Claims
- 1. A PCD element comprising a body with a working surface, wherein a first volume of the body remote from the working surface contains a catalyzing material, a second volume of the body adjacent to the working surface is substantially free of the catalyzing material.
- 2. The PCD element of claim 1, wherein the second volume extends to a depth of at least about 0.1 mm from the working surface.
- 3. The PCD element of claim 2, wherein the second volume extends to a depth of between about 0.2 mm and 0.3 mm from the working surface.
- 4. The PCD element of claim 1, wherein the second volume of the body has a diamond density higher than elsewhere in the body.
- 5. The PCD element of claim 1, wherein a majority of the catalyzing material remaining in the second volume of the body adheres to surfaces of diamond crystals.
- 6. The PCD element of claim 1, wherein an amount of catalyzing material within the second volume of the body continuously decreases with distance from the first volume.
- 7. The PCD element of claim 1, wherein an amount of catalyzing material within the second volume of the body increases with increasing distance from the first volume.
- 8. The PCD element of claim 7, wherein the amount of catalyzing material within the second volume increases in steps.
- 9. The PCD element of claim 1 wherein the body is bonded to a substrate of less hard material.
- 10. The PCD element of claim 9 wherein the less hard material is cemented tungsten carbide.
- 11. The PCD element of claim 1 comprising a preform cutting element having a facing table and a cutting surface, wherein the working surface comprises a portion of the cutting surface.
- 12. The PCD element of claim 11, wherein the cutting element is mounted upon a cutting face of a fixed cutter rotary drill bit.
- 13. The PCD element of claim 11, wherein the cutting element is mounted upon a body of a rolling cutter drill bit.
- 14. The PCD element of claim 1, wherein the body comprises a plurality of partially bonded diamond crystals and an interstitial matrix, and wherein the part of the interstitial matrix located within the first volume contains the catalyzing material, and the part of the interstitial matrix located within the second volume is substantially free of the catalyzing material.
- 15. The PCD element of claim 14, wherein the second volume extends to a depth of at least about 0.1 mm from the working surface.
- 16. The PCD element of claim 15, wherein the second volume extends to a depth of between about 0.2 mm and 0.3 mm from the working surface.
- 17. The PCD element of claim 14, wherein the second volume of the body has a diamond density higher than elsewhere in the body.
- 18. The PCD element of claim 14, wherein a majority of diamond crystals located within the second volume of the body have a surface which is substantially free of catalyzing material.
- 19. The PCD element of claim 14, wherein a majority of the catalyzing material remaining in the second volume of the body adheres to surfaces of the diamond crystals.
- 20. The PCD element of claim 14, wherein the diamond crystals in the second volume remote from the first volume have less catalyzing material adhering to their surfaces than the diamond crystals in the second volume which are adjacent to the first volume.
- 21. The PCD element of claim 14, wherein an amount of catalyzing material within the second volume of the body continuously decreases with distance from the first volume.
- 22. The PCD element of claim 14, wherein an amount of catalyzing material within the second volume of the body increases with increasing distance from the first volume.
- 23. The PCD element of claim 22, wherein the amount of catalyzing material within the second volume increases in steps.
- 24. The PCD element of claim 14 comprising a preform cutting element having a facing table and a cutting surface, wherein the working surface comprises a portion of the cutting surface.
- 25. The PCD element of claim 24, wherein the cutting element is mounted upon a cutting face of a fixed cutter rotary drill bit.
- 26. The PCD element of claim 24, wherein the cutting element is mounted upon a body of a rolling cutter drill bit.
- 27. The PCD element of claim 14, comprising a cutting element with a cutting surface adapted for use as a cutting insert in a machining operation, wherein the working surface comprises a portion of the cutting surface.
- 28. The PCD element of claim 14, comprising a drawing die, wherein the working surface comprises a portion of the drawing die contact surface.
- 29. The PCD element of claim 14, comprising a heat sink.
- 30. The PCD element of claim 14, comprising a device selected from the group consisting of a valve surface, indentor, tool mandrel, and wear element for a measuring device.
- 31. The PCD element of claim 14 wherein the body is bonded to a substrate of less hard material.
- 32. The PCD element of claim 31 wherein the less hard material is cemented tungsten carbide.
- 33. A preform cutting element comprising a facing table of a superhard polycrystalline material having a plurality of partially bonded superhard crystals, a plurality of interstitial regions among the superhard crystals and a catalyzing material, the facing table having a cutting surface and a body, wherein the interstitial regions adjacent to at least a portion of the cutting surface are substantially free of the catalyzing material and the remainder of the interstitial regions contain the catalyzing material.
- 34. The preform cutting element of claim 33, wherein the cutting element is mounted upon a cutting face of a fixed cutter rotary drill bit.
- 35. The preform cutting element of claim 33, wherein the cutting element is mounted upon a body of a rolling cutter drill bit.
- 36. The preform cutting element of claim 33, comprising a cutting element with the cutting surface adapted for use as a cutting insert in a machining operation.
- 37. The preform cutting element of claim 33 wherein the body is bonded to a substrate of less hard material.
- 38. The preform cutting element of claim 37 wherein the less hard material is cemented tungsten carbide.
- 39. An element comprising a plurality of partially bonded diamond crystals, a catalyzing material, and an interstitial matrix, and a body with a working surface, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and the remaining interstitial matrix contains the catalyzing material.
- 40. The element of claim 39, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material to a depth of at least about 0.1 mm from the working surface.
- 41. The element of claim 40, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material to a depth of between about 0.2 mm and 0.3 mm from the working surface.
- 42. The element of claim 39, wherein the interstitial matrix in the body adjacent to the working surface of the body has a diamond density higher than elsewhere in the body.
- 43. The element of claim 39, wherein a majority of the catalyzing material remaining in the interstitial matrix in the body adjacent to the working surface of the body adheres to surfaces of diamond crystals.
- 44. The element of claim 39, wherein an amount of catalyzing material within the interstitial matrix in the body adjacent to the working surface of the body continuously decreases with distance from the remaining interstitial matrix.
- 45. The element of claim 39, wherein an amount of catalyzing material within the interstitial matrix in the body adjacent to the working surface of the body increases with increasing distance from the remaining interstitial matrix.
- 46. The element of claim 45, wherein the amount of catalyzing material within the interstitial matrix in the body adjacent to the working surface increases in steps.
- 47. The element of claim 39 comprising a preform cutting element having a facing table and a cutting surface, wherein the working surface comprises a portion of the cutting surface.
- 48. The element of claim 47, wherein the cutting element is mounted upon a cutting face of a fixed cutter rotary drill bit.
- 49. The element of claim 47, wherein the cutting element is mounted upon a body of a rolling cutter drill bit.
- 50. The element of claim 39 wherein the body is bonded to a substrate of less hard material.
- 51. The element of claim 50 wherein the less hard material is cemented tungsten carbide.
- 52. A PCD element comprising a catalyzing material, an interstitial matrix, and a body with a working surface, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and the remaining interstitial matrix contains the catalyzing material.
- 53. The PCD element of claim 52, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material to a depth of at least about 0.1 mm from the working surface.
- 54. The PCD element of claim 53, wherein the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material to a depth of between about 0.2 mm and 0.3 mm from the working surface.
- 55. The PCD element of claim 52, wherein the interstitial matrix in the body adjacent to the working surface of the body has a diamond density higher than elsewhere in the body.
- 56. The PCD element of claim 52, wherein a majority of the catalyzing material remaining in the interstitial matrix in the body adjacent to the working surface of the body adheres to surfaces of diamond crystals.
- 57. The PCD element of claim 52, wherein an amount of catalyzing material within the interstitial matrix in the body adjacent to the working surface of the body continuously decreases with distance from the remaining interstitial matrix.
- 58. The PCD element of claim 52, wherein an amount of catalyzing material within the interstitial matrix in the body adjacent to the working surface of the body increases with increasing distance from the remaining interstitial matrix.
- 59. The PCD element of claim 58, wherein the amount of catalyzing material within the interstitial matrix in the body adjacent to the working surface increases in steps.
- 60. The PCD element of claim 52 comprising a preform cutting element having a facing table and a cutting surface, wherein the working surface comprises a portion of the cutting surface.
- 61. The PCD element of claim 60, wherein the cutting element is mounted upon a cutting face of a fixed cutter rotary drill bit.
- 62. The PCD element of claim 60, wherein the cutting element is mounted upon a body of a rolling cutter drill bit.
- 63. The PCD element of claim 52 wherein the body is bonded to a substrate of less hard material.
- 64. The PCD element of claim 63 wherein the less hard material is cemented tungsten carbide.
- 65. A PCD element comprising a plurality of superhard crystals, a catalyzing material, and a body with a working surface, wherein a majority of the crystals in the body within at least a 0.1 mm depth from the working surface have a surface which is substantially free of the catalyzing material, the remaining crystals contact the catalyzing material.
- 66. The PCD element of claim 65, wherein said majority of the crystals in the body are within between about 0.2 mm and 0.3 mm depth from the working surface.
- 67. The PCD element of claim 65 wherein the body is bonded to a substrate of less hard material.
- 68. The PCD element of claim 67 wherein the less hard material is cemented tungsten carbide.
- 69. An element comprising a plurality of partially bonded diamond crystals, a catalyzing material, and a body with a working surface, wherein a volume of the body adjacent the working surface has a substantially higher diamond density than elsewhere in the body, and the volume is substantially free of the catalyzing material.
- 70. The element of claim 69, wherein the volume extends to a depth of at least about 0.1 mm from the working surface.
- 71. The element of claim 70, wherein the volume extends to a depth of between about 0.2 mm and 0.3 mm from the working surface.
- 72. The element of claim 69, wherein a majority of diamond crystals located within the volume of the body have a surface which is substantially free of catalyzing material.
- 73. The element of claim 69, wherein a majority of the catalyzing material remaining in the volume of the body adheres to surfaces of the diamond crystals.
- 74. The element of claim 69 comprising a preform cutting element having a facing table and a cutting surface, wherein the working surface comprises a portion of the cutting surface.
- 75. The element of claim 74 wherein the cutting element is mounted upon a cutting face of a fixed cutter rotary drill bit.
- 76. The element of claim 74, wherein the cutting element is mounted upon a body of a rolling cutter drill bit.
- 77. The element of claim 69 wherein the body is bonded to a substrate of less hard material.
- 78. The element of claim 77 wherein the less hard material is cemented tungsten carbide.
- 79. A PCD element comprising a body with a working surface, wherein a volume of the body adjacent the working surface has a diamond density substantially higher than elsewhere in the body, and the volume is substantially free of a catalyzing material.
- 80. The PCD element of claim 79, wherein the volume extends to a depth of at least about 0.1 mm from the working surface.
- 81. The PCD element of claim 80, wherein the volume extends to a depth of between about 0.2 mm and 0.3 mm from the working surface.
- 82. The PCD element of claim 79, wherein a majority of diamond crystals located within the volume of the body have a surface which is substantially free of catalyzing material.
- 83. The PCD element of claim 79, wherein a majority of the catalyzing material remaining in the volume of the body adheres to surfaces of the diamond crystals.
- 84. The PCD element of claim 79 comprising a preform cutting element having a facing table and a cutting surface, wherein the working surface comprises a portion of the cutting surface.
- 85. The PCD element of claim 84, wherein the cutting element is mounted upon a cutting face of a fixed cutter rotary drill bit.
- 86. The PCD element of claim 84, wherein the cutting element is mounted upon a body of a rolling cutter drill bit.
- 87. The PCD element of claim 79 wherein the body is bonded to a substrate of less hard material.
- 88. The PCD element of claim 87 wherein the less hard material is cemented tungsten carbide.
- 89. A PCD element comprising a body with a working surface, wherein a diamond density adjacent the working surface is substantially higher than elsewhere in the body, and is substantially free of a catalyzing material.
- 90. The PCD element of claim 89, wherein the body comprises a plurality of partially bonded diamond crystals and an interstitial matrix, and wherein a part of the interstitial matrix located within a first volume contains the catalyzing material, and a part of the interstitial matrix located within a second volume is substantially free of the catalyzing material.
- 91. The PCD element of claim 90, wherein the second volume extends to a depth of at least about 0.1 mm from the working surface.
- 92. The PCD element of claim 91, wherein the second volume extends to a depth of between about 0.2 mm and 0.3 mm from the working surface.
- 93. The PCD element of claim 90, wherein the second volume of the body has a diamond density higher than elsewhere in the body.
- 94. The PCD element of claim 90, wherein a majority of diamond crystals located within the second volume of the body have a surface which is substantially free of catalyzing material.
- 95. The PCD element of claim 90, wherein a majority of the catalyzing material remaining in the second volume of the body adheres to surfaces of the diamond crystals.
- 96. The PCD element of claim 90, wherein the diamond crystals in the second volume remote from the first volume have less catalyzing material adhering to their surfaces than the diamond crystals in the second volume which are adjacent to the first volume.
- 97. The PCD element of claim 90, wherein an amount of catalyzing material within the second volume of the body continuously decreases with distance from the first volume.
- 98. The PCD element of claim 90, wherein an amount of catalyzing material within the second volume of the body increases with increasing distance from the first volume.
- 99. The PCD element of claim 98, wherein the amount of catalyzing material within the second volume increases in steps.
- 100. The PCD element of claim 90 comprising a preform cutting element having a facing table and a cutting surface, wherein the working surface comprises a portion of the cutting surface.
- 101. The PCD element of claim 100, wherein the cutting element is mounted upon a cutting face of a fixed cutter rotary drill bit.
- 102. The PCD element of claim 100, wherein the cutting element is mounted upon a body of a rolling cutter drill bit.
- 103. The PCD element of claim 90 wherein the body is bonded to a substrate of less hard material.
- 104. The PCD element of claim 103 wherein the less hard material is cemented tungsten carbide.
- 105. A method of manufacture of a PCD element comprising treating a body containing a catalyzing material to render a second volume thereof substantially free of the catalyzing material while permitting the catalyzing material to remain in a first volume of the body.
- 106. The method of claim 105, wherein the second volume is rendered substantially free of catalyzing material by leaching the catalyzing material from the second volume.
- 107. The method of claim 105, wherein the second volume is rendered substantially free of catalyzing material by converting the catalyzing material in the second volume to a form in which it does not have a catalyzing effect.
- 108. The method of claim 105, wherein the second volume is rendered substantially free of catalyzing material by reacting the catalyzing material to form a substance which does not have a catalyzing effect.
- 109. The method of claim 105, wherein the second volume is rendered substantially free of catalyzing material by electrical discharge.
- 110. The method of claim 105, wherein the second volume is rendered substantially free of catalyzing material using a galvanic process.
- 111. The method of claim 105, wherein the second volume is rendered substantially free of catalyzing material using an evaporation process.
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application No. 60/234,075 filed Sep. 20, 2000, and from U.S. Provisional Patent Application No. 60/281,054 filed Apr. 2, 2001.
Provisional Applications (2)
|
Number |
Date |
Country |
|
60234075 |
Sep 2000 |
US |
|
60281054 |
Apr 2001 |
US |