US Synthetic Corporation

Trevor Allen Olsen

Joshua Adam Hawks

Daniel Call Mortensen

David Paul Miess

Jason Keith Wiggins

Mark Pehrson Chapman

Trent Neil Butcher

Michael James Gleason

Julie Ann Kidd

Shawn Casey Scott

Matthew Brown

Ryan LeRoy Woodland

Lindsay Sue Patton

Casey Wade Swan

Kenneth Eugene Bertagnolli

Jiang Qian

Matthew Kimball Baker

Anne-Grethe Slotnaes

Jason Lott

Heather Marie Schaefer

Daniel Preston Wilding

Method of processing a polycrystalline diamond element may include laser ablating at least a portion of a polycrystalline diamond element to form a laser-shaped surface and exposing at least a portion of the laser-shaped surface to a leaching solution to define a leached polycrystalline diamond volume and an unleached polycrystalline diamond volume.

Leached diamond elements and leaching systems, methods and assemblies for processing diamond elements

PDCs, methods of fabricating the PDCs, and methods of using the PDCs are disclosed herein. The PDCs include a PCD table bonded to a substrate. The PCD table includes an upper surface having a plurality of recessed features formed therein. The plurality of recessed features are configured to attract at least some cracks that form in the PCD table. As such, the plurality of recessed features limit or prevent crack propagation into other portions of the PCD table and limit a volume of the PCD table that spalls. Methods of fabricating the PDCs include partially leaching the PCD table and, after leaching the PCD table, forming the plurality of recessed features in the upper surface thereof. Method of using the PDCs include rotating a PDC that has spalled relative to a rotary drill bit such that a portion of the upper surface of the PDC that has not spalled forms a cutting surface thereof.

Polycrystalline diamond compacts, methods of fabricating the same, and methods of using the same

A polycrystalline diamond element includes a polycrystalline diamond table having a body of bonded diamond particles with interstitial regions. A first volume of the body includes an interstitial material and a second volume of the body has a lower concentration of interstitial material within the interstitial regions than the first volume. The polycrystalline diamond element includes an element face and a peripheral surface. The first volume is adjacent to a central portion of the element face and the second volume is adjacent to the peripheral surface. A method of processing a polycrystalline diamond element includes forming a concave region in the polycrystalline diamond element, exposing at least a portion of the concave region to a leaching solution, and removing at least a portion of the polycrystalline diamond element that was exposed to the leaching solution from the polycrystalline diamond element.

Leached superabrasive elements and leaching systems, methods and assemblies for processing superabrasive elements

A polycrystalline diamond element includes a polycrystalline diamond table having a body of bonded diamond particles with interstitial regions. A first volume of the body includes an interstitial material and a second volume of the body has a lower concentration of interstitial material within the interstitial regions than the first volume. The polycrystalline diamond element includes an element face and a peripheral surface. The first volume is adjacent to a central portion of the element face and the second volume is adjacent to the peripheral surface. A method of processing a polycrystalline diamond element includes forming a concave region in the polycrystalline diamond element, exposing at least a portion of the concave region to a leaching solution, and removing at least a portion of the polycrystalline diamond material that was exposed to the leaching solution from the polycrystalline diamond element.

Leached superabrasive elements and leaching systems methods and assemblies for processing superabrasive elements

Superabrasive compact

A polycrystalline diamond element leaching assembly includes a polycrystalline diamond element, a protective leaching cup surrounding at least a portion of the polycrystalline diamond element, and a protective layer positioned between the polycrystalline diamond element and the protective leaching cup. A method of processing a polycrystalline diamond element includes covering a selected portion of a polycrystalline diamond element with a curable resin layer, curing the curable resin layer to form a protective layer, and exposing at least a portion of the polycrystalline diamond element to a leaching agent. Another method of processing a polycrystalline diamond element includes depositing a curable resin within a protective leaching cup and positioning a polycrystalline diamond element within the protective leaching cup such that the curable resin is displaced so as to surround at least a portion of the polycrystalline diamond element.

Leaching assemblies, systems, and methods for processing superabrasive elements

Growing community of inventors

Pleasant Grove, UT, United States of America

Trevor Allen Olsen