Abstract: A diamond composite heat spreader having a low thermal mismatch stress can improve reliability and cost of diamond-based heat spreaders. A diamond composite heat spreader can have a thermally conductive base and a diamond film in thermal contact with the thermally conductive base. The diamond film and the thermally conductive base can have a residual thermal mismatch stress which is less than about 75% of a residual thermal mismatch stress which would result from forming the diamond film on the thermally conductive base using a high temperature deposition process at 700° C. The diamond film can be formed on the thermally conductive base using a low temperature vapor deposition process performed at a temperature from about 10° C to less than 700° C, and typically lower than about 450° C. The diamond films further have high thermal diffusivity and thermal conductivity which allow for dramatic improvements in heat transfer away from a heat source without the need for growing a thick diamond film.

Abstract: A heat spreader including a plurality of carbonaceous particles present in an amount of at least about 50% by volume of the heat spreader. A non-carbonaceous material is also present in an amount of at least about 5% by volume of the heat spreader, the non-carbonaceous material including an element selected from the group consisting of Cu, Al and Ag. In another aspect, the carbonaceous particles may be sintered or fused directly to one another. The heat spreader can be incorporated into a cooling unit for transferring heat away from a heat source, which includes a heat sink with the heat spreader disposed in thermal communication with both the heat sink and the heat source.

Abstract: CMP pad dressers with superabrasive particles oriented into an attitude that controls CMP pad performance, and methods associated therewith are disclosed and described. The controlled CMP pad performance may be selected to optimize CMP pad dressing rate and dresser wear.

Abstract: A replaceable superabrasive tool insert for use in an abrading tool body includes an attachable shank, having a working end and an attachment end. At least one superabrasive particle is individually attached to the shank at the working end of the shank to provide an abrading interface between the shank and a work piece to be abraded. The attachment end of the shank is configured to be removably attached to the abrading tool body.

Abstract: Methods of maximizing retention of superabrasive particles in a metal matrix are disclosed. The superabrasive particles may be chemically bonded with the metal matrix to a degree which holds the superabrasive particles in the metal matrix without substantially degrading the superabrasive particles. Substantially degrading the superabrasive particles can be avoided by protecting the superabrasive particles from over-bonding during the chemical bonding process.

Abstract: A method for forming diamond tools using CVD techniques. In one aspect, a mold is provided which has an interface surface configured to inversely match a configuration intended for the working surface of a diamond layer in a tool. An adynamic diamond mass or layer is then deposited upon the diamond interface surface of the mold, and a support layer is joined to the growth surface of the adynamic diamond layer. At least a portion of the mold is then removed to expose the working surface of the diamond which has received a shape which inversely corresponds to the configuration of the mold's diamond interface surface.

Abstract: Polycrystalline grits and methods of making grits which allow for a high degree of shape and size distribution control, as well as improved abrasive performance are described and disclosed. In one aspect, an abrasive slurry can be formed into a plurality of abrasive precursors arranged on a substrate using screen-printing or other techniques. The abrasive slurry can include a binder and a plurality of abrasive particles. The abrasive precursors on the substrate can then be covered with a pressure medium and then subjected to pressure and temperature conditions sufficient to cause sintering of the abrasive particles to form polycrystalline grits. The polycrystalline grits produced by such methods can have a substantially uniform shape and size distribution.

Abstract: High pressure synthesis of various crystals such as diamond, cBN and the like can be carried out using reaction assemblies suitable for use in methods such as temperature gradient methods. The reaction assembly can be oriented substantially perpendicular to gravity during application of high pressure. Orienting the reaction assembly in this manner can avoid detrimental effects of gravity on the molten catalyst, e.g., convection, hence increasing available volumes for growing high quality crystals. Multiple reaction assemblies can be oriented in series or parallel, each reaction assembly having one or more growth cells suitable for growth of high quality crystals. Additionally, various high pressure apparatuses can be used. A split die design allows for particularly effective results and control of temperature and growth conditions for individual crystals.

Abstract: An improved high pressure apparatus can include a plurality of complementary die segments. The die segments can have inner surfaces which are shaped to form a die chamber upon assembly of the die segments. A pair of anvils can be oriented such that an anvil is at each end of the die chamber. To prevent the die segments from being forced apart during movement of the anvils, force members can be connected to the die segments. The force members can apply discrete forces to the die segments sufficient to retain the die segments in substantially fixed positions relative to each other during application of force by the pair of anvils. Using such a high pressure apparatus can achieve pressures as high as 10 GPa with improved useful die life and larger reaction volumes.

Abstract: An improved method for synthesizing superabrasive particles provides high quality industrial superabrasive particles with high yield and a narrow size distribution. The synthesis method can include forming a growth precursor of a substantially homogeneous mixture of raw material and catalyst material or layers of raw material and metal catalyst. The growth precursor can have a layer of adhesive over at least a portion thereof. A plurality of crystalline seeds can be placed in a predetermined pattern on the layer of adhesive. 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. Advantageously, the patterned placement of crystalline seeds and disclosed processes allow for production of various morphologies of synthetic diamonds, including octahedral and cubic diamonds, and improved growth conditions generally.

Abstract: A diamond composite heat spreader having a variable thermal conductivity gradient can improve control of heat transfer based on a specific application. A diamond-containing region of the heat spreader can contain diamond particles such that the diamond concentration and/or the diamond particle size a varied to produce a desired thermal conductivity gradient. Regions proximate to a heat source can have a higher thermal conductivity than regions further away from the heat source. Thin diamond films can also be used in conjunction with the particulate diamond in order to provide a region of maximum thermal conductivity adjacent a heat source.

Abstract: A heat spreader including a plurality of carbonaceous particles present in an amount of at least about 50% by volume of the heat spreader. A non-carbonaceous infiltrant is also present in an amount of at least about 5% by volume of the heat spreader, the non-carbonaceous infiltrant including an element selected from the group consisting of Cu, Al and Ag. In another aspect, the carbonaceous particles may be sintered or fused directly to one another. The heat spreader can be incorporated into a cooling unit for transferring heat away from a heat source, which includes a heat sink with the heat spreader disposed in thermal communication with both the heat sink and the heat source.

Abstract: Diamond-like carbon based thermoelectric conversion devices and methods of making and using the same which have improved conversion efficiencies and increased reliability. The device can include a cathode having a base member with a layer of diamond-like carbon material such as amorphous diamond coated over the cathode. A dielectric intermediate member can be electrically coupled between the diamond-like carbon material and an anode. Various additional layers and configurations can allow for improved performance such as multiple cathode layers and/or multiple intermediate layers. The thermoelectric conversion devices can be configured as an electrical generator and/or a cooling device and can be conveniently formed. In addition, the devices of the present invention do not require formation of a vacuum space and are typically completely solid throughout.

Abstract: The present invention provides diamond tools, and a method for the formation thereof, using CVD techniques. In one aspect, an ephemeral mold is provided which has a diamond interface surface configured to inversely correspond to the desired shape for the working surface of a diamond layer in a tool. After the mold is provided, various CVD techniques may be used to deposit diamond layers upon the diamond interface surface of the mold. Following diamond deposition upon the diamond interface surface, the mold may be removed by various means, such as chemical etching, etc. Thus, the working surface of the diamond receives a shape which inversely corresponds to the configuration of the mold's diamond interface surface. The diamond mass may then be incorporated into a tool, if such incorporation has not yet taken place.

Abstract: A diamond composite heat spreader having a variable thermal conductivity gradient can improve control of heat transfer based on a specific application. A diamond-containing region of the heat spreader can contain diamond particles such that the diamond concentration and/or the diamond particle size a varied to produce a desired thermal conductivity gradient. Regions proximate to a heat source can have a higher thermal conductivity than regions further away from the heat source. Thin diamond films can also be used in conjunction with the particulate diamond in order to provide a region of maximum thermal conductivity adjacent a heat source.

Abstract: An improved abrasive composite tool having a compositional gradient is disclosed and described. The composite tool can include a first region including abrasive particles, a second region, and a transition region connecting the first and second regions. The transition region can have a compositional gradient from the first region to the second region. The transition region can have compositional gradients among materials such as metals, ceramics, diamond-containing materials, polymers, or composites of such materials. The compositional gradient can include multiple intermediate regions or may transition directly from the first region to the second region. Most often, the transition region can be formed by vapor deposition methods such as PVD and CVD. Advantageously, the transition region can be formed on an abrasive tool to provide improved chemical and/or mechanical erosion resistance.

Abstract: A graphite composite thermal sealant having a graphite matrix and a metal is disclosed and described. The metal can be dispersed in the graphite matrix or provided in a separate layer. Graphite having a high degree of graphitization can be of particular benefit. Further, the metal can be a soft metal such as In, Ag, Cu, Pb, Zn, Sn, Au, or alloys of these metals. The thermal sealant materials described herein can have thermal conductivities in excess of about 200 W/mK, while also minimizing or eliminating voids or pores between sealed surfaces.

Abstract: A superabrasive particle coated with a solidified coating of a molten braze alloy that is chemically bonded to the superabrasive particle is disclosed and described. In one aspect, the reactive metal alloy may be chemically bonded to at least about 80% of an outer surface of the superabrasive particle. Various methods for making and using such a coated superabrasive particle are additionally disclosed and described.

Abstract: A fixed abrasive tool incorporating nanodiamond particles is described and disclosed. A fixed abrasive tool can include a polishing layer on a substrate. The polishing layer can include an organic matrix with nanodiamond particles therein. The polishing layer can be formed in a wide variety of configurations, depending on the specific polishing application. Most often, the polishing layer can include a plurality of projections which can have a wide variety of configurations in order to achieve a particular polishing performance. Nanodiamond particles used in the present invention can have a particle size from about 1 nm to about 50 nm, and preferably about 2 nm to about 10 nm. Optionally, the nanodiamond particles can include a carbonaceous coating. Such fixed abrasive tools can be formed by screen printing of a slurry of nanodiamond particles and an organic binder to form a predetermined three-dimensional pattern. Other methods can also be used to form the disclosed nanodiamond fixed abrasive tools.

Abstract: Nanodiamonds can be included in various compositions to take advantage of the ability of nanodiamond to bond with biological materials and to improve mechanical strength. Nanodiamonds can be dispersed in a biologically acceptable carrier to form various nanodiamond compositions. The presence of nanodiamonds can increase binding with many biological materials, making the compositions of the present invention useful for a large variety of purposes such as cleansing, testing and identification of materials, and treatment of adverse conditions. Specific examples of nanodiamond compositions that can be formulated include deodorants, toothpastes, shampoos, antibiotics, dermal strips, DNA test strips, skin cleansers, and the like. Similarly, nanodiamond particles can be included in a cosmetic nanodiamond composition within a cosmetically acceptable carrier. Cosmetic nanodiamond compositions can include, for example, nail polish, eyeliner, lip gloss, exfoliant, and the like.