Embedded single crystal diamond(s) in a polycrystalline diamond structure and a method of growing it

Abstract

A method of a growing an embedded single crystal diamond structure, comprising: disposing a single crystal diamond on a non-diamond substrate, wherein the non-diamond substrate is larger than the single crystal diamond; masking a top portion of the single crystal diamond using a masking material; and using a chemical vapor deposition (CVD) growth chamber, growing polycrystalline diamond material surrounding the single crystal diamond in order to join the single crystal diamond to the polycrystalline diamond material.

What is claimed is: 
     
         1 - 9 . (canceled) 
     
     
         10 . An embedded single crystal diamond structure comprising:
 a single crystal diamond; and   a polycrystalline diamond surrounding at least a portion of one edge of the single crystal diamond, wherein thickness of polycrystalline diamond is more than a thickness of single crystal diamond, and wherein boundary between the single crystal diamond and the polycrystalline diamond has a Raman full-width half maxima (FWHM) ranging from 2 cm -1  to 2.5 cm -1 .   
     
     
         11 . The embedded single crystal diamond structure as defined in  claim 10  wherein the single crystal diamond has a thickness of 2 µm or less. 
     
     
         12 . The embedded single crystal diamond structure as defined in  claim 10 , wherein the single crystal diamond is having a thickness of less than 10 microns (µm). 
     
     
         13 . The embedded single crystal diamond structure as defined in  claim 12 , wherein the single crystal diamond is having an area of 1.0 mm x 1.0 mm or larger. 
     
     
         14 . The embedded single crystal diamond structure as defined in  claim 13 , wherein the thickness of polycrystalline diamond is having a thickness of more than 3 mm. 
     
     
         15 . The embedded single crystal diamond structure as defined in  claim 14 , wherein the single crystal diamond and the polycrystalline diamond are having identical purity that enables post-processing step. 
     
     
         16 . The embedded single crystal diamond structure as defined in  claim 10 , wherein the single crystal diamond has a thickness of 20 µm or less.