Patents by Inventor Matthew A. Simpson
Matthew A. Simpson has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
-
Patent number: 5776553Abstract: A method is disclosed for depositing diamond film, including the following steps: providing an environment comprising hydrogen gas and a hydrocarbon gas; dissociating hydrogen gas of the environment by dielectric barrier discharge to obtain atomic hydrogen; and providing a deposition surface in the environment and implementing diamond deposition on the deposition surface from the hydrocarbon gas, assisted by the atomic hydrogen. In a preferred embodiment, the atomic hydrogen is transported by molecular diffusion from its dissociation site to the deposition surface.Type: GrantFiled: February 23, 1996Date of Patent: July 7, 1998Assignee: Saint Gobain/Norton Industrial Ceramics Corp.Inventors: Stephen M. Jaffe, Matthew Simpson, Cecil B. Shepard, Michael S. Heuser
-
Patent number: 5736252Abstract: Diamond film with substantially no non-diamond carbon and a high thermal conductivity is deposited by means of a direct current arc jet apparatus with a substrate temperature below about 975 degrees Celsius, an arc power of between about 20 and 40 kw. a pressure of about 12 torr, and an enthalpy greater than 30 from a activated gas jet fed with hydrogen and methane, the methane being supplied at a concentration of less than 0.07%. The resulting material has a high transparency and thermal conductivity.Also disclosed is the use of the diamond material made by the present method for cutting tool applications, particularly milling.Type: GrantFiled: May 19, 1995Date of Patent: April 7, 1998Assignee: Saint-Gobain/Norton Industrial Ceramics Corp.Inventors: Louis K. Bigelow, Kevin J. Gray, Grant Lu, Matthew A. Simpson, Gordon L. Cann
-
Patent number: 5679404Abstract: A method for depositing a substance, such as diamond, on a surface of a substrate with temperature control, which comprises the steps of providing a cooling block having a surface that is cooled by heat exchange; supporting said substrate from said cooling block so that the bottom surface of said substrate is spaced from said cooling block surface by a gap, the size of said gap being in the range of 0.01 cm to 0.30 cm; providing a gas in said gap; and depositing said substance on the top surface of said substrate, whereby heat, resulting from said depositing of said substance, flows by conduction across said gap from said substrate to said cooling block.Type: GrantFiled: June 7, 1995Date of Patent: October 21, 1997Assignees: Saint-Gobain/Norton Industrial Ceramics Corporation, Celestech, Inc.Inventors: Donald O. Patten, Jr., Matthew A. Simpson, Henry Windischmann, Michael S. Heuser
-
Patent number: 5667344Abstract: A cutting tool of the type having a tool support with a cutting tip of CVD diamond film brazed to it has the diamond material so oriented that the general direction of grain boundaries is not normal to the general plane of the rake face.Type: GrantFiled: September 27, 1996Date of Patent: September 16, 1997Assignee: Saint-Gobain/Norton Industrial Ceramics Corp.Inventors: Matthew A. Simpson, Robert A. Hay, Steven J. Brox
-
Patent number: 5648148Abstract: A heat-sinked electronic component includes a first layer of synthetic diamond having a relatively low thermal conductivity. A second layer of synthetic diamond is adjacent the first layer, the second layer of synthetic diamond having a relatively high thermal conductivity, the second layer being thinner than the first layer. An electronic component is mounted on the second layer of synthetic diamond. In a disclosed embodiment, the thermal conductivity of the diamond of the second layer is at least fifteen percent higher than the thermal conductivity of the diamond of the first layer, and the first layer is at least twice as thick as second layer.Type: GrantFiled: May 17, 1995Date of Patent: July 15, 1997Assignee: Saint Gobain/Norton Industrial Ceramics Corp.Inventor: Matthew Simpson
-
Patent number: 5644089Abstract: A method is disclosed for making a wear component that includes providing a base surface, producing a synthetic diamond film having at least a particular equivalent strain, and applying the diamond film to the base surface. A method is also disclosed for producing synthetic diamond for use as a wear surface, by chemical vapor deposition wherein the equivalent strain of the synthetic diamond is monitored, and deposition parameters are modified when the equivalent strain of the synthetic diamond is less than a predetermined percentage.Type: GrantFiled: May 12, 1995Date of Patent: July 1, 1997Assignee: Norton CompanyInventor: Matthew Simpson
-
Patent number: 5643523Abstract: A method of making a diamond-coated insert includes, obtaining a substrate of durable and diamond adherent material having a substantially smooth surface on which is coated a diamond layer using any known CVD technique, and partitioning the diamond covered substrate with a laser beam into multiple inserts with desired geometries. If desired, the insert edges and corners may be thereafter machined or ablated until the desired smoothness and finish are achieved, and a fastening throughbore may be preformed or drilled in the center of each insert. The diamond-coated inserts as formed have a top surface entirely coated by a surface layer of diamond of a first thickness, and at least one rake face which is not diamond-coated beyond the surface layer of diamond.Type: GrantFiled: April 18, 1995Date of Patent: July 1, 1997Assignee: Saint-Gobain/Norton Industrial Ceramics Corp.Inventor: Matthew A. Simpson
-
Patent number: 5633087Abstract: A method is disclosed for making a wear component that includes providing a base surface, producing a synthetic diamond film having at least a particular equivalent strain, and applying the diamond film to the base surface. A method is also disclosed for producing synthetic diamond for use as a wear surface, by chemical vapor deposition wherein the equivalent strain of the synthetic diamond is monitored, and deposition parameters are modified when the equivalent strain of the synthetic diamond is less than a predetermined percentage.Type: GrantFiled: May 12, 1995Date of Patent: May 27, 1997Assignee: Norton CompanyInventor: Matthew Simpson
-
Patent number: 5620745Abstract: A method for depositing synthetic diamond film on a substrate, including the following steps: pre-stressing the substrate to obtain a pre-deposition stress across a surface thereof; depositing the diamond film on the pre-stressed substrate surface; and cooling the film and substrate, and relieving the pre-deposition stress during the cooling. When the substrate has a higher coefficient of thermal expansion than the diamond film, the pre-stress is a compressional stress. When the substrate has a lower coefficient of thermal expansion than diamond film, the pre-stress is a tensile stress.Type: GrantFiled: December 19, 1995Date of Patent: April 15, 1997Assignee: Saint Gobain/Norton Industrial Ceramics Corp.Inventor: Matthew A. Simpson
-
Patent number: 5589232Abstract: A method for making a wear component that includes providing a base surface, producing a synthetic diamond film by plasma jet CVD having at least a particular equivalent strain, and applying the diamond film to the base surface.Type: GrantFiled: September 19, 1994Date of Patent: December 31, 1996Assignee: Norton CompanyInventor: Matthew Simpson
-
Patent number: 5529633Abstract: An apparatus for depositing a substance includes a rotating mandrel assembly with a mandrel having a deposition surface exposed to the vapor so that the substance is deposited on the deposition surface and having a base having a plurality of radiator fins extending therefrom. A plurality of receptor fins interleave with the radiator fins and provide heat exchange to the receptor fins to cool the mandrel during deposition of the substance on the deposition surface of the mandrel.Type: GrantFiled: May 11, 1995Date of Patent: June 25, 1996Assignee: Saint-Gobain/Norton Industrial Ceramics CorporationInventors: Dan O. Enniss, Matthew Simpson
-
Patent number: 5527559Abstract: A method of making a diamond film on a graphite substrate is disclosed, which comprises the steps of forming a layer of carbon-containing compound on a surface of the graphite substrate and controlling said compound to be rich or lean in carbon with respect to the stoichiometric carbon content in the compound to adjust the adherence of a diamond layer to be deposited on said layer of carbon-containing compound; and depositing a synthetic diamond layer on said layer of carbon-containing compound.Type: GrantFiled: July 18, 1994Date of Patent: June 18, 1996Assignee: Saint Gobain/Norton Industrial Ceramics Corp.Inventor: Matthew Simpson
-
Patent number: 5514242Abstract: A method for forming a heat-sinked electronic component includes the following steps: depositing, at a first deposition rate, a first layer of synthetic diamond having a relatively high thermal conductivity; depositing, on the first layer, at a second deposition rate that is higher than the first deposition rate, a second layer of synthetic diamond having a relatively low thermal conductivity; and mounting an electronic component on the first layer of synthetic diamond. Alternatively, the layers may be deposited in the opposite order.Type: GrantFiled: December 30, 1993Date of Patent: May 7, 1996Assignee: Saint Gobain/Norton Industrial Ceramics CorporationInventor: Matthew Simpson
-
Patent number: 5486380Abstract: A method for depositing a substance includes the following steps: producing a vapor containing constituents of the substance; providing a rotating mandrel assembly that includes a mandrel, having a deposition surface exposed to the vapor so that the substance is deposited on the deposition surface, and a base having a plurality of radiator fins extending therefrom; interleaving a plurality of receptor fins with the radiator fins; and providing heat exchange to the receptor fins to cool the mandrel during deposition of the substance on the deposition surface of the mandrel.Type: GrantFiled: December 30, 1993Date of Patent: January 23, 1996Assignee: Saint-Gobain/Norton Industrial Ceramics CorporationInventors: Dan O. Enniss, Matthew Simpson
-
Patent number: 5411758Abstract: A method is disclosed for making a wear component that includes providing a base surface, producing a synthetic diamond film having at least a particular equivalent strain, and applying the diamond film to the base surface. A method is also disclosed for producing synthetic diamond for use as a wear surface, by chemical vapor deposition wherein the equivalent strain of the synthetic diamond is monitored, and deposition parameters are modified when the equivalent strain of the synthetic diamond is less than a predetermined percentage.Type: GrantFiled: October 9, 1991Date of Patent: May 2, 1995Assignee: Norton CompanyInventor: Matthew Simpson
-
Patent number: 5314652Abstract: A method for making a free-standing synthetic diamond film of desired thickness, including the following steps: providing a substrate; selecting a target thickness of diamond to be produced, the target thickness being in the range 200 microns to 1000 microns; finishing a surface of the substrate to a roughness, R.sub.A, that is a function of the target thickness, the roughness being determined from ##EQU1## where t is the target thickness; depositing an interlayer on the substrate, the interlayer having a thickness in the range 1 to 20 microns; depositing synthetic diamond on the interlayer, by chemical vapor deposition, to about the target thickness; and cooling the synthetic diamond to effect the release thereof.Type: GrantFiled: November 10, 1992Date of Patent: May 24, 1994Assignee: Norton CompanyInventors: Matthew Simpson, Robert M. Frey
-
Patent number: 5132984Abstract: An electric furnace comprising a container having electrically isolated wall segments useful for melting materials, particlularly ceramics, is disclosed.The electric fornace's side walls are constructed from electrically isolated segments, which cause electric current from a plasma torch to be concentrated on the material in the furnace to be melted rather than diverted to the walls of the furnace.Type: GrantFiled: November 1, 1990Date of Patent: July 21, 1992Assignee: Norton CompanyInventor: Matthew Simpson
-
Patent number: 5076991Abstract: A novel process for rapid solidification of ceramic melts combines certain features of cooling by atomization and by contact with chilling surfaces. The material to be solidified is divided into fine liquid droplets that are propelled by a rapid flow of gas toward a rapidly moving chill surface, striking the surface with sufficient velocity to flatten each drop into a flat flake like shape. Apparatus for the process is also disclosed. The process is particularly applicable to making very fine grained, or even amorphous, ceramic materials that can be powdered and then sintered into strong, tough ceramic structures.Type: GrantFiled: February 16, 1990Date of Patent: December 31, 1991Assignee: Norton CompanyInventors: John W. Poole, Merton C. Flemings, Thomas A. Gaspar, Matthew A. Simpson
-
Patent number: 4917852Abstract: A novel process for rapid solidification of ceramic melts combines certain features of cooling by atomization and by contact with chilling surfaces. The material to be solidified is divided into fine liquid dropletes that are propelled by a rapid flow of gas toward a rapidly moving chill surface, striking the surface with sufficient velocity to flatten each drop into a flat flake like shape. Apparatus for the process is also disclosed. The process is particularly applicable to making very fine grained, or even amorphous, ceramic materials that can be powdered and then sintered into strong, tough ceramic structures.Type: GrantFiled: April 29, 1988Date of Patent: April 17, 1990Assignee: Norton CompanyInventors: John W. Poole, Merton C. Flemings, Thomas A. Gaspar, Matthew A. Simpson