Polycrystalline diamond elements and systems and methods for fabricating the same

Patent metadata

Field	Value
Publication number	US-11946320-B2
Application number	US-202117145285-A
Country	US
Kind code	B2
Filing date	Jan 9, 2021
Priority date	Sep 18, 2017
Publication date	Apr 2, 2024
Grant date	Apr 2, 2024

Abstract

Polycrystalline diamond may include a working surface and a peripheral surface extending around an outer periphery of the working surface. The polycrystalline diamond includes a first volume including an interstitial material and a second volume having a leached region that includes boron and titanium. A method of fabricating a polycrystalline diamond element may include positioning a first volume of diamond particles adjacent to a substrate, the first volume of diamond particles including a material that includes a group 13 element, and positioning a second volume of diamond particles adjacent to the first volume of diamond particles such that the first volume of diamond particles is disposed between the second volume of diamond particles and the substrate, the second volume of diamond particles having a lower concentration of material including the group 13 element than the first volume of diamond particles.

First claim

What is claimed is:

1. A method of fabricating a polycrystalline diamond element, the method comprising:
positioning a first volume of diamond particles adjacent to a substrate, the first volume of diamond particles including a material comprising a group 13 element;
positioning a second volume of diamond particles adjacent to the first volume of diamond particles such that the first volume of diamond particles is disposed between the second volume of diamond particles and the substrate, the second volume of diamond particles having a lower concentration of the material comprising the group 13 element than the first volume of diamond particles;
enclosing the substrate, the first volume of diamond particles, and the second volume of diamond particles in a pressure transmitting medium to form a cell assembly; and
subjecting the cell assembly to a high-pressure/high-temperature process to form a polycrystalline diamond table coupled to the substrate.

2. The method of claim 1 , further comprising selecting the second volume of diamond particles to be substantially free of the group 13 element.

3. The method of claim 1 , further comprising selecting the group 13 element to comprise at least one of boron, aluminum, gallium, indium, or thallium.

4. The method of claim 1 , further comprising selecting the first volume of diamond particles to include a compound comprising the group 13 element at a concentration of approximately 10% or less by weight.

5. The method of claim 1 , further comprising exposing at least a portion of the polycrystalline diamond table to a leaching agent.

6. The method of claim 5 , further comprising leaching at least a sintered portion of the second volume of diamond particles.

7. The method of claim 1 , further comprising defining a working surface of the polycrystalline diamond element with the second volume of diamond particles.

8. The method of claim 1 , further comprising defining a generally arcuate boundary between at least a portion of the first volume of diamond particles and the second volume of diamond particles.

9. The method of claim 1 , further comprising positioning a third volume of diamond particles substantially free of the group 13 element between at least a portion of the first volume of diamond particles and the second volume of diamond particles.

10. A method of fabricating a polycrystalline diamond element, the method comprising:
placing diamond particles in a diamond particulate volume into a pressure transmitting medium, the diamond particulate volume comprising:
a first volume of the diamond particles including a material comprising a group 13 element; and
a second volume of the diamond particles having a lower concentration of the material comprising the group 13 element than the first volume of the diamond particles;

positioning the second volume of the diamond particles to define at least a portion of a working surface of the polycrystalline diamond element;
enclosing the diamond particles in the diamond particulate volume in the pressure transmitting medium to define a cell assembly;
subjecting the cell assembly to a high-pressure/high-temperature process to define a polycrystalline diamond table; and
leaching at least a portion of the polycrystalline diamond table.

11. The method of claim 10 , wherein leaching the at least a portion of the polycrystalline diamond table comprises leaching at least a sintered portion the second volume of the diamond particles.

12. The method of claim 10 , further comprising defining a non-linear boundary between the first volume of diamond particles and the second volume of diamond particles.

13. The method of claim 10 , further comprising positioning the diamond particles in the diamond particulate volume in the pressure transmitting medium adjacent to a substrate.

14. A method of fabricating a polycrystalline diamond element, the method comprising:
placing diamond particles in diamond particulate volume into a pressure transmitting medium, the diamond particulate volume comprising:
a first volume of the diamond particles including a material comprising a group 13 element; and
a second volume of the diamond particles having a lower concentration of the material comprising the group 13 element than the first volume of the diamond particles;

positioning the diamond particles in the diamond particulate volume in the pressure transmitting medium adjacent to a substrate;
positioning the first volume of the diamond particles between the second volume of diamond particles and the substrate;
enclosing the diamond particles in the diamond particulate volume in the pressure transmitting medium to define a cell assembly;
subjecting the cell assembly to a high-pressure/high-temperature process to define a polycrystalline diamond table; and
leaching at least a portion of the polycrystalline diamond table.

15. The method of claim 10 , further comprising defining an arcuate boundary between volumes of the diamond particulate volume.

16. The method of claim 15 , further comprising defining the arcuate boundary between a leached portion of the polycrystalline diamond table and a substantially unleached portion of the polycrystalline diamond table.

17. The method of claim 16 , further comprising defining the arcuate boundary within the sintered second volume of diamond particles.

18. A method of fabricating a polycrystalline diamond element, the method comprising:
placing a diamond particulate volume into a pressure transmitting medium, the diamond particulate volume comprising:
a first volume of diamond particles including an interstitial material; and
a second volume of diamond particles having a lower concentration of the interstitial material than the first volume of diamond particles, the second volume of the diamond particles positioned to define at least a portion of a working surface of the polycrystalline diamond element;

enclosing the first volume of diamond particles and the second volume of diamond particles in the pressure transmitting medium to define a cell assembly;
subjecting the cell assembly to a high-pressure/high-temperature process to define a polycrystalline diamond table;
leaching at least a portion of the polycrystalline diamond table to define a leached portion of the polycrystalline diamond table and a substantially unleached portion of the polycrystalline diamond table; and
defining a non-linear boundary between at least one of:
the leached portion and the substantially unleached portion of the polycrystalline diamond table;
the first volume of diamond particles and the second volume of diamond particles of the diamond particulate volume.

19. The method of claim 18 , further comprising selecting the interstitial material to comprise a group 13 element.

20. The method of claim 19 , further comprising defining an arcuate boundary between the first volume of the diamond particles and the second volume of the diamond particles.

Assignees

• Us Synthetic Corp

Inventors

• Heaton Daren Nathaniel
• Lynn Jeremy Brett

Classifications

• E21B10/55 Primary

  with preformed cutting elements · CPC title

• B24D3/10

  for porous or cellular structure, e.g. for use with diamonds as abrasives · CPC title

• B24D3/348

  utilised as impregnating agent for porous abrasive bodies · CPC title

• B32B18/00

  Layered products essentially comprising ceramics, e.g. refractory products · CPC title

• C04B35/528

  obtained from carbonaceous particles with or without other non-organic components · CPC title