Methods of cleaning a polycrystalline diamond body and methods of forming polycrystalline diamond compacts

Patent metadata

Field	Value
Publication number	US-9352450-B1
Application number	US-201414166443-A
Country	US
Kind code	B1
Filing date	Jan 28, 2014
Priority date	Jan 28, 2014
Publication date	May 31, 2016
Grant date	May 31, 2016

Abstract

Embodiments of the invention relate to methods of cleaning a leaching agent and/or leaching agent by-products from an at least partially leached polycrystalline diamond body, and methods of making a polycrystalline diamond compact using the same.

First claim

The invention claimed is:

1. A method of cleaning an at least partially leached polycrystalline diamond body, the method comprising:
positioning the at least partially leached polycrystalline diamond body within a pressure vessel such that at least one surface of the at least partially leached polycrystalline diamond body is exposed to an environment inside of the pressure vessel and at least one surface is exposed to an environment outside of the pressure vessel;
at least partially filling the pressure vessel with a removal agent;
elevating a pressure of the removal agent in the pressure vessel relative to an ambient atmospheric pressure of the environment outside of the pressure vessel; and
exposing the at least partially leached polycrystalline diamond body to the removal agent in the pressure vessel.

2. The method of claim 1 , wherein exposing the at least partially leached polycrystalline diamond body to the removal agent in the pressure vessel includes diffusing the removal agent through the at least partially leached polycrystalline diamond body to the environment outside of the pressure vessel.

3. The method of claim 1 , wherein positioning the at least partially leached polycrystalline diamond body within a pressure vessel includes forming an interior volume within the pressure vessel between at least one sidewall, a back wall, and a surface of the polycrystalline diamond body.

4. The method of claim 3 , wherein the interior volume includes the removal agent therein.

5. The method of claim 1 , wherein elevating a pressure of a removal agent in the pressure vessel includes heating the removal agent to create an increased vapor pressure.

6. The method of claim 5 , wherein heating the removal agent includes operating a heating element located within the pressure vessel.

7. The method of claim 5 , wherein heating the removal agent includes operating a heating system positioned outside of the pressure vessel including one or more of an oven, kiln, heating element, induction heating system, microwave system, or a salt bath.

8. The method of claim 1 , wherein elevating a pressure of a removal agent in the pressure vessel includes using a pump.

9. The method of claim 1 , wherein the removal agent includes one or more of an aqueous component, a supercritical component, a chelating component, inorganic component, or an organic component.

10. The method of claim 9 , wherein the aqueous component includes at least one of sodium hydroxide, potassium hydroxide, lithium hydroxide, hydrochloric acid, nitric acid, hydrofluoric acid, sulfuric acid, or aqua regia.

11. The method of claim 9 , wherein the supercritical component includes one or more of water or carbon dioxide.

12. The method of claim 9 , wherein the chelating component includes one or more of sodium bis-(2-ethylhexyl)sulfosuccinate, a fluorinated sodium bis-(2-ethylhexyl)sulfosuccinate, or a perfluoropolyether phosphate.

13. The method of claim 9 , wherein the organic component includes at least one chemical selected from the group consisting of methane, ethane, propane, ethylene, propylene, methanol, ethanol, acetone, pentane, butane, sulfur hexafluoride, xenon dichlorodifluoromethane, trifluoromethane, isopropanol, nitrous oxide, ammonia, methylamine, and diethyl ether.

14. A method of cleaning an at least partially leached polycrystalline diamond body, the method comprising:
positioning the at least partially leached polycrystalline diamond body within a pressure vessel such that at least one surface of the at least partially leached polycrystalline diamond body is exposed to an environment inside of the pressure vessel and at least one is surface exposed to an environment outside of the pressure vessel;
at least partially filling the pressure vessel with a removal agent including at least one of a supercritical component, an aqueous component, a chelating component, or an organic component;
elevating a pressure and a temperature of the removal agent in the pressure vessel relative to an ambient atmospheric pressure and temperature of the environment outside of the pressure vessel to induce a supercritical state in at least one component of the removal agent; and
exposing the at least partially leached polycrystalline diamond body to the removal agent.

15. The method of claim 14 wherein exposing the at least partially leached polycrystalline diamond body to the removal agent includes diffusing the removal agent through the at least partially leached polycrystalline diamond body.

16. The method of claim 14 , wherein the supercritical component includes one or more of water or carbon dioxide.

17. The method of claim 16 , wherein the pressure within the pressure vessel is more than about 7.3 MPa and the temperature within the pressure vessel is more than about 31° C.

18. The method of claim 16 , wherein the pressure within the pressure vessel is more than about 22.1 MPa and the temperature within the pressure vessel is more than about 374° C.

19. The method of claim 15 , wherein the aqueous component includes one or more of sodium hydroxide, potassium hydroxide, lithium hydroxide, hydrochloric acid, nitric acid, hydrofluoric acid, sulfuric acid, phosphoric acid, potassium permanganate, or aqua regia.

20. The method of claim 15 , wherein the organic component includes one or more of methane, ethane, propane, ethylene, propylene, methanol, ethanol, acetone, pentane, butane, sulfur hexafluoride, xenon dichlorodifluoromethane, trifluoromethane, isopropanol, nitrous oxide, ammonia, methylamine, or diethyl ether.

Assignees

• Us Synthetic Corp

Inventors

• Vail Michael A
• Jones Paul D

Classifications

• B24D3/10

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

• B24D18/0027 Primary

  by impregnation · CPC title

• B08B3/08

  the liquid having chemical or dissolving effect · CPC title

• B08B7/0021

  by liquid gases or supercritical fluids · CPC title