US Synthetic Corporation

Alberto Castillo

Mohammad N Sani

Brandon Paul Linford

Jedediah Chad Clarke

Jair Jahaziel Gonzalez

Mark Pehrson Chapman

In an embodiment, a polycrystalline diamond compact ('PDC') includes a substrate and a polycrystalline diamond ('PCD') table bonded to the substrate. The PCD table includes an upper surface. The PCD table includes a first PCD region including bonded-together diamond grains and exhibits a first diamond density. At least a portion of the first PCD region extending inwardly from the working surface is substantially free of metal-solvent catalyst. The PCD table includes an intermediate second PCD region bonded to the substrate, which is disposed between the first PCD region and the substrate. The second PCD region includes bonded-together diamond grains defining interstitial regions, with at least a portion of the interstitial regions including metal-solvent catalyst disposed therein. The second PCD region exhibits a second diamond density that is greater than that of the first diamond density of the first PCD region.

Methods of manufacturing a polycrystalline diamond compact including an at least bi-layer polycrystalline diamond table

Embodiments of the invention relate to polycrystalline diamond compacts including a substrate having a convexly-curved interfacial surface bonded to a polycrystalline diamond table. In an embodiment, a polycrystalline diamond compact includes a substrate including at least one side surface and a convexly-curved interfacial surface that may, in some embodiments, extend inwardly directly from the at least one side surface to form at least one peripheral edge therebetween. The polycrystalline diamond compact further includes a polycrystalline diamond table bonded to the convexly-curved interfacial surface of the substrate.

Polycrystalline diamond compact including a substrate having a convexly-curved interfacial surface bonded to a polycrystalline diamond table, and related applications

Embodiments of the invention relate to polycrystalline diamond compacts ('PDCs') including a domed polycrystalline diamond ('PCD') table that exhibit improved wear resistance and/or thermal stability. In an embodiment, a PDC includes a substrate having an interfacial surface, and a domed PCD table bonded to the interfacial surface of the substrate. The domed PCD table includes an exterior, convex generally cylindrical peripheral surface extending away from the interfacial surface of the substrate. The domed PCD table further includes a domed portion defining an upper, convex generally spherical surface, and an optional chamfer extending between the exterior, convex generally cylindrical peripheral surface and the upper, convex generally spherical surface.

Polycrystalline diamond compacts including a domed polycrystalline diamond table, and applications therefor

Polycrystalline diamond compact including a substrate having a convexly-curved interfacial surface bonded to a polycrystalline diamond table, and related methods and applications

Polycrystalline diamond compact including an at least bi-layer polycrystalline diamond table, methods of manufacturing same, and applications therefor

Growing community of inventors

Orem, UT, United States of America

Alberto Castillo