Cutting element assembly including one or more superabrasive cutting elements and drill bit utilizing the same

Patent metadata

Field	Value
Publication number	US-9404308-B1
Application number	US-201414196773-A
Country	US
Kind code	B1
Filing date	Mar 4, 2014
Priority date	Apr 20, 2010
Publication date	Aug 2, 2016
Grant date	Aug 2, 2016

Abstract

Some embodiments relate to cutting element assemblies including a superabrasive cutting element that may be axially compressed to enhance the damage tolerance thereof, enclosed in an enclosure that exposes the superabrasive cutting element therethrough, enclosed in an enclosure that restricts rotation of the superabrasive cutting element, or combinations of the foregoing. Additionally, some embodiments relate to cutting element assemblies in which a superabrasive cutting element is mechanically fastened to a base, such as a substrate or directly to a bit body of a rotary drill bit. Some embodiments also relate to cutting element assemblies including one or more superabrasive cutting elements that are rotatable about a longitudinal axis of the cutting element assembly, that may be axially compressed to enhance the damage tolerance thereof, that may be enclosed in an enclosure that exposes the superabrasive cutting element therethrough, or combinations thereof.

First claim

What is claimed is:

1. A cutting element assembly, comprising:
an enclosure including a recess partially defined by an interior surface, and at least one cutting opening;
a base disposed in the recess;
at least one superabrasive cutting element disposed in the recess between the interior surface of the enclosure and the base, the at least one superabrasive cutting element exposed through the at least one cutting opening; and
a bearing element disposed between the at least one superabrasive cutting element and a portion of the interior surface of the enclosure.

2. The cutting element assembly of claim 1 wherein the at least one superabrasive cutting element is axially compressed between the base and the bearing element at a compressive stress of about 20 percent to about 90 percent of a compressive fracture strength of the at least one superabrasive cutting element as measured in a bend test.

3. The cutting element assembly of claim 2 wherein the compressive stress is about 30 percent to about 75 percent of the compressive fracture strength of the at least one superabrasive cutting element as measured in the bend test.

4. The cutting element assembly of claim 2 wherein the compressive stress is about 35 percent to about 50 percent of the compressive fracture strength of the at least one superabrasive cutting element as measured in the bend test.

5. The cutting element assembly of claim 1 wherein the enclosure is connected to the base by at least one of threads, a press fit, a snap fit, welding, brazing, or gluing.

6. The cutting element assembly of claim 1 wherein the enclosure includes at least one connecting member, and wherein the base includes at least one connecting channel that receives the at least one connecting member.

7. The cutting element assembly of claim 1 wherein at least one cutting opening includes a plurality of cutting openings exposing a portion of the at least one superabrasive cutting element therethrough.

8. The cutting element assembly of claim 1 wherein the bearing element is compressible.

9. The cutting element assembly of claim 1 wherein the bearing element is generally ring shaped.

10. The cutting element assembly of claim 1 wherein the bearing element has a footprint similar to that of the at least one superabrasive cutting element.

11. The cutting element assembly of claim 1 wherein the bearing element includes a metal or an alloy.

12. The cutting element assembly of claim 1 wherein the bearing element induces compressive stresses at or near an edge of the at least one superabrasive cutting element to enhance the damage tolerance thereof.

13. The cutting element assembly of claim 1 , further comprising at least one additional bearing element disposed between the at least one superabrasive cutting element and the base.

14. The cutting element assembly of claim 13 wherein the bearing element is compressible.

15. The cutting element assembly of claim 13 wherein the bearing element is generally ring shaped.

16. The cutting element assembly of claim 13 wherein the bearing element includes a metal or an alloy.

17. The cutting element assembly of claim 1 wherein the superabrasive cutting element includes polycrystalline diamond.

18. The cutting element assembly of claim 17 wherein the polycrystalline diamond is at least partially leached of catalyst.

19. A cutting element assembly, comprising:
an enclosure including a recess partially defined by an interior surface, at least one cutting opening, and a longitudinal axis;
a base disposed in the recess; and
at least one polycrystalline diamond cutting element disposed in the recess between the interior surface of the enclosure and the base, the at least one polycrystalline diamond cutting element exposed through the at least one cutting opening; and
a bearing element disposed between the at least one polycrystalline diamond cutting element and a portion of the interior surface of the enclosure;
wherein the at least one polycrystalline diamond cutting element is axially compressed between the base and the bearing element, and rotation of the at least one polycrystalline diamond cutting element about the longitudinal axis is restricted.

20. The cutting element assembly of claim 19 wherein the compressive stress is about 30 percent to about 75 percent of the compressive fracture strength of the at least one polycrystalline diamond cutting element as measured in the bend test.

21. The cutting element assembly of claim 20 wherein the compressive stress is about 35 percent to about 50 percent of the compressive fracture strength of the at least one polycrystalline diamond cutting element as measured in the bend test.

22. The cutting element assembly of claim 19 wherein the bearing element exhibits a uniform thickness and/or cross-section.

23. The cutting element assembly of claim 19 wherein the bearing element exhibits a non-uniform thickness and/or cross-section.

24. The cutting element assembly of claim 19 wherein the bearing element includes a metal or an alloy.

25. A rotary drill bit, comprising:
a bit body configured to engage a subterranean formation; and
a plurality of superabrasive cutting elements mounted to the bit body, at least one of the plurality of superabrasive cutting elements including:
an enclosure including a recess partially defined by an interior surface, and at least one cutting opening;
a base disposed in the recess;
at least one superabrasive cutting element disposed in the recess between the interior surface of the enclosure and the base, the at least one superabrasive cutting element exposed through the at least one cutting opening; and
a bearing element disposed between the at least one superabrasive cutting element and a portion of the interior surface of the enclosure.

Assignees

• Us Synthetic Corp

Inventors

• Qian Jiang
• Mukhopadhyay Debkumar
• Wiggins Jason
• Bertagnolli Kenneth E
• Scott Shawn C
• Nguyen Kevin Duy
• Vail Michael A

Classifications

• E21B10/62

  characterised by parts, e.g. cutting elements, which are detachable or adjustable (E21B10/64 takes precedence; for roller bits E21B10/20; for augers E21B10/44) · CPC title

• E21B10/567 Primary

  with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts · CPC title

• E21B10/52

  with chisel- or button-type inserts · CPC title

• E21B10/56 Primary

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

• E21B10/633

  independently detachable · CPC title