Patent ID: 9210972
Filing Date: 2015-12-15
Classification: A44C,C23C,H04R,Y10T

Abstract:
1. A free-standing non-planar polycrystalline CVD synthetic diamond component which comprises a nucleation face and a growth face, the nucleation face comprising smaller grains than the growth face, the nucleation face having a surface roughness R a no more than 50 nm; wherein the free-standing non-planar polycrystalline CVD synthetic diamond component has a longest linear dimension when projected onto a plane of no less than 10 mm and is substantially crack free over at least a central region thereof, wherein the central region is at least 70% of a total area of the free-standing non-planar polycrystalline CVD synthetic diamond component; wherein the central region has no cracks which intersect both external major faces of the free-standing non-planar polycrystalline CVD synthetic diamond component and extend greater than 2 mm in length; wherein the free-standing non-planar polycrystalline CVD synthetic diamond component comprises a central dome-shaped portion with the growth face of the central dome-shaped portion being convex; wherein the free-standing non-planar polycrystalline CVD synthetic diamond component further comprises a substantially cylindrical peripheral portion extending from an outer circumference of the dome-shaped portion and having side walls oriented within 20° of a central rotational axis of the free-standing non-planar polycrystalline CVD synthetic diamond component; wherein the free-standing non-planar polycrystalline CVD synthetic diamond component has a thickness of no more than 100 μm; and wherein the component further comprises one or more of the following characteristics: a silicon concentration as measured by secondary ion mass spectrometry of no more than 10 a difference in silicon concentration between the nucleation face and the growth face of the free-standing non-planar polycrystalline CVD synthetic diamond component of no more than 10 no detectable silicon carbide at the nucleation face of the free-standing non-planar polycrystalline CVD synthetic diamond component; and a detectable level of a refractory metal carbide at the nucleation face of the free-standing non-planar polycrystalline CVD synthetic diamond component.