Superabrasive elements and methods for processing and manufacturing the same using protective layers

Patent metadata

Field	Value
Publication number	US-2016016290-A1
Application number	US-201514864649-A
Country	US
Kind code	A1
Filing date	Sep 24, 2015
Priority date	Sep 8, 2009
Publication date	Jan 21, 2016
Grant date	—

Abstract

A method of processing a polycrystalline diamond element includes forming a protective layer over a selected portion of a polycrystalline diamond element, the polycrystalline diamond element having a polycrystalline diamond table that includes a superabrasive face, a superabrasive side surface, and a chamfer extending between the superabrasive face and the superabrasive side surface. A portion of the superabrasive side surface is covered by the protective layer and the protective layer is not formed over the chamfer. The method includes exposing at least a portion of the polycrystalline diamond element to a leaching solution. A polycrystalline diamond element has a polycrystalline diamond table that includes a leached volume extending from the superabrasive face to a portion of the chamfer proximate to the superabrasive side surface, and the leached volume does not substantially extend along the superabrasive side surface.

First claim

What is claimed is:

1 . A method of processing a polycrystalline diamond element, the method comprising:
forming a protective layer over a selected portion of a polycrystalline diamond element, the polycrystalline diamond element comprising a polycrystalline diamond table comprising:
a superabrasive face;
a superabrasive side surface;
a chamfer extending between the superabrasive face and the superabrasive side surface;
exposing at least a portion of the polycrystalline diamond element 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; wherein:
a portion of the superabrasive side surface is covered by the protective layer;
the protective layer is not formed over the chamfer.

2 . The method of claim 1 , wherein:
the polycrystalline diamond element further comprises a substrate bonded to the polycrystalline diamond table; at least a portion of a surface of the substrate is covered by the protective layer.

3 . The method of claim 1 , wherein the protective layer comprises a substantially inert material.

4 . The method of claim 1 , wherein the protective layer is substantially impermeable to the leaching solution.

5 . The method of claim 1 , wherein forming the protective layer over the selected portion of the polycrystalline diamond element comprises exposing the protective layer to an elevated temperature of about 50° C. or higher and an elevated pressure of about 1000 psi or higher.

6 . The method of claim 1 , wherein an intercalated hybrid layer is formed at an interface between the protective layer and the polycrystalline diamond element.

7 . The method of claim 1 , wherein the protective layer comprises a metallic material.

8 . The method of claim 7 , wherein the metallic material comprises at least one of:
a refractory metal; a precious metal; a steel alloy; a steel derivative alloy.

9 . The method of claim 1 , wherein the protective layer comprises a thermoplastic material.

10 . The method of claim 1 , wherein the protective layer comprises a glass sealant.

11 . The method of claim 1 , wherein the protective layer comprises graphite.

12 . The method of claim 1 , wherein:
the protective layer comprises a thermosetting material; forming the protective layer over the selected portion of the polycrystalline diamond element comprises curing the thermosetting material.

13 . The method of claim 1 , further comprising, prior to exposing at least a portion of the polycrystalline diamond element to the leaching solution:
forming the protective layer over the selected portion of the polycrystalline diamond element; partially removing the protective layer from the selected portion of the polycrystalline diamond element.

14 . The method of claim 1 , further comprising forming an outer layer on at least a portion of an outer surface of the protective layer.

15 . The method of claim 1 , wherein a portion of the superabrasive side surface proximate to the chamfer is covered by the protective layer.

16 . A polycrystalline diamond element, comprising:
a polycrystalline diamond table comprising:
a superabrasive face;
a superabrasive side surface extending around an outer periphery of the superabrasive face;
a chamfer extending between the superabrasive face and the superabrasive side surface;
wherein:
the polycrystalline diamond table comprises a leached volume extending from the superabrasive face to a portion of the chamfer proximate to the superabrasive side surface;
the leached volume does not substantially extend along the superabrasive side surface.

17 . The polycrystalline diamond element of claim 16 , further comprising a substrate bonded to the polycrystalline diamond table.

18 . The polycrystalline diamond element of claim 16 , wherein the polycrystalline diamond table further comprises a transition region between the leached volume and an unleached volume of the polycrystalline diamond table.

19 . The polycrystalline diamond element of claim 18 , wherein the transition region extends to an intersection between the chamfer and the superabrasive side surface.

Assignees

• Miess David P
• Dadson Andrew E
• Us Synthetic Corp

Inventors

• Miess David P
• Dadson Andrew E

Classifications

• B24D3/005 Primary

  the constituent being used during pre- or after-treatment (B24D3/348 takes precedence) · CPC title

• B24D99/005

  Segments of abrasive wheels · CPC title

• B24D18/0054

  by impressing abrasive powder in a matrix · CPC title

• B24D18/0009

  using moulds or presses · CPC title

• F16C17/04

  for axial load only · CPC title