Polycrystalline diamond compact (PDC) cutting element having multiple catalytic elements

Patent metadata

Field	Value
Publication number	US-9719307-B1
Application number	US-201414507638-A
Country	US
Kind code	B1
Filing date	Oct 6, 2014
Priority date	Aug 24, 2005
Publication date	Aug 1, 2017
Grant date	Aug 1, 2017

Abstract

A polycrystalline diamond compact useful for wear, cutting, drilling, drawing and like applications is provided with a first diamond region remote from the working surface which has a metallic catalyzing material and a second diamond region adjacent to or including the working surface containing a non-metallic catalyst and the method of making such a compact is provided. This compact is particularly useful in high temperature operations, such as hard rock drilling because of the improved thermal stability at the working surface.

First claim

What is claimed is:

1. A polycrystalline diamond compact, comprising:
a volume of polycrystalline diamond material having a plurality of interstitial spaces, wherein a material comprising cobalt is disposed in at least some interstitial spaces and wherein a material comprising phosphorous is disposed in at least some other interstitial spaces.

2. The polycrystalline diamond compact of claim 1 , wherein the volume of polycrystalline diamond material includes a top surface and a side surface, and wherein the material comprising phosphorous is disposed in at least some interstitial spaces adjacent the top surface.

3. The polycrystalline diamond compact of claim 2 , further comprising a substrate, wherein the volume of polycrystalline diamond material is attached to the substrate.

4. The polycrystalline diamond compact of claim 3 , wherein the substrate comprises tungsten carbide.

5. The polycrystalline diamond compact of claim 4 , wherein the material comprising phosphorous is also disposed in at least some interstitial spaces adjacent the side surface.

6. The polycrystalline diamond compact of claim 5 ,
wherein the volume of polycrystalline diamond material is beveled.

7. The polycrystalline diamond compact of claim 2 , wherein the material comprising phosphorous is disposed in substantially all of the interstices adjacent the top surface.

8. The polycrystalline diamond compact of claim 2 , wherein the material comprising phosphorous is also disposed in at least some interstitial spaces adjacent the side surface.

9. A drill bit, comprising:
a shank; and
a bit body attached to the shank;
at least one polycrystalline diamond compact attached to the body, wherein the at least one polycrystalline body comprises:
a substrate; and
a volume of polycrystalline diamond material having a plurality of interstitial spaces, wherein a material comprising cobalt is disposed in at least some interstitial spaces and wherein a material comprising phosphorous is disposed in at least some other interstitial spaces.

10. The drill bit of claim 9 , wherein the volume of polycrystalline diamond material includes a top surface and a side surface, and wherein the material comprising phosphorous is disposed in at least some interstitial spaces adjacent the top surface.

11. The drill bit of claim 10 , further comprising a substrate,
wherein the volume of polycrystalline diamond material is attached to the substrate.

12. The drill bit of claim 11 , wherein the substrate comprises tungsten carbide.

13. The drill bit of claim 10 , wherein the material comprising phosphorous is disposed in substantially all of the interstices adjacent the top surface.

14. The drill bit of claim 10 , wherein the material comprising phosphorous is also disposed in at least some interstitial spaces adjacent the side surface.

15. The drill bit of claim 14 , wherein the volume of polycrystalline diamond material is beveled.

Assignees

• Us Synthetic Corp
• Us Synthetic Corp

Inventors

• Bertagnolli Kenneth E
• Vail Michael A

Classifications

• C04B35/645

  Pressure sintering · CPC title

• C04B35/6303

  Inorganic additives · CPC title

• B24D3/10

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

• E21B10/55

  with preformed cutting elements · CPC title

• E21B10/567 Primary

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