 particulate crystal growth layer, including a substantially homogeneous mixture of raw material and catalyst material;
b) placing crystalline seeds in a predetermined pattern at least partially in the particulate crystal growth layer to form a growth precursor; and
c) heating and pressing the growth precursor to a temperature and pressure sufficient for growth of superabrasive particles to produce grown superabrasive particles;
wherein the step of placing crystalline seeds includes the steps of;
a) placing a template having a pattern of apertures upon a surface of the crystal growth layer, each of said apertures being configured to receive a single crystalline seed;
b) filling the apertures of said template with the crystalline seeds; and
c) pressing said crystalline seeds at least partially into the crystal growth layer;
orwherein the step of placing crystalline seeds includes the steps of;
d) providing a transfer sheet having an adhesive layer thereon;
e) placing a template having a pattern of apertures upon the adhesive layer, each of said apertures being configured to receive a single crystalline seed;
f) filling the apertures of said template with the crystalline seeds;
g) placing the transfer sheet against a surface of the crystal growth layer; and
h) pressing said crystalline seeds at least partially into the crystal growth layer;
orwherein the step of placing crystalline seeds includes the steps of;
i) providing a vacuum chuck configured with a pattern of apertures;
j) pulling a vacuum through the apertures and engaging a single crystalline seed in each aperture;
k) depositing the crystalline seeds on a surface of the crystal growth layer such that the crystalline seeds are arranged in a predetermined pattern corresponding to the pattern of apertures; and
l) pressing said crystalline seeds at least partially into the crystal growth layer.
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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 particulate crystal growth layer by mixing a raw material and a catalyst material 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.
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Citations
16 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 particulate crystal growth layer, including a substantially homogeneous mixture of raw material and catalyst material; b) placing crystalline seeds in a predetermined pattern at least partially in the particulate crystal growth layer to form a growth precursor; and c) heating and pressing the growth precursor to a temperature and pressure sufficient for growth of superabrasive particles to produce grown superabrasive particles; wherein the step of placing crystalline seeds includes the steps of; a) placing a template having a pattern of apertures upon a surface of the crystal growth layer, each of said apertures being configured to receive a single crystalline seed; b) filling the apertures of said template with the crystalline seeds; and c) pressing said crystalline seeds at least partially into the crystal growth layer;
orwherein the step of placing crystalline seeds includes the steps of; d) providing a transfer sheet having an adhesive layer thereon; e) placing a template having a pattern of apertures upon the adhesive layer, each of said apertures being configured to receive a single crystalline seed; f) filling the apertures of said template with the crystalline seeds; g) placing the transfer sheet against a surface of the crystal growth layer; and h) pressing said crystalline seeds at least partially into the crystal growth layer;
orwherein the step of placing crystalline seeds includes the steps of; i) providing a vacuum chuck configured with a pattern of apertures; j) pulling a vacuum through the apertures and engaging a single crystalline seed in each aperture; k) depositing the crystalline seeds on a surface of the crystal growth layer such that the crystalline seeds are arranged in a predetermined pattern corresponding to the pattern of apertures; and l) pressing said crystalline seeds at least partially into the crystal growth layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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Specification