Device and method for growing diamond in a liquid phase

Abstract

A method of growing a diamond mass in a liquid growth medium. The liquid growth medium can include a carbon source, a diamond growth catalyst such as a diamond catalyst metal-rare earth element alloy or nanocatalyst, and a dissociated hydrogen of a hydrogen source. The carbon source provides carbon atoms for growing diamond and can include a diamond seed material for diamond growth. The molten liquid phase provides a diamond growth catalyst which allows the carbon to form diamond at the temperature and low pressure conditions discussed. Furthermore, the dissociated hydrogen acts as a concentrator for assembling carbon atoms at a relatively high concentration which mimicks, in some respects, diamond growth under more conventional high pressure processes without the high pressure.

What is claimed is: 
     
         1 . A diamond growth apparatus, comprising:
 a) a substantially enclosed furnace including an inlet and an outlet;   b) a heating mechanism thermally associated with the furnace;   c) a porous ceramic oriented in the inlet to allow hydrogen gas into the furnace and prevent egress of molten liquid from the furnace; and   d) a hydrogen source fluidly connected to the inlet.   
     
     
         2 . The apparatus of  claim 1 , wherein the furnace enclosure further comprises upper and lower portions that are optionally detachable. 
     
     
         3 . The apparatus of  claim 2 , wherein the upper portion includes the outlet. 
     
     
         4 . The apparatus of  claim 2 , wherein the lower portion includes the inlet. 
     
     
         5 . The apparatus of  claim 1 , wherein the furnace comprises one or more materials selected from the group consisting essentially of: ceramics, metals, metal alloys, and composite materials having a melting point above the desired operating temperature for the apparatus. 
     
     
         6 . The apparatus of  claim 1 , wherein the porous ceramic is a single layer. 
     
     
         7 . The apparatus of  claim 1 , wherein the porous ceramic includes multiple layers. 
     
     
         8 . The apparatus of  claim 8 , wherein the layer include at least zeolite and sintered alumina. 
     
     
         9 . The apparatus of  claim 1 , wherein the hydrogen source includes a device that allows for variable adjustment of injection pressures to sufficiently inject the hydrogen gas into the same inlet. 
     
     
         10 . The apparatus of  claim 10 , wherein the device is a compressor. 
     
     
         11 . The apparatus of  claim 1 , wherein the heating mechanism comprises electrically resistive coils oriented on outer surfaces of the lower portion of the surface. 
     
     
         12 . The apparatus of  claim 11 , wherein the heating mechanism transfers heat into a liquid growth medium within the apparatus that creates upward convective currents in the liquid medium. 
     
     
         13 . The apparatus of  claim 12 , wherein the upward convective currents in the liquid medium augment current caused by incoming hydrogen gas. 
     
     
         14 . The apparatus of  claim 1 , wherein the outlet is configured to allow excess gas to escape. 
     
     
         15 . The apparatus of  claim 1 , wherein the outlet is substantially unimpeded and in fluid communication with the atmosphere such that the interior of the furnace is substantially at atmospheric pressures. 
     
     
         16 . The apparatus of  claim 1 , wherein the outlet further includes a pressure control relief valve. 
     
     
         17 . The apparatus of  claim 16 , wherein the control relief valve is operable to control internal pressure. 
     
     
         18 . The apparatus of  claim 16 , wherein the control relief valve is operable to control flame height. 
     
     
         19 . The apparatus of  claim 1 , further comprising a high temperature crucible suspended within the furnace by a thermally insulating stand, said crucible operable to hold diamond seeds and a molten liquid phase material. 
     
     
         20 . The apparatus of  claim 19 , further comprising a heater to heat materials in the crucible.