Cutting elements having non-planar surfaces and downhole cutting tools using such cutting elements

Patent metadata

Field	Value
Publication number	US-2019264511-A1
Application number	US-201916410135-A
Country	US
Kind code	A1
Filing date	May 13, 2019
Priority date	Mar 11, 2014
Publication date	Aug 29, 2019
Grant date	—

Abstract

A cutting element may include a substrate, an upper surface of the substrate including a crest, the crest transitioning into a depressed region, and an ultrahard layer on the upper surface, thereby forming a non-planar interface between the ultrahard layer and the substrate. A top surface of the ultrahard layer includes a cutting crest extending along at least a portion of a diameter of the cutting element, the top surface having a portion extending laterally away from the cutting crest having a lesser height than a peak of the cutting crest.

First claim

What is claimed is:

1 . A cutting element comprising:
a substrate; and an ultrahard layer on an upper surface of the substrate, a top surface of the ultrahard layer comprising:
a plurality of cutting crests extending from a peripheral edge of top surface radially inward to a central flat region, the top surface having a portion extending laterally away from at least one of the plurality of cutting crests into a recessed region having a lesser height than a peak of the cutting crest,
wherein the central flat region has a convex transition into the recessed regions.

2 . The cutting element of claim 1 , wherein the central flat region extends along from ⅛ to ⅔ of the diameter of the cutting element.

3 . The cutting element of claim 1 , wherein the cutting crest extends along a major dimension of the cutting crest to the peripheral edge of the top surface and wherein the portion of the top surface extending laterally away from the cutting crest to the peripheral edge of the top surface is, adjacent to the peripheral edge, non-perpendicular to a longitudinal axis of the cutting element.

4 . The cutting element of claim 1 , wherein the top surface has a peripheral edge extending around the cutting element and a cutting edge portion of the peripheral edge is adjacent the cutting crest, and wherein the peripheral edge decreases in height in a direction away from the cutting crest and the cutting edge portion to another portion of the peripheral edge adjacent to the recessed region of the ultrahard layer.

5 . The cutting element of claim 1 , wherein at least a portion of the cutting crest has a radius of curvature ranging from 0.06 to 0.18 inches.

6 . The cutting element of claim 5 , wherein the radius of curvature of the cutting crest tangentially transitions into the portion extending laterally therefrom.

7 . The cutting element of claim 1 , wherein an included angle formed between the portions extending laterally from the cutting crest ranges from 90 to 160 degrees.

8 . The cutting element of claim 7 , wherein the included angle ranges from 110 to 160 degrees.

9 . A cutting element, comprising:
a substrate; and an ultrahard layer on an upper surface of the substrate, a top surface of the ultrahard layer comprising:
a plurality of cutting crests extending from a peripheral edge of top surface radially inward to a central region, the top surface having a portion extending laterally away from the cutting crest into a recessed region having a lesser height than a peak of the cutting crest,
wherein the central region is curved or has a different height than the peripheral edge of the top surface adjacent the cutting crest.

10 . The cutting element of claim 9 , wherein the central region extends along from ⅛ to ⅔ of the diameter of the cutting element.

11 . The cutting element of claim 9 , wherein the cutting crest extends along a major dimension of the cutting crest to the peripheral edge of the top surface and wherein the portion of the top surface extending laterally away from the cutting crest to the peripheral edge of the top surface is, adjacent to the peripheral edge, non-perpendicular to a longitudinal axis of the cutting element.

12 . The cutting element of claim 9 , wherein the top surface has a peripheral edge extending around the cutting element and a cutting edge portion of the peripheral edge is adjacent the cutting crest, and wherein the peripheral edge decreases in height in a direction away from the cutting crest and the cutting edge portion to another portion of the peripheral edge adjacent to the recessed region of the ultrahard layer.

13 . The cutting element of claim 9 wherein at least a portion of the cutting crest has a radius of curvature ranging from 0.06 to 0.18 inches.

14 . The cutting element of claim 13 , wherein the radius of curvature of the cutting crest tangentially transitions into the portion extending laterally therefrom.

15 . The cutting element of claim 13 , wherein an included angle formed between the portions extending laterally from the cutting crest ranges from 90 to 160 degrees.

16 . The cutting element of claim 15 , wherein the included angle ranges from 110 to 160 degrees.

17 . A cutting element, comprising:
a substrate; and an ultrahard layer on an upper surface of the substrate, a top surface of the ultrahard layer comprising:
a plurality of cutting crests extending from a peripheral edge of top surface radially inward to a central region, the top surface having a portion extending laterally away from the cutting crest into a recessed region having a lesser height than a peak of the cutting crest,
wherein an included angle formed between the portions extending laterally from the cutting crest ranges from 90 to 160 degrees.

18 . The cutting element of claim 17 , wherein the included angle ranges from 110 to 160 degrees.

19 . The cutting element of claim 17 , wherein at least a portion of the cutting crest has a radius of curvature ranging from 0.06 to 0.18 inches.

20 . The cutting element of claim 19 , wherein the radius of curvature of the cutting crest tangentially transitions into the portion extending laterally therefrom.

21 . A cutting element, comprising:
a substrate; and an ultrahard layer on an upper surface of the substrate, a top surface of the ultrahard layer comprising:
a plurality of cutting crests extending from a peripheral edge of top surface radially inward to a central region, the top surface having a portion extending laterally away from the cutting crest into a recessed region having a lesser height than a peak of the cutting crest,
wherein at least one cutting crest has an uneven height along its length.

22 . The cutting element of claim 21 , wherein the at least one cutting crest has a height differential of less than 50% of a peak height of the cutting crest.

Assignees

• Smith International

Inventors

• Chen Chen
• Song Huimin
• Zhao Liang
• Zhang Youhe
• Azar Michael G
• Gan Xiaoge
• Keshavan Madapusi K
• Lin Zhijun
• Durairajan Bala
• Stewart Michael L

Classifications

• E21B10/5735

  Interface between the substrate and the cutting element · CPC title

• E21B10/56

  Button-type inserts (E21B10/52 takes precedence) · CPC title

• E21B10/5673 Primary

  having a non planar or non circular cutting face · CPC title

• E21B2010/565

  Fixed Constructions · mapped topic