Patent ID: 6858080
Filing Date: 2005-02-22
Classification: C30B,Y10T

Abstract:
1. A method of forming a synthetic monocrystalline diamond comprising the steps of: a) forming on a substrate by a chemical vapor deposition process a first synthetic diamond layer incorporating one or more impurities and one or more carbon isotopes; and b) selecting concentrations of the one or more carbon isotopes and the one or more impurities during the formation of the first synthetic diamond layer, in order to form the first synthetic diamond layer with a predetermined lattice constant having a corresponding level of lattice strain, wherein the level of lattice strain corresponds to how much the lattice constant of the first synthetic diamond layer varies from a lattice constant of natural diamond, wherein a ratio comprised of a difference between the lattice constant of the first synthetic diamond layer and the lattice constant of pure diamond over the lattice constant of pure diamond is used in determining a critical thickness that the first synthetic diamond layer can be formed to without damaging the layer, wherein the critical thickness of the first synthetic diamond layer is the level which if exceeded results in dislocations in the diamond structure followed by fracturing of the diamond structure, wherein the formation of the dislocations in the first synthetic diamond layer can be lessened or eliminated by further forming by a chemical vapor deposition process a series of synthetic diamond layers that alternate in tension and compression thereon.