[특허]Superabrasive materials and methods of manufacture

Superabrasive materials and methods of manufacture 원문보기

IPC분류정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	E21B-010/36 E21B-010/46
출원번호	US-0659703 (2012-10-24)
등록번호	US-8602132 (2013-12-10)
발명자 / 주소	Bertagnolli, Kenneth E. Cooley, Craig H. Wiggins, Jason
출원인 / 주소	US Synthetic Corporation
대리인 / 주소	Holland & Hart LLP
인용정보	피인용 횟수 : 0 인용 특허 : 53

초록 ▼

Methods of manufacturing sintered superabrasive structures are disclosed. For example, a plurality of agglomerated granules comprising at least one superabrasive material may be provided and exposed to a pressure and a temperature sufficient to sinter the at least one superabrasive material. In another example, a plurality of agglomerated granules comprising diamond may be provided and exposed to a pressure and a temperature sufficient to form polycrystalline diamond. Articles of manufacture including at least one superabrasive material are disclosed. For example, a polycrystalline diamond compact may comprise a volume of polycrystalline diamond bonded to a substrate, wherein the volume of polycrystalline diamond includes a plurality of agglomerated granules which have been sintered. A drill bit comprising at least one cutting element including a volume of polycrystalline diamond bonded to a substrate wherein the volume of polycrystalline diamond includes a plurality of agglomerated granules which have been sintered is disclosed.

대표청구항 ▼

1. A rotary drill bit for drilling a subterranean formation, comprising: a bit body comprising a leading end having generally radially extending blades structured to facilitate drilling of a subterranean formation;at least one cutting element affixed to the bit body, the at least one cutting element comprising:a substrate;a coherent matrix of polycrystalline diamond defining a superhard table bonded to the substrate;wherein the coherent matrix of polycrystalline diamond includes a plurality of agglomerated granules extending from the substrate to an exposed surface of the superhard table distal of the substrate, at least a majority of the plurality of agglomerated granules being sintered directly to adjacent agglomerated granules to exhibit diamond-to-diamond bonds therebetween, the granules comprising at least two different size diamond particles and binder, wherein the diamond particles have a size of less than about 100 μm. 2. The rotary drill bit of claim 1, wherein the diamond particles have a size between about 2 μm and about 20 μm. 3. The rotary drill bit of claim 1, wherein the diamond particles have a size between about 2 μm and about 10 μm. 4. The rotary drill bit of claim 1, wherein the diamond particles have a size between about 10 μm and about 100 μm. 5. The rotary drill bit of claim 1, wherein the substrate comprises at least one of the following: cobalt-cemented tungsten carbide, titanium carbide, niobium carbide, tantalum carbide, vanadium carbide, iron, and nickel. 6. The rotary drill bit of claim 1, wherein the plurality of agglomerated granules comprise a plurality of agglomerated granules exhibiting at least one of the following shapes: generally spherical, generally ellipsoid, and generally cylindrical. 7. The rotary drill bit of claim 1, wherein the plurality of agglomerated granules comprise a plurality of agglomerated granules exhibiting different sizes. 8. The rotary drill bit of claim 6, wherein the plurality of agglomerated granules comprise a plurality of agglomerated granules exhibiting at least two different sizes having a relative size ratio of at least 7:1, wherein the plurality of particles of at least one of the plurality of agglomerated granules includes diamond particles having at least two different sizes. 9. The rotary drill bit of claim 1, wherein the plurality of agglomerated granules comprise a plurality of agglomerated granules exhibiting a packing density, prior to sintering, of at least about 64%. 10. The rotary drill bit of claim 1, wherein the cutting element is substantially cylindrical.

이 특허에 인용된 특허 (53)

Corrigan Francis Raymond ; Marek Henry Samuel, Abrasive compact with improved properties.
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Wood, William P.; McArdle, James L., Agglomerate abrasive grain and a method of making the same.
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Cho Hyun S. (Sandy UT) Sung Chien-Min (Sandy UT) Merrill Leo (Orem UT) Chen Sy-Hwa (Salt Lake City UT), Cemented and cemented/sintered superabrasive polycrystalline bodies and methods of manufacture thereof.
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Cho Hyun S. (Sandy UT) Sung Chien-Min (Sandy UT) Merrill Leo (Orem UT) Chen Sy-Hwa (Salt Lake City UT) Csillag Frank (Salt Lake City UT), Cemented and cemented/sintered superabrasive polycrystalline bodies and methods of manufacture thereof.
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Bovenkerk Harold P. (Worthington OH), Compact of boron-doped diamond and method for making same.
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Dennis Mahlon D. (Kingwood TX), Cutting composite formed of cemented carbide substrate and diamond layer.
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Dennis Mahlon D. (Kingwood TX), Cutting element for drill bits.
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Meany Nigel C. (Kincardineshire UT GB6) Cooley Craig H. (Bountiful UT) Tibbitts Gordon A. (Salt Lake City UT), Diamond cutting structure for drilling hard subterranean formations.
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Waldenstrm Mats G. (Bromma SEX) Fischer Udo K. R. (Vallingby SEX) Hillert Lars H. (Nacka TX SEX) Dennis Mahlon D. (Kingwood TX), Diamond rock tools for percussive and rotary crushing rock drilling.
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Hall David R. (Provo UT), Diamond thrust bearing and method for manufacturing same.
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Dillon Kenneth R. (White Bear Lake MN) Terchek Richard L. (White Bear Lake MN), Dimensionally-controlled cobalt-containing precision molded metal article.
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Jones Mark L. (Midvale UT), Drill bit having improved cutter configuration.
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Overstreet James Leslie ; Scott Danny Eugene, Earth boring bits with nanocrystalline diamond enhanced elements.
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Horton M. Duane (Provo UT) Peterson Gary R. (Orem UT), Infiltrated thermally stable polycrystalline diamond.
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Sung Chien-Min (Northboro MA) Chen Sy-Hwa (Salt Lake City UT) Merrill Leo (Orem UT) Bigelow Louis K. (Salt Lake City UT), Low pressure bonding of PCD bodies and method.
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Nagel Dave D. (Houston TX), Manufacture of diamond bearings.
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Wisniewski Richard, Method for freeze granulation.
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Corrigan Francis Raymond ; Marek Henry Samuel, Method for producing abrasive compact with improved properties.
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Bovenkerk Harold P. (Worthington OH), Method of dressing a plated cubic boron nitride grinding wheel.
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Tank Klaus (9 Warbleton Avenue Essexwold ; Johannesburg ZAX) Jarvis Alan R. (320 Suncrest ; Isipingo Road ; Bellevue East Johannesburg ZAX) Stewart Aulette (45 Arend Avenue Randburg ZAX), Method of making an abrasive compact.
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Tank Klaus (9 Warbleton Avenue Essexwold ; Johannesburg ZAX) Jarvis Alan R. (320 Suncrest ; Isipingo Road Bellevue East ZAX) Stewart Aulette (45 Arend Avenue Randburg ZAX), Method of making an abrasive compact.
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Mueller Walter B. (Taylors SC) Schirmer Henry G. (Spartanburg SC) Schoenberg Julian H. (Greenville SC) Weinberg Alan S. (Greenville SC), Multi-layer polyester/polyolefin shrink film.
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Hall David R. (Provo UT) Cross Donald G. (Laguna Beach CA), Polycrystalline diamond bearing system for a roller cone rock bit.
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Fang,Zhigang; Griffo,Anthony; White,Brian A.; Middlemiss,Stewart; Eyre,Ron K., Polycrystalline diamond carbide composites.
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Zhigang Fang ; Anthony Griffo ; Brian A. White ; Stewart Middlemiss ; Ron K. Eyre, Polycrystalline diamond carbide composites.
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Miess, David P., Polycrystalline diamond compact, methods of fabricating same, and rotary drill bit using same.
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Vail, Michael A., Polycrystalline diamond element comprising ultra-dispersed diamond grain structures and applications utilizing same.
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Belnap, Daniel J.; Anderson, Nathan R.; Fang, Zhigang; Griffo, Anthony; White, Brian A., Polycrystalline diamond materials formed from coarse-sized diamond grains.
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Wang,Zhaolin; Finlay,Warren H., Powder formation by atmospheric spray-freeze drying.
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Williams, III, Robert O.; Johnston, Keith P.; Young, Timothy J.; Rogers, True L.; Barron, Melisa K.; Yu, Zhongshui; Hu, Jiahui, Process for production of nanoparticles and microparticles by spray freezing into liquid.
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Enomoto Ryo (Ohgaki JPX), Process for the production of silicon carbide sintered bodies.
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Kirchnerova Jitka,CAX ; Klvana Danilo,CAX, Process of making fine ceramic powders from aqueous suspensions.
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Pope, Bill Jordan; Taylor, Jeffery K.; Dixon, Richard H.; Gardinier, Clayton F.; Pope, Louis M.; Blackburn, Dean C.; Vail, Michael A., Prosthetic hip joint having a polycrystalline diamond articulation surface and a plurality of substrate layers.
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Salesky William J. (Irvine CA) Campbell Bruce L. (Pleasant Grove UT), Rock bits and inserts therefor.
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Miess, David P., Rotary drill bit employing polycrystalline diamond cutting elements.
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Smith Redd H. (Salt Lake City UT) Cooley Craig H. (Bountiful UT), Rotary drill bit with abrasion and erosion resistant facing.
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Smith,Redd H.; Skeem,Marcus R.; Cooley,Craig H., Superabrasive cutting element having an asperital cutting face and drill bit so equipped.
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Bertagnolli, Kenneth E.; Cooley, Craig H.; Wiggins, Jason, Superabrasive materials and methods of manufacture.
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Miess, David P., Superabrasive materials, methods of fabricating same, and applications using same.
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Corrigan Francis R. (Westerville OH), Surface characteristics of boron rich cubic boron nitride.
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Wisniewski Richard, System for freeze granulation.
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Wisniewski Richard, System for freeze granulation.
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Geczy, Bela A., Thrust bearing assembly for a downhole drill motor.
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Cunningham James K. (P.O. Box 126 ; 504 E. Main Big Cabin OK 74332), Thrust bearing for use in downhole drilling systems.
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Belnap,J. Daniel; Griffo,Anthony; Eyre,Ronald K.; Middlemiss,Stewart N., Ultrahard composite constructions.
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Nagel Dave D. (Houston TX) Aparicio ; Jr. Thomas (Houston TX), Well drilling tool with diamond radial/thrust bearings.
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