Thermally stable diamond polycrystalline diamond constructions

Patent metadata

Field	Value
Publication number	US-9931732-B2
Application number	US-82051810-A
Country	US
Kind code	B2
Filing date	Jun 22, 2010
Priority date	Sep 21, 2004
Publication date	Apr 3, 2018
Grant date	Apr 3, 2018

Abstract

Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals, a plurality of interstitial regions disposed among the crystals, and a substrate attached to the body. The body includes a working surface and a side surface extending away from the working surface to the substrate. The body comprises a first region adjacent the side surface that is substantially free of a catalyst material and that extends a partial depth into the diamond body. The first region can further extend to at least a portion of the working surface and a partial depth therefrom into the diamond body. The diamond body can be formed from natural diamond grains and/or a mixture of natural and synthetic diamond grains. A surface of the diamond body is treated to provide the first region, and before treatment is finished to an approximate final dimension.

First claim

What is claimed is:

1. A thermally stable diamond construction comprising:
a substrate; and
a diamond body attached to the substrate and comprising a plurality of bonded diamond crystals and a plurality of interstitial regions disposed among the bonded diamond crystals,
the diamond body including a working surface and a side surface extending away from the working surface, and
the diamond body comprising:
a first region of the diamond body being substantially free of a Group VIII metal, wherein first region extends a partial depth into the diamond body along a partial length of the side surface, wherein the partial depth decreases as a function of distance from the working surface and is at least 0.1 mm for a length of at least 25 percent of the total length of the side surface as measured from the working surface; and
a second region adjacent the first region, the second region comprising the Group VIII metal.

2. The thermally stable diamond construction of 1 , wherein the working surface comprises a top surface and a beveled surface, the beveled surface interposed between the top and side surfaces.

3. The thermally stable diamond construction of claim 2 , wherein the partial depth decreases as a function of distance from the beveled surface and is at least 0.1 mm for a length of at least 25 percent of the total length of the side surface as measured from the beveled surface.

4. The thermally stable diamond construction of claim 2 , wherein the partial depth decreases as a function of distance from the beveled surface and is at least 0.1 mm. for a length of at least 40 percent of the total length of the side surface as measured from the beveled surface.

5. The thermally stable diamond construction of claim 1 , wherein the partial depth from the side surface is up to about 1 mm at some portion of the side surface.

6. The thermally stable diamond construction of claim 1 , wherein the partial depth from the side surface is up to about 0.5 mm at some portion of the side surface.

7. The thermally stable diamond construction of claim 1 , wherein the partial depth from the side surface is up to about 0.3 mm at some portion of the side surface.

8. The thermally stable diamond construction of claim 1 , wherein the partial depth from the side surface is at least about 0.15 mm at some portion of the side surface.

9. The thermally stable diamond construction of claim 1 , wherein the partial depth from the side surface is at least 0.02 mm from the side surface at some portion of the side surface.

10. The thermally stable diamond construction of claim 1 , wherein the interstitial regions in the first region are substantially empty.

11. The thermally stable diamond construction of claim 1 , wherein the Group VIII material was used to initially sinter the diamond body.

12. The thermally stable diamond construction of claim 1 , wherein the source of the Group VIII material is the substrate.

13. The thermally stable diamond construction of claim 1 , wherein the partial depth is sufficient to increase the thermal conductivity of the diamond body.

14. The thermally stable diamond construction of claim 1 , wherein the partial length is sufficient to increase the thermal conductivity of the diamond body.

15. A thermally stable diamond construction comprising:
a substrate; and
a diamond body attached to the substrate and comprising a plurality of bonded diamond crystals and a plurality of interstitial regions disposed among the bonded diamond crystals,
the diamond body including a top surface, a side surface extending away from the top surface, and a beveled surface interposed between the top and sides surfaces and
the diamond body comprising:
a first region of the diamond body being substantially free of a Group VIII metal, wherein first region extends a partial depth into the diamond body from the top surface substantially parallel to the top surface for at least a portion of the top surface, a partial depth from the beveled edge surface, and a partial depth from the side surface along a partial length of the side surface,
wherein the first region extends into the diamond body from the side surface a depth of at least about 0.1 mm for at least a portion of the partial length; and.
a second region adjacent the first region, the second region comprising the Group VIII metal.

16. The thermally stable diamond construction of claim 15 , wherein the first region extends a partial depth into the diamond body from the side surface substantially parallel with the side surface along a portion of the side surface.

17. The thermally stable diamond construction of claim 15 , wherein the first region extends a partial depth into the diamond body from the side surface substantially parallel with the beveled surface.

18. The thermally stable diamond construction of claim 15 , wherein the first region extends along the side surface a length from the beveled surface towards the metallic substrate of about 25 to less than 100 percent of the side surface length as measured from the beveled surface.

19. The thermally stable diamond construction of claim 18 , wherein the first region extends along the side surface a length from the beveled surface towards the metallic substrate of at least 40 percent of the side surface length as measured from the beveled surface.

20. The thermally stable diamond construction of claim 15 , wherein the first region is substantially uniform around a circumference of the diamond body.

21. The thermally stable diamond construction of claim 15 , wherein the first region extends from the side surface a depth within the diamond body that changes along the length of the diamond body side surface.

22. The thermally stable diamond construction of claim 21 , wherein the partial depth decreases as a function of distance from the beveled surface.

23. The thermally stable diamond construction of claim 21 , wherein the depth changes as a gradient.

24. The thermally stable diamond construction of claim 21 , wherein the depth changes in a step-wise manner.

25. The thermally stable diamond construction of claim 21 , wherein the partial depth from the side surface is at least 0.02 mm from the side surface at some portion of the side surface.

26. The thermally stable diamond construction of claim 15 , wherein the partial depth from the side surface is up to about 1 mm at some portion of the side surface.

27. The thermally stable diamond construction of claim 15 , wherein the partial depth from the side surface is up to about 0.5 mm at some portion of the side surface.

28. The thermally stable diamond construction of claim 15 , wherein the partial depth from the side surface is up to about 0.3 mm at some portion of the side surface.

29. The thermally stable diamond construction of claim 15 , wherein the partial depth from the side surface is at least about 0.15 mm at some portion of the side surface.

30. The thermally stable diamond construction of claim 15 , wherein the interstitial regions in the first region are substantially empty.

31. The thermally stable diamond construction of claim 15 , wherein the Group VIII material was used to initially sinter the diamond body.

32. The thermally stable diamond construction of claim 15 , wherein the source of the Group VIII material is the substrate.

Assignees

• Eyre Ronald K
• Smith International

Inventors

• Eyre Ronald K

Classifications

• B22F2207/03

  of the metallic binder phase in cermets · CPC title

• Y10T428/31678

  Of metal · CPC title

• C22C26/00

  Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} · CPC title

• B22F2998/00

  Supplementary information concerning processes or compositions relating to powder metallurgy · CPC title

• Y10T407/27

  comprising tool of specific chemical composition · CPC title