Free-standing diamond structures and methods

Abstract

The present invention is directed in one aspect to methods of making free-standing, internally-supported, three-dimensional objects having an outer surface comprising a plurality of intersecting facets wherein a sub-set of the intersecting facets have a diamond layer of substantially uniform thickness. The diamond layer may be formed by chemical vapor deposition (CVD) over the surface of a substrate that has been fabricated to form a mold defining the sub-set of intersecting facets. A backing layer may be formed over at least a portion of the exposed diamond layer to enhance the rigidity of the layer when the substrate is removed.

1 - 34 . (canceled)  
   
   
       35 . A free-standing, internally-supported, three-dimensional object having an outer surface comprising a plurality of intersecting facets, at least a sub-set of said intersecting facets having a diamond layer of substantially uniform depth.  
   
   
       36 . The three-dimensional object of  claim 35  further comprising a backing layer.  
   
   
       37 . The three-dimensional object of  claim 35  wherein said sub-set of intersecting facets includes planar facets.  
   
   
       38 . The three-dimensional object of  claim 35  wherein said sub-set of intersecting facets includes non-planar facets.  
   
   
       39 . A free-standing, internally-supported, three-dimensional object comprising a rigid backing layer, said object having an outer surface comprising a plurality of intersecting facets, at least a sub-set of said intersecting facets having an exposed diamond surface.  
   
   
       40 . The three-dimensional object of  claim 39  wherein said backing layer is electrically conducting.  
   
   
       41 . The three-dimensional object of  claim 39  wherein said backing layer is electrically non-conducting.  
   
   
       42 . The three-dimensional object of  claim 39  wherein said backing layer is an epoxy.  
   
   
       43 . The three-dimensional object of  claim 39  wherein said sub-set of intersecting facets include planar facets.  
   
   
       44 . The three-dimensional object of  claim 39  wherein said sub-set of intersecting facets include non-planar facets.  
   
   
       45 . An apparatus comprising: 
 a rigid backing layer; and    a diamond structure of substantially uniform depth overlaying at least a portion of said backing layer, said diamond structure having an exposed surface forming a plurality of intersecting facts.    
   
   
       46 . The apparatus of  claim 45  wherein said exposed surface is suitable for guiding high frequency radiation.  
   
   
       47 . The apparatus of  claim 45  having a size and shape suitable for forming a bi-polar plate for a fuel cell.