| Patent application number | Description | Published |
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| 20090090563 | DIAMOND-BONDED CONSTRCUTIONS WITH IMPROVED THERMAL AND MECHANICAL PROPERTIES - Diamond-bonded constructions include a diamond-bonded body having a thermally stable region extending a distance below a diamond-bonded body surface. The thermally stable region comprises a matrix phase of bonded-together diamond crystals, and interstitial regions comprising a reaction product. The reaction product is formed by reaction between the diamond crystals and a reactive material. The reactant is a carbide former and the reaction product is a carbide. The diamond-bonded body includes a further diamond region extending from the thermally stable region that comprises the matrix phase and a Group VIII metal disposed within interstitial regions of the matrix phase. The thermally stable region is substantially free of a catalyst material used to initially form the diamond-bonded body. The diamond-bonded body may include a material layer formed from the reaction product that is disposed on a surface of the diamond-bonded body thermally stable region. | 04-09-2009 |
| 20090173014 | POLYCRYSTALLINE ULTRA-HARD CONSTRUCTIONS WITH MULTIPLE SUPPORT MEMBERS - Polycrystalline ultra-hard constructions comprise a polycrystalline ultra-hard material body and two or more support members attached to the body by braze material. The support members include a backside support member and a side support member. The side support member is a one- or two-piece construction, and is positioned circumferentially around and extends axially along the body or both the body and the backside support member such that a working surface of the body remains exposed. The support members can be configured to provide a mechanical attachment or interlocking attachment with the body or another support member. The braze materials used in the construction can be different and selected to enhance the attachment and/or reduce the creation of thermal stress within the construction during assembly. The support members can be selected having different thermal expansion characteristics that also operate to reduce the thermal stress during construction assembly. | 07-09-2009 |
| 20090173547 | ULTRA-HARD AND METALLIC CONSTRUCTIONS COMPRISING IMPROVED BRAZE JOINT - An ultra-hard and metallic construction comprises an ultra-hard component that is attached to a metallic component via a braze joint. The braze joint is interposed between the ultra-hard component and the metallic component, and comprises a first braze material bonded to a surface of the ultra-hard component. The braze joint includes an intervening layer in direct contact with the first braze material, and that is formed from a rigid material. The braze joint further comprises a second braze material that is interposed between the intervening layer and the metallic component, and that is different from the first braze material. Configured in this manner, the use of the braze joint operates to provide an optimum level of bond strength within the construction to enable its use in certain demanding wear and/or cutting applications. | 07-09-2009 |
| 20090173548 | POLYCRYSTALLINE ULTRA-HARD COMPACT CONSTRUCTIONS - Polycrystalline ultra-hard compact constructions comprise a polycrystalline ultra-hard compact having a polycrystalline ultra-hard body attached to a substrate. A support member is attached to the compact by a braze material. The support member can have a one-piece construction including one or more support sections. The support member has a first section extending axially along a wall surface of the compact, and extending circumferentially along a portion of the compact. The support member can include a second section extending radially along a backside surface of the compact, and/or a third section extending radially along a front side surface of the compact. In one embodiment, the support member includes a second and/or third section and the compact disposed therein is in an axially compressed state. The support member is interposed between the compact and an end-use device, and improves the compact attachment strength to an end-use device when compared to conventional compacts. | 07-09-2009 |
| 20100084197 | DIAMOND BONDED CONSTRUCTION WITH THERMALLY STABLE REGION - Diamond bonded constructions comprise a polycrystalline diamond body having a matrix phase of bonded-together diamond grains and a plurality of interstitial regions between the diamond grains including a catalyst material used to form the diamond body disposed within the interstitial regions. A sintered thermally stable diamond element is disposed within and bonded to the diamond body, and is configured and positioned to form part of a working surface. The thermally stable diamond element is bonded to the polycrystalline diamond body, and a substrate is bonded to the polycrystalline diamond body. The thermally stable diamond element comprises a plurality of bonded-together diamond grains and interstitial regions, wherein the interstitial regions are substantially free of a catalyst material used to make or sinter the thermally stable diamond element. A barrier material may be disposed over or infiltrated into one or more surfaces of the thermally stable diamond element. | 04-08-2010 |
| 20100236836 | THERMALLY STABLE POLYCRYSTALLINE DIAMOND MATERIAL WITH GRADIENT STRUCTURE - A diamond construction may include a diamond body comprising a plurality of bonded-together diamond crystals forming a matrix phase, and a plurality of interstitial regions disposed between the bonded-together diamond crystals, the diamond body comprising: a first diamond region extending a depth from a surface of the diamond body being substantially free of a catalyst material used to form the diamond body, wherein the first diamond region comprises the matrix phase and in at least a portion of the plurality of interstitial spaces, the first diamond region comprises a metal carbide and an inert metal, wherein the metal carbide is formed as a result of reaction between the diamond crystals in the matrix phase and a carbide-forming metal; and a second diamond region adjacent the first diamond region comprising the matrix phase and a Group VIII metal in the interstitial regions. | 09-23-2010 |
| 20100264198 | THERMALLY STABLE POLYCRYSTALLINE ULTRA-HARD CONSTRUCTIONS - Thermally stable polycrystalline constructions comprise a body having a polycrystalline ultra-hard phase and a plurality of empty voids. A population of the voids can be filled with a reaction product. The body is substantially free of a catalyst material. The construction comprises a first support member attached to the body by a first braze material. A second support member is attached to the body and the first support member by a second braze material. The construction may include a third support member attached to the body that is integral or separate from one of the other support members. The braze materials used to attached the support members can be the same or different, as can be the materials used to form the different support members. | 10-21-2010 |
| 20100294571 | CUTTING ELEMENTS, METHODS FOR MANUFACTURING SUCH CUTTING ELEMENTS, AND TOOLS INCORPORATING SUCH CUTTING ELEMENTS - The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having a high diamond content which are configured to provide improved properties of thermal stability and wear resistance, while maintaining a desired degree of impact resistance, when compared to prior polycrystalline diamond bodies. In various embodiments disclosed herein, a cutting element with high diamond content includes a modified PCD structure and/or a modified interface (between the PCD body and a substrate), to provide superior performance. | 11-25-2010 |
| 20100300767 | Diamond Bonded Construction with Improved Braze Joint - Diamond bonded constructions comprise a body comprising a plurality of bonded together diamond grains with interstitial regions disposed between the grains that are substantially free of the catalyst material used to initially sinter the body. A metallic substrate is attached to the body, and a braze joint is interposed between the body and the substrate. The body is metallized to include a metallic material disposed along a substrate attachment surface in contact with the braze joint, wherein the metallic material is different from the braze joint material. The metallic material may exist within a region of the body extending fully or partially into the body, and/or may exist as a layer extending away from the substrate attachment surface. The body includes a working surface characterized by empty interstitial regions or by interstitial regions filled with an infiltrant material, wherein the infiltrant material is different from the metallizing material. | 12-02-2010 |
| 20110036642 | NON-PLANAR INTERFACE CONSTRUCTION - A cutting element is provided, including a substrate and an ultra-hard material layer formed over the substrate. At one end of the substrate is an interface surface that interfaces with the ultra-hard material layer to bond the layer to the substrate. The interface surface includes a first or outer annular section that extends to the peripheral edge of the substrate, and a second or inner section that is radially inside the first section. The interface surface includes several spaced-apart projections arranged in an annular row. In one aspect, each projection has an upper surface that defines a groove bisecting the projection. In another aspect, the interface surface may include a bridge coupling adjacent projections. | 02-17-2011 |
| 20110036643 | THERMALLY STABLE POLYCRYSTALLINE DIAMOND CONSTRUCTIONS - Thermally stable polycrystalline constructions comprise a diamond body joined with a substrate, and may have a nonplanar interface. The construction may include an interlayer interposed between the diamond body and substrate. The diamond body preferably has a thickness greater than about 1.5 mm, and comprises a matrix phase of bonded together diamond crystals and interstitial regions disposed therebetween that are substantially free of a catalyst material used to sinter the diamond body. A replacement material is disposed within the interstitial regions. A population of the interstitial regions may include non-solvent catalyst material and/or an infiltrant aid disposed therein. The diamond body comprises two regions; namely, a first region comprising diamond grains that may be sized smaller than diamond grains in a second region, and/or the first region may comprise a diamond volume that is greater than that in the second region. | 02-17-2011 |
| 20110127088 | POLYCRYSTALLINE ULTRA-HARD COMPACT CONSTRUCTIONS - Polycrystalline ultra-hard compact constructions comprise a polycrystalline ultra-hard compact having a polycrystalline ultra-hard body attached to a substrate. A support member is attached to the compact by a braze material. The support member can have a one-piece construction including one or more support sections. The support member has a first section extending axially along a wall surface of the compact, and extending circumferentially along a portion of the compact. The support member can include a second section extending radially along a backside surface of the compact, and/or a third section extending radially along a front side surface of the compact. In one embodiment, the support member includes a second and/or third section and the compact disposed therein is in an axially compressed state. The support member is interposed between the compact and an end-use device, and improves the compact attachment strength to an end-use device when compared to conventional compacts. | 06-02-2011 |
| 20110139514 | Thermally Stable Diamond Bonded Materials and Compacts - Thermally stable diamond bonded construction comprise a diamond bonded body including a thermally stable region, comprising a plurality of diamond grains bonded together by a reaction product of the diamond grains with a reactant such as Si, and a polycrystalline diamond region, comprising intercrystalline bonded diamond and a catalyst material. The body further comprises a ceramic compound formed by reaction of an Nb, Zr, Ti, or Mo getter material with a gaseous element generated during HPHT sintering of the diamond bonded body. The diamond bonded body may comprise from 0.1 to 15 percent by weight of the ceramic compound. The diamond bonded body can be formed during a single HPHT process operated at different temperatures when the reactant has a melting temperature above the catalyst material. The construction may include a metallic substrate attached to the diamond bonded body to facilitate use as a wear or cutting element. | 06-16-2011 |
