Rotary drill bit employing polycrystalline diamond cutting elements
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E21B-010/36
E21B-010/46
출원번호
US-0414180
(2012-03-07)
등록번호
US-8448727
(2013-05-28)
발명자
/ 주소
Miess, David P.
출원인 / 주소
US Synthetic Corporation
대리인 / 주소
Workman Nydegger
인용정보
피인용 횟수 :
1인용 특허 :
51
초록▼
Embodiments of the present invention relate to superabrasive materials, superabrasive compacts employing such superabrasive materials, and methods of fabricating such superabrasive materials and compacts. In one embodiment, a superabrasive material includes a matrix comprising a plurality of coarse-
Embodiments of the present invention relate to superabrasive materials, superabrasive compacts employing such superabrasive materials, and methods of fabricating such superabrasive materials and compacts. In one embodiment, a superabrasive material includes a matrix comprising a plurality of coarse-sized superabrasive grains, with the coarse-sized superabrasive grains exhibiting a coarse-sized average grain size. The superabrasive material further includes a plurality of superabrasive regions dispersed within the matrix, with each superabrasive region including a plurality of fine-sized superabrasive grains exhibiting a fine-sized average grain size less than the coarse-sized average grain size. In another embodiment, the superabrasive materials may be employed in a superabrasive compact. The superabrasive compact comprises a substrate including a superabrasive table comprising any of the disclosed superabrasive materials. Further embodiments are directed to applications utilizing the disclosed superabrasive articles in applications, such as rotary drill bits.
대표청구항▼
1. A rotary drill bit, comprising: a bit body configured for drilling a subterranean formation, the bit body including a plurality of blades, each of the plurality of blades having a plurality of polycrystalline diamond cutting elements affixed thereto, at least one of the plurality of polycrystalli
1. A rotary drill bit, comprising: a bit body configured for drilling a subterranean formation, the bit body including a plurality of blades, each of the plurality of blades having a plurality of polycrystalline diamond cutting elements affixed thereto, at least one of the plurality of polycrystalline diamond cutting elements including: a polycrystalline diamond table including: a matrix including a plurality of coarse-sized diamond grains, the coarse-sized diamond grains exhibiting a coarse-sized average grain size of at least about 6 μm and at least a bimodal grain size distribution; anda plurality of polycrystalline diamond regions dispersed within the matrix, at least a portion of the polycrystalline diamond regions including a plurality of fine-sized polycrystalline diamond grains exhibiting a fine-sized average grain size less than the coarse-sized average grain size, each of the at least a portion of the polycrystalline diamond regions exhibiting an average size of at least about 50 μm; anda substrate bonded to the polycrystalline diamond table. 2. The rotary drill bit of claim 1 wherein the average size of each of the at least a portion of the polycrystalline diamond regions is greater than the coarse-sized average grain size. 3. The rotary drill bit of claim 1 wherein the fine-sized average grain size of each of the at least a portion of the polycrystalline diamond regions is about 6 μm or less. 4. The rotary drill bit of claim 1 wherein the coarse-sized average grain size of the matrix is about 5 times or more than the fine-sized average grain size of the plurality of polycrystalline diamond regions. 5. The rotary drill bit of claim 1 wherein the coarse-sized average grain size of the plurality of coarse-sized diamond grains is about 6 μm to about 30 μm. 6. The rotary drill bit of claim 1 wherein the coarse-sized average grain size of the plurality of coarse-sized diamond grains is about 6 μm to about 20 μm. 7. The rotary drill bit of claim 1 wherein: the plurality of coarse-sized diamond grains define a plurality of first interstitial regions;the plurality of fine-sized diamond grains define a plurality of second interstitial regions; andat least a portion of the first and second interstitial regions include metal-solvent catalyst disposed therein. 8. The rotary drill bit of claim 7 wherein at least a portion of the first and the second interstitial regions are substantially free of the metal-solvent catalyst. 9. The rotary drill bit of claim 1 wherein the polycrystalline diamond table is pre-sintered. 10. The rotary drill bit of claim 1 wherein the polycrystalline diamond table is integrally formed with the substrate. 11. The rotary drill bit of claim 1 wherein the substrate comprises a cemented carbide material including iron, nickel, cobalt, or alloys thereof. 12. A rotary drill bit, comprising: a bit body configured for drilling a subterranean formation, the bit body including a plurality of blades, each of the plurality of blades having a plurality of polycrystalline diamond cutting elements affixed thereto, at least one of the plurality of polycrystalline diamond cutting elements including: at least one region including a plurality of coarse-sized diamond grains, the coarse-sized diamond grains exhibiting a coarse-sized average grain size of at least about 6 μm and at least a bimodal grain size distribution; anda plurality of polycrystalline diamond regions dispersed through the at least one region, at least a portion of the polycrystalline diamond regions including a plurality of fine-sized polycrystalline diamond grains exhibiting a fine-sized average grain size less than the coarse-sized average grain size, each of the at least a portion of the polycrystalline diamond regions exhibiting an average size of at least about 50 μm. 13. A rotary drill bit, comprising: a bit body configured for drilling a subterranean formation, the bit body including a plurality of blades, each of the plurality of blades having a plurality of polycrystalline diamond cutting elements affixed thereto, at least one of the plurality of polycrystalline diamond cutting elements including: a matrix including a plurality of coarse-sized diamond grains, the coarse-sized diamond grains exhibiting a coarse-sized average grain size of at least about 6 μm; anda plurality of polycrystalline diamond regions dispersed within the matrix, at least a portion of the polycrystalline diamond regions including a plurality of fine-sized polycrystalline diamond grains exhibiting a fine-sized average grain size less than the coarse-sized average grain size, each of the at least a portion of the polycrystalline diamond regions exhibiting an average size of about 50 μm to about 200 μm; anda substrate bonded to the polycrystalline diamond table. 14. The rotary drill bit of claim 13 wherein the average size of each of the at least a portion of the polycrystalline diamond regions is greater than the coarse-sized average grain size. 15. The rotary drill bit of claim 13 wherein the fine-sized average grain size of each of the at least a portion of the polycrystalline diamond regions is less than 6 μm. 16. The rotary drill bit of claim 13 wherein the coarse-sized average grain size of the matrix is about 5 times or more than the fine-sized average grain size of the plurality of polycrystalline diamond regions. 17. The rotary drill bit of claim 13 wherein the coarse-sized average grain size of the plurality of coarse-sized diamond grains is about 6 μm to about 30 μm. 18. The rotary drill bit of claim 13 wherein the coarse-sized average grain size of the plurality of coarse-sized diamond grains is about 6 μm to about 20 μm. 19. The rotary drill bit of claim 13 wherein the polycrystalline diamond table is pre-sintered. 20. The rotary drill bit of claim 13 wherein the polycrystalline diamond table is integrally formed with the substrate.
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