Diamond capsules and methods of manufacture
Capsules and similar objects are made from materials having diamond (sp 3 ) lattice structures, including diamond materials in synthetic crystalline, polycrystalline (ordered or disordered), nanocrystalline and amorphous forms. The capsules generally include a hollow shell made of a diamond material that defines an interior region that may be empty or that may contain a fluid or solid material. Some of the capsules include access ports that can be used to fill the capsule with a fluid. Capsules and similar structures can be manufactured by growing diamond on suitably shaped substrates. In some of these methods, diamond shell sections are grown on substrates, then joined together. In other methods, a nearly complete diamond shell is grown around a form substrate, and the substrate can be removed through a relatively small opening in the shell.
1 - 200 . (canceled)
201 . A method of fabricating a diamond shell, comprising:
providing a substrate;
symmetrically depositing a diamond film on said substrate; and
removing said substrate so as to produce a hollow core.
202 . The method of claim 201 , further comprising polishing said diamond film so as to produce an RMS roughness of less than about 200 nm.
203 . The method of claim 201 , further comprising polishing said diamond film so as to produce an RMS roughness of between about 10 nm and about 75 nm.
204 . The method of claim 201 , further comprising polishing said diamond film so as to produce an RMS roughness of down to about 10 nm RMS.
205 . The method of claim 201 , further comprising a seeding step prior to the deposition of said diamond film.
206 . The method of claim 201 , further comprising the step of rotating said substrate during a deposition of said diamond and/or a seeding of said substrate.
207 . The method of claim 206 , wherein said rotating of said substrate is random.
208 . The method of claim 201 , further comprising the step of providing one or more perforations through said diamond film.
209 . The method of claim 201 , further comprising the step of providing a perforation therethrough said diamond film and said substrate.
210 . The method of claim 201 , wherein said one or more perforations are produced by at least one beam selected from a focused ion beam (FIB) and a laser beam.
211 . The method of claim 201 , wherein said substrate is removed by at least one etching method selected from wet and dry etching.
212 . The method of claim 211 , wherein said etching step comprises HF and HNO 3 etching.
213 . The method of claim 211 , wherein said etching step further comprises etching while in an ultrasonic bath.
214 . The method of claim 201 , wherein the step of depositing said diamond film comprises depositing a layer of diamond from an activated gas phase comprising carbon and hydrogen.
215 . The method of claim 201 , wherein the use of said fabricated diamond shell comprises use as a ball bearing.
216 . The method of claim 201 , wherein the use of said fabricated diamond shell comprises use as a light focusing element.
217 . The method of claim 201 , wherein the use of said fabricated diamond shell comprises use as an ornament.
218 . The method of claim 201 , wherein the use of said fabricated diamond shell comprises use as a pen-point.
219 . A coating apparatus, comprising:
a vacuum chamber;
a vacuum pump system configured for introducing process gases; and
a substrate holder that further comprises,
a beveled rotating disk;
a stationary outer retaining ring; and
a groove between said disk and said outer retaining ring adapted to receive one or more substrates.
220 . The coating apparatus of claim 219 , further comprising means for providing a random motion to said one or more substrates.
221 . An article of manufacture, comprising:
a shell enclosing a hollow volume; wherein a nanocrystalline diamond film having a surface roughness less than about 400 nm comprises the wall of said shell, wherein said diamond film is capable of isotropic transmission of sound.
222 . An article of manufacture, comprising:
a shell enclosing a hollow volume; wherein a nanocrystalline diamond film having a surface roughness less than about 400 nm comprises the wall of said shell, wherein said dopant comprises up to about 5% of the atomic fraction of the coating, wherein said perforation comprises at least one closure selected from diamond like carbon and solid deuterium.