| US SYNTHETIC CORPORATION Patent applications |
| Patent application number | Title | Published |
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| 20120057814 | BEARING ELEMENTS, BEARING ASSEMBLIES AND RELATED METHODS - Bearing elements, assemblies and apparatuses are provided as well as a method of manufacturing such components. In one embodiment, a bearing element comprises a superhard table forming a convex bearing surface and a radiused edge formed on the superhard table adjacent to the convex bearing surface. In another embodiment, a bearing element comprises a superhard table forming a concave bearing surface and a radiused edge formed on the superhard table adjacent to the concave bearing surface. In one embodiment, a bearing apparatus includes an inner bearing race assembly and an outer bearing race assembly. Each of the bearing race assemblies include a plurality of bearing elements. At least one of the inner and outer bearing race assemblies include a bearing element having an arcuate bearing surface and a radiused edge formed adjacent the arcuate bearing surface. | 03-08-2012 |
| 20120039551 | BEARING ASSEMBLIES, APPARATUSES, AND RELATED METHODS OF MANUFACTURE - In an embodiment, a bearing assembly may include a support ring to which one or more superhard bearing elements may be mounted. The support ring may include one or more relief features configured to reduce residual stresses in the superhard bearing elements that are induced by brazing the superhard bearing elements to the support ring, operational loads, other processes, or combinations of the foregoing. Reducing the residual stresses in the superhard bearing elements may help prevent damage to the superhard bearing elements. The bearing assembly may be used in subterranean drilling systems and/or other types of systems. | 02-16-2012 |
| 20120037425 | BEARING ASSEMBLY INCLUDING BEARING SUPPORT RING CONFIGURED TO REDUCE THERMAL WARPING DURING USE, BEARING APPARATUSES USING THE SAME, AND RELATED METHODS - Various embodiments relate to a bearing assembly including a support ring configured to reduce thermal warping under operational temperature conditions, a bearing apparatus that may utilize such a thrust-bearing assembly, and applications that incorporate the disclosed bearing apparatuses such as downhole motors in subterranean drilling systems, directional drilling systems, and many other apparatuses. In an embodiment, a bearing assembly includes a plurality of superhard bearing elements distributed circumferentially about an axis. The thrust-bearing assembly further includes a support ring having the plurality of superhard bearing elements mounted thereto. The support ring includes at least one thermal-warping-reducing feature configured to reduce a radial moment, compared to if the at least one thermal-warping-reducing feature were absent from the support ring, which is thermally induced in the support ring when the support ring and the plurality of superhard bearing elements are exposed to operational temperature conditions. | 02-16-2012 |
| 20120012401 | POLYCRYSTALLINE DIAMOND COMPACT INCLUDING A SUBSTRATE HAVING A RAISED INTERFACIAL SURFACE BONDED TO A POLYCRYSTALLINE DIAMOND TABLE, AND APPLICATIONS THEREFOR - In various embodiments, a polycrystalline diamond compact (“PDC”) comprises a substrate including an interfacial surface having a raised region. In an embodiment, a PDC comprises a substrate including an interfacial surface having a generally cylindrical raised region and a peripheral region extending about the generally cylindrical raised region. The generally cylindrical raised region extends to a height above the peripheral region of about 450 μm or less. The PDC includes a PCD table bonded to the interfacial surface of the substrate. The PCD table includes an upper surface and at least one peripheral surface, and includes a plurality of bonded diamond grains defining interstitial regions. At least a portion of the interstitial regions includes a metallic constituent therein. In another embodiment, instead of employing a generally cylindrical raised region, the interfacial surface may include a plurality of raised arms extending above the face. Each raised arm extends radially and circumferentially. | 01-19-2012 |
| 20120011779 | POLYCRYSTALLINE DIAMOND MATERIALS AND RELATED PRODUCTS - Embodiments relate to methods of fabricating PCD materials by subjecting a mixture that exhibits a broad diamond particle size distribution to an HPHT process, PCD materials so-formed, and PDCs including a polycrystalline diamond table comprising such PCD materials. In an embodiment, a PCD material includes a plurality of bonded diamond grains that exhibit a substantially unimodal diamond grain size distribution characterized, at least in part, by a parameter θ that is less than about 1.0. | 01-19-2012 |
| 20120000136 | METHODS OF FABRICATING A POLYCRYSTALLINE DIAMOND STRUCTURE - In an embodiment, a method of fabricating a polycrystalline diamond structure includes forming an assembly including a sintered polycrystalline diamond body positioned between an aluminum-containing layer and a substrate. The method further includes subjecting the assembly to a high-pressure/high-temperature process to form the polycrystalline diamond structure including a polycrystalline diamond table bonded to the substrate. | 01-05-2012 |
| 20110297453 | POLYCRYSTALLINE DIAMOND COMPACTS AND RELATED DRILL BITS - In an embodiment, a polycrystalline diamond compact (“PDC”) comprises a cemented carbide substrate including a first cemented carbide portion and a second cemented carbide portion bonded to the first cemented carbide portion and exhibiting an erosion resistance that is greater than the first cemented carbide portion. The PDC further comprises a polycrystalline diamond (“PCD”) table bonded to the first cemented carbide portion. The PCD table includes a plurality of bonded diamond grains exhibiting diamond-to-diamond bonding therebetween, with the plurality of bonded diamond grains defining a plurality of interstitial regions. | 12-08-2011 |
| 20110284294 | ROTATIONAL DRILL BITS AND DRILLING APPARATUSES INCLUDING THE SAME - A rotary drill bit may include a bit body rotatable about a central axis. The rotary drill bit may also include at least one cutting element coupled to the bit body. The at least one cutting element may have a cutting face, a cutting edge adjacent the cutting face, and a back surface opposite the cutting face. The at least one cutting element may be oriented so that a substantial portion of the cutting edge has a positive clearance angle, which may be defined by a first vector that is normal to the cutting face and a second vector that is tangential to a helical path traveled by the cutting edge during drilling. | 11-24-2011 |
| 20110259648 | POLYCRYSTALLINE DIAMOND COMPACT AND METHOD OF MAKING SAME - A polycrystalline diamond compact includes a substrate and a polycrystalline diamond table attached to the substrate. The polycrystalline diamond table includes an upper surface and at least one peripheral surface. Diamond grains of the polycrystalline diamond table define a plurality of interstitial regions. The polycrystalline diamond table includes a region having silicon carbide positioned within at least some of the interstitial regions thereof. In an embodiment, the first region extends over only a selected portion of the upper surface and/or at least a portion of the at least one peripheral surface. In another embodiment, the first region substantially contours the upper surface and a chamfer. | 10-27-2011 |
| 20110258937 | METHODS OF FABRICATING A SUPERABRASIVE COMPACT INCLUDING A DIAMOND-SILICON CARBIDE COMPOSITE TABLE - Embodiments relate to superabrasive compacts including a diamond-silicon carbide composite table, and methods of fabricating such superabrasive compacts. In an embodiment, a method of fabricating a superabrasive compact is disclosed. An assembly comprising a mixture including diamond particles and silicon is formed. The silicon comprises amorphous silicon, crystalline silicon crystallized from amorphous silicon formed by a milling process, or combinations thereof. A substrate is positioned in proximity to the mixture. The assembly is subjected to a high-pressure/high-temperature process to form a superabrasive compact comprising a superabrasive table bonded to the substrate. The superabrasive table comprises diamond-silicon carbide composite including diamond grains dispersed through a matrix of silicon carbide grains. | 10-27-2011 |
| 20110225896 | METHODS OF FABRICATING POLYCRYSTALLINE DIAMOND ELEMENTS AND COMPACTS USING SP2-CARBON-CONTAINING PARTICLES - Methods of fabricating polycrystalline diamond elements and compacts using sp | 09-22-2011 |
| 20110210056 | GAS PHASE APPROACH TO IN-SITU/EX-SITU FUNCTIONALIZATION OF POROUS GRAPHITIC CARBON VIA RADICAL-GENERATED MOLECULES - Embodiments disclosed herein include graphitic stationary phase materials functionalized through a gas-phase functionalization reaction, as well as and methods for making and using these materials, including the use of these materials in separation technologies such as, but not limited to, chromatography and solid phase extraction. In an embodiment, a functionalized graphitic stationary phase material may be prepared from high surface area porous graphitic carbon and a radical forming volatilized functionalizing agent. The radical forming volatilized functionalizing agent produces an intermediate that forms a covalent bond with the surface of the porous graphitic material and imparts desired properties to the surface of the graphitic carbon. | 09-01-2011 |
| 20110189468 | POLYCRYSTALLINE DIAMOND COMPACT AND METHOD OF FABRICATING SAME - Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteads or more and a specific magnetic saturation of about 15 Gauss·cm | 08-04-2011 |
| 20110174547 | BEARING ASSEMBLIES, AND BEARING APPARATUSES AND MOTOR ASSEMBLIES USING SAME - Various embodiments of the present invention relate to bearing assemblies configured to accommodate non-uniform loading and misalignment with an adjacent bearing assembly. In one embodiment of the present invention, a bearing assembly for use in a subterranean drilling system is disclosed. The bearing assembly includes a support ring and a retention ring attached to the support ring, with the retention ring including a plurality of through holes. The bearing assembly includes a plurality of bearing elements each of which includes a superhard bearing surface. Each of the bearing elements is positioned in and extends from a corresponding through hole of the plurality of through holes. At least a number of the bearing elements are configured to restrict displacement through the corresponding through hole and away from the support ring. Further embodiments of the present invention are directed to a thrust-bearing apparatus, a radial bearing apparatus, and a downhole motor that incorporates disclosed thrust-bearing and radial bearing assemblies. | 07-21-2011 |
| 20110174544 | Bearing Assemblies, Bearing Apparatuses Using the Same, and Related Methods - Various embodiments relate to bearing assemblies configured to enable removal and replacement of superhard bearing elements, and bearing apparatuses that may utilize such bearing assemblies. The disclosed bearing assemblies may be used in a number of applications, such as downhole motors in subterranean drilling systems, directional drilling systems, roller-cone drill bits, and many other applications. In an embodiment, a bearing assembly includes a support ring and a retention ring assembled with the support ring. The retention ring includes a plurality of through holes. The bearing assembly further includes a plurality of superhard bearing elements, with each superhard bearing element inserted partially through and projecting from a corresponding one of the through holes of the retention ring. The retention ring and each superhard bearing element are collectively configured to restrict displacement of each superhard bearing element beyond a selected position in a direction away from the support ring. | 07-21-2011 |
| 20110120782 | POLYCRYSTALLINE DIAMOND COMPACT INCLUDING A SUBSTRATE HAVING A RAISED INTERFACIAL SURFACE BONDED TO A LEACHED POLYCRYSTALLINE DIAMOND TABLE, AND APPLICATIONS THEREFOR - In various embodiments, a polycrystalline diamond compact (“PDC”) comprises a substrate including an interfacial surface having a raised region. The PDC comprises a polycrystalline diamond (“PCD”) table bonded to the interfacial surface of the substrate. The PCD table defines an upper surface and exhibits a thickness over the raised region. The PCD table includes a plurality of bonded diamond grains defining a plurality of interstitial regions. A first region of the PCD table adjacent to the substrate includes metal-solvent catalyst disposed interstitially between the bonded diamond grains thereof, and a leached second region of the PCD table extends inwardly from the upper surface. The interstitial regions of the leached second region are depleted of metal-solvent catalyst. The geometry of the PCD table and raised region may be selected so that residual compressive stresses therein are retained to a sufficient level after leaching to provide a damage tolerant/thermally-stable PCD table. | 05-26-2011 |
| 20110120776 | HYDRODYNAMIC BEARING ASSEMBLIES, AND HYDRODYNAMIC BEARING APPARATUSES AND MOTOR ASSEMBLIES USING SAME - Hydrodynamic bearing assemblies and apparatuses are disclosed. Such hydrodynamic bearing assemblies may be employed in bearing apparatuses for use in downhole motors of a subterranean drilling system or other mechanical systems. In one embodiment of the present invention, a hydrodynamic bearing assembly includes a plurality of bearing elements distributed circumferentially about an axis. Each bearing segment includes a superhard bearing surface. The plurality of bearing elements defines a plurality of seams. Each seam is formed between circumferentially-adjacent bearing elements of the plurality of bearing elements. Further embodiments of the present invention include hydrodynamic bearing apparatuses and downhole motors that may utilize any of the disclosed hydrodynamic bearing assemblies. | 05-26-2011 |
| 20110088955 | CUTTING ELEMENT APPARATUSES, DRILL BITS INCLUDING SAME, METHODS OF CUTTING, AND METHODS OF ROTATING A CUTTING ELEMENT - A subterranean drilling system may include a drill string and a rotary drill bit coupled to the drill string. The rotary drill bit may include a bit body and a cutting element coupled to the bit body, with the cutting element being structured to rotate in response to torque applied to the cutting element. The system also may include a cam assembly coupled to the drill string, a cam follower assembly in contact with a cam surface of the cam assembly, and a torque-applying structure coupled to the cam follower assembly. The torque-applying structure may be configured to apply torque to the cutting element in response to relative rotation between the cam assembly and the cam follower assembly. | 04-21-2011 |
| 20110067929 | POLYCRYSTALLINE DIAMOND COMPACTS, METHODS OF MAKING SAME, AND APPLICATIONS THEREFOR - In an embodiment, a polycrystalline diamond compact (“PDC”) comprises a cemented carbide substrate including a first cemented carbide portion exhibiting a first concentration of chromium carbide and a second cemented carbide portion bonded to the first cemented carbide portion and exhibiting a second concentration of chromium carbide that is greater than the first concentration. The PDC further comprises a polycrystalline diamond (“PCD”) table bonded to the first cemented carbide portion. The PCD table includes a plurality of bonded diamond grains exhibiting diamond-to-diamond bonding therebetween, with the plurality of bonded diamond grains defining a plurality of interstitial regions. The PCD table includes chromium present in a concentration less than about 0.25 weight %. | 03-24-2011 |
| 20110061940 | CONFORMAL BEARING FOR ROCK DRILL BIT - A rock drilling bit having PDC radial bearings has journal and cone bearing surfaces with increased contact area to increase load support. The radius of curvature of the bearing pin journal and cone bearing surfaces are matched or conformed on the bearing pressure side. The conformal journal surfaces may be formed on the main journal bearing, the pilot pin radial bearing, or both surfaces. In addition, diamond inlays may be located on the bearing surfaces of the cone, the bearing pin, or both components. | 03-17-2011 |
| 20110056141 | Superabrasive Elements and Methods for Processing and Manufacturing the Same Using Protective Layers - An exemplary method of processing a polycrystalline diamond element is disclosed. According to the method, a protective layer may be formed over only a selected portion of a polycrystalline diamond element. The polycrystalline diamond element may include a polycrystalline diamond table. At least a portion of the polycrystalline diamond element may be exposed to a leaching solution such that the leaching solution contacts an exposed surface region of the polycrystalline diamond table and at least a portion of the protective layer. The protective layer may be substantially impermeable to the leaching solution. An exemplary method of manufacturing a polycrystalline diamond element is also disclosed. | 03-10-2011 |
| 20110017519 | POLYCRYSTALLINE DIAMOND COMPACTS, METHOD OF FABRICATING SAME, AND VARIOUS APPLICATIONS - Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, polycrystalline diamond compact (“PDC”) includes a PCD table having a maximum thickness. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteds (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm | 01-27-2011 |
| 20100310855 | POLYCRYSTALLINE DIAMOND - Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteads (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm | 12-09-2010 |
| 20100307070 | METHOD OF FABRICATING POLYCRYSTALLINE DIAMOND AND A POLYCRYSTALLINE DIAMOND COMPACT - Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteads (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm | 12-09-2010 |
| 20100307069 | POLYCRYSTALLINE DIAMOND COMPACT - Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteads (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm | 12-09-2010 |
| 20100288558 | BEARING ASSEMBLY INCLUDING AT LEAST ONE SUPERHARD BEARING ELEMENT HAVING AT LEAST ONE REGISTRATION FEATURE, BEARING APPARATUS INCLUDING SAME, AND METHODS FOR MAKING SAME - Embodiments of the invention relate to a bearing assembly including at least one superhard bearing element having at least one bearing registration feature configured to facilitate orientating of a curved, pre-machined bearing surface thereof with respect to a bearing body, methods of fabricating such bearing assemblies, and bearing apparatuses incorporating such bearing assemblies. Subterranean drilling systems incorporating such bearing assemblies are also disclosed. | 11-18-2010 |
| 20100264134 | APPARATUSES AND METHODS FOR INDUCTION HEATING - A heating apparatus for induction heating is disclosed. The heating apparatus may comprise a bearing ring, at least one bearing element disposed in the bearing ring, and a braze material adjacent to the at least one bearing element and the bearing ring. The heating apparatus may additionally comprise an inductor positioned radially adjacent to at least a portion of the bearing ring. A current source may be electrically coupled to the inductor. A bearing orienting member may also abut a surface of the at least one bearing element. The bearing orienting member may orient a surface of the at least one bearing element. A heating method is also disclosed. | 10-21-2010 |
| 20100226759 | BEARING APPARATUSES, SYSTEMS INCLUDING SAME, AND RELATED METHODS - A bearing apparatus is disclosed. Such a bearing apparatus may comprise a rotor including at least one bearing element mounted to the rotor and a stator including at least one bearing element mounted to the stator. At least one compliant member may be positioned between at least one selected bearing element of the at least one bearing element mounted to the rotor and the at least one bearing element mounted to the stator. Mechanical systems including such a bearing apparatus are disclosed, such as, for example, a motor for use in subterranean drilling. A method of assembling a bearing apparatus is disclosed. More specifically, a rotor and a stator each including at least one bearing element may be provided and a compressive force may be applied to the rotor and the stator to compress the bearing surfaces of the rotor and the stator against one another. Rotors and stators are disclosed. | 09-09-2010 |
| 20100225311 | METHOD OF CHARACTERIZING A POLYCRYSTALLINE DIAMOND ELEMENT BY AT LEAST ONE MAGNETIC MEASUREMENT - In an embodiment, a method of characterizing a polycrystalline diamond element is disclosed. The method includes providing the polycrystalline diamond element, and measuring at least one magnetic characteristic of the polycrystalline diamond element. | 09-09-2010 |
| 20100218995 | BEARING APPARATUSES, SYSTEMS INCLUDING SAME, AND RELATED METHODS - In an embodiment, a bearing apparatus comprises a first bearing assembly including a plurality of circumferentially-spaced first bearing elements each of which includes a first bearing surface. The bearing apparatus further includes a second bearing assembly including a plurality of circumferentially-spaced second bearing elements each of which includes a second bearing surface oriented to engage the first bearing surfaces of the first bearing assembly during operation. At least one of the second bearing elements may be circumferentially spaced from an adjacent one of the second bearing elements by a lateral spacing greater than a lateral dimension of the at least one of the second bearing elements. | 09-02-2010 |
| 20100212971 | Polycrystalline Diamond Compact Including A Cemented Tungsten Carbide Substrate That Is Substantially Free Of Tungsten Carbide Grains Exhibiting Abnormal Grain Growth And Applications Therefor - Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table that is substantially free of defects formed due to abnormal grain growth of tungsten carbide grains, and methods of fabricating such PDCs. In an embodiment, a PDC comprises a cemented tungsten carbide substrate including an interfacial surface that is substantially free of tungsten carbide grains exhibiting abnormal grain growth, and a PCD table bonded to the interfacial surface of the cemented tungsten carbide substrate. The PCD table includes a plurality of bonded diamond grains defining a plurality of interstitial regions. At least a portion of the interstitial regions includes a metal-solvent catalyst disposed therein. The PCD table may be substantially free of chromium or the PCD table and the cemented tungsten carbide substrate may each include chromium. | 08-26-2010 |
| 20100084196 | POLYCRYSTALLINE DIAMOND, POLYCRYSTALLINE DIAMOND COMPACT, METHOD OF FABRICATING SAME, AND VARIOUS APPLICATIONS - Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteads (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm | 04-08-2010 |
| 20090324348 | CUTTING ELEMENT APPARATUSES, DRILL BITS INCLUDING SAME, METHODS OF CUTTING, AND METHODS OF ROTATING A CUTTING ELEMENT - A rotary drill bit for drilling a subterranean formation may comprise a bit body, a cutting element coupled to the bit body, and a torque-generating assembly configured to apply torque, either continuously or periodically, to the cutting element. The torque-generating assembly may be powered by the rotary motion of the rotary drill bit or may be hydraulically or electrically powered. The cutting element may comprise a substrate, a table of superabrasive material disposed on an end of the substrate, and at least one impelling feature formed along the exterior surface of the substrate. In addition, a method of rotating a cutting element coupled to a drill bit for drilling a subterranean formation may comprise providing a cutting element comprising a table bonded to a substrate, coupling the substrate of the cutting element to a drill bit body, and applying torque to the substrate of the cutting element. | 12-31-2009 |
| 20090283332 | CONFORMAL BEARING FOR ROCK DRILL BIT - A rock drilling bit having PDC radial bearings has journal and cone bearing surfaces with increased contact area to increase load support. The radius of curvature of the bearing pin journal and cone bearing surfaces are matched or conformed on the bearing pressure side. The conformal journal surfaces may be formed on the main journal bearing, the pilot pin radial bearing, or both surfaces. In addition, diamond inlays may be located on the bearing surfaces of the cone, the bearing pin, or both components. | 11-19-2009 |
| 20090272583 | SUPERABRASIVE INSERTS INCLUDING AN ARCUATE PERIPHERAL SURFACE - Superabrasive inserts are disclosed. More particularly, a superabrasive insert may comprise a superabrasive layer bonded to a substrate at an interface. Further, the superabrasive layer may include a central substantially planar surface, a peripheral side surface, and an arcuate peripheral surface extending between the central substantially planar surface and the peripheral side surface. In one embodiment, the arcuate peripheral surface may comprise a lateral extent and an extension depth, wherein a ratio of the lateral extent to the extension depth is at least about | 11-05-2009 |
| 20090260895 | Polycrystalline diamond materials, methods of fabricating same, and applications using same - Embodiments relate to methods of fabricating PCD materials by subjecting a mixture that exhibits a broad diamond particle size distribution to a HPHT process, PCD materials so-formed, and PDCs including a polycrystalline diamond table comprising such PCD materials. In an embodiment, a method includes subjecting a mixture to heat and pressure sufficient to form a PCD material. The mixture comprises a plurality of diamond particles exhibiting a diamond particle size distribution characterized, in part, by a parameter θ that is less than about 1.0, where | 10-22-2009 |
| 20090218287 | Solid phase extraction apparatuses and methods - Embodiments of the present invention relate to solid phase extraction (“SPE”) apparatuses that include a sintered polycrystalline diamond (“PCD”) stationary phase and methods of performing SPE using a sintered PCD stationary phase. In one embodiment, an SPE cartridge includes a housing that comprises a proximal first end including a housing inlet, a distal second end including a housing outlet, and an interior space extending between the housing inlet and the housing outlet. An SPE stationary phase may be positioned within the interior space and includes an inlet and an outlet. The SPE stationary phase comprises a mass of sintered diamond grains including a plurality of passageways extending therethrough between the inlet and the outlet. In other embodiments, an SPE apparatus may employ a sintered PCD stationary phase in the form of a disk. In yet another embodiment of the present invention, an SPE stationary phase of an SPE apparatus may comprise un-sintered diamond particles. | 09-03-2009 |
| 20090158670 | SUPERABRASIVE ELEMENT COMPRISING ULTRA-DISPERSED DIAMOND GRAIN STRUCTURES, STRUCTURES UTILIZING SAME, AND METHODS OF MANUFACTURE - Superabrasive elements, methods of fabricating such elements, and applications utilizing such elements. In one embodiment, a superabrasive element includes a mass of polycrystalline diamond including ultra-dispersed diamond grain structures present in an amount greater than zero weight percent and less than about 75 weight percent of the mass of polycrystalline diamond. Various structures and apparatuses that utilize the superabrasive elements, such as polycrystalline diamond compacts (PDCs) and drill bits are disclosed. Methods of manufacture are also disclosed. | 06-25-2009 |
| 20090152018 | POLYCRYSTALLINE DIAMOND COMPACTS, AND RELATED METHODS AND APPLICATIONS - Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) and methods of fabricating such PDCs. In an embodiment of a “two-step” manufactured PDC, a PDC includes a substrate and a pre-sintered polycrystalline diamond (“PCD”) table bonded to the substrate. The pre-sintered PCD table includes bonded diamond grains defining interstitial regions. At least a portion of the interstitial regions include at least one material disposed therein selected from a silicon-cobalt alloy, silicon carbide, cobalt carbide, or a mixed carbide of silicon and cobalt. The pre-sintered PCD table lacks an intermediate contaminant region therein that includes at least one type of fabrication by-product generated during the fabrication of the pre-sintered PCD table. | 06-18-2009 |
| 20090152015 | SUPERABRASIVE MATERIALS AND COMPACTS, METHODS OF FABRICATING SAME, AND APPLICATIONS USING SAME - Embodiments of the present invention relate to superabrasive materials, superabrasive compacts employing such superabrasive materials, and methods of fabricating such superabrasive materials and compacts. One or more embodiments of a superabrasive material include a plurality of first superabrasive regions characteristic of being formed at least partially from a plurality of agglomerates, with each first superabrasive region including a plurality of first superabrasive grains that exhibit a first average grain size, and a matrix through which the plurality of first superabrasive regions is dispersed. The matrix includes a plurality second intercrystalline-bonded superabrasive grains that exhibit a second average grain size. The superabrasive material exhibits one or more of the following characteristics: (1) the first average grain size being less than that of the second average grain size; (2) the plurality of first superabrasive regions exhibiting a selectivity to be preferentially removed from the matrix; or (3) a thermal stability of the plurality of first superabrasive regions being greater than that of the matrix. | 06-18-2009 |
| 20090097788 | Hydrodynamic bearing assemblies, and hydrodynamic bearing apparatuses and motor assemblies using same - Hydrodynamic bearing assemblies and apparatuses are disclosed. Such hydrodynamic bearing assemblies may be employed in bearing apparatuses for use in downhole motors of a subterranean drilling system or other mechanical systems. In one embodiment of the present invention, a hydrodynamic bearing assembly includes a plurality of bearing segments distributed circumferentially about an axis. Each bearing segment includes a superhard bearing surface. The plurality of bearing segments define a plurality of seams. Each seam is formed between circumferentially-adjacent bearing segments of the plurality of bearing segments. Further embodiments of the present invention include hydrodynamic bearing apparatuses and downhole motors that may utilize any of the disclosed hydrodynamic bearing assemblies. | 04-16-2009 |
| 20080236900 | CUTTING ELEMENT APPARATUSES AND DRILL BITS SO EQUIPPED - A cutting element assembly for use on a rotary drill bit for forming a borehole in a subterranean formation. A cutting element assembly includes a cutting element having a substrate. The cutting element assembly additionally includes a superabrasive material bonded to the substrate. The substrate extends from an end surface to a back surface. A base member is also coupled to the back surface of the substrate. Additionally, a recess is defined in the base member and a structural element is coupled to the base member. The cutting element assembly also includes a biasing element configured to selectively bias the structural element. | 10-02-2008 |
| 20080206576 | Superabrasive compact including diamond-silicon carbide composite, methods of fabrication thereof, and applications therefor - Embodiments of the present invention relate to diamond-silicon carbide composites, superabrasive compacts including such diamond-silicon carbide composites, and methods of fabricating such diamond-silicon carbide composites and superabrasive compacts. In one embodiment, a superabrasive compact includes a substrate and a superabrasive table bonded to the substrate. The superabrasive table comprises diamond-silicon carbide composite including a matrix comprising nanometer-sized silicon carbide grains and micrometer-sized diamond grains dispersed through the matrix. In another embodiment, a method of fabricating a superabrasive compact is disclosed. An assembly comprising a mixture including diamond particles and silicon is formed. The silicon comprises amorphous silicon, crystalline silicon crystallized from amorphous silicon formed by a milling process, or combinations thereof. A substrate is positioned in proximity to the mixture. The assembly is subjected to heat and pressure to form a superabrasive compact comprising a superabrasive table bonded to the substrate. The superabrasive table comprises diamond-silicon carbide composite including diamond grains dispersed through a matrix of silicon carbide grains. | 08-28-2008 |
