# US 10,870,606 B2 · Polycrystalline diamond comprising nanostructured polycrystalline diamond particles and method of making the same

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- Number: US 10,870,606 B2
- Document ID: US10870606B2
- Status: Granted
- Kind: B2
- Application number: 16/262,529
- Filed: 2019-01-30
- Published: 2020-07-30
- Granted: 2020-12-22
- Earliest claimed: 2018-03-05
- Applicants: Wenhui Jiang
- Inventors: Wenhui Jiang
- Web page: https://patentgrep.com/patent/US10870606B2

## CPC

- C04B 35/52: based on carbon, e.g. graphite
- C04B 35/528: obtained from carbonaceous particles with or without other non-organic components
- B01J 3/08: Application of shock waves for chemical reactions or for modifying the crystal structure of substances
- B22F 3/14: simultaneously
- C04B 35/62675: {characterised by the treatment temperature}
- C04B 35/645: Pressure sintering
- C22C 26/00: Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes}
- E21B 10/567: with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
- B01J 2203/0655: Diamond
- B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware}
- B22F 2998/10: Processes characterised by the sequence of their steps
- C04B 2235/3206: Magnesium oxides or oxide-forming salts thereof
- C04B 2235/3208: Calcium oxide or oxide-forming salts thereof, e.g. lime
- C04B 2235/3826: Silicon carbides
- C04B 2235/3847: Tungsten carbides
- C04B 2235/405: Iron group metals
- C04B 2235/427: Diamond
- C04B 2235/428: Silicon
- C04B 2235/442: Carbonates
- C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron
- C04B 2235/5445: submicron sized, i.e. from 0,1 to 1 micron
- C04B 2235/5472: Bimodal, multi-modal or multi-fraction
- C04B 2235/656: characterised by specific heating conditions during heat treatment
- C04B 2235/6562: Heating rate
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS

## Abstract

A polycrystalline diamond and a polycrystalline diamond compact comprise nanostructured polycrystalline diamond particles (aggregates) and binder material. The nanostructured polycrystalline diamond particles (aggregates) are from starting raw materials of nanostructured polycrystalline diamond particles (aggregates) with a size of between 1 μm-40 μm. The polycrystalline diamond and the polycrystalline diamond compact may comprise micrometer-sized monocrystalline diamond particles. The binder material in the polycrystalline diamond or the polycrystalline diamond compact may be removed partially or completely by a leaching process. The method of making the polycrystalline diamond or the polycrystalline diamond compact comprises sintering diamond particles comprising the nanostructured polycrystalline diamond particles (aggregates) with a size of between 1 μm-40 μm under high temperature and high pressure in the presence of the binder material.

## Claims

### Claim 1

A polycrystalline diamond compact comprising:
a cemented carbide body as a supporting substrate;
a polycrystalline diamond layer comprising:
diamond constituents comprising nanostructured polycrystalline diamond particles (aggregates) with a particle size of between 1 μm-40 μm, wherein the particles or aggregates consist of nanometer-sized diamond grains; and
binder material, wherein the binder material is located at the interstitial spaces among the diamond constituents.

### Claim 2 (depends on 1)

The polycrystalline diamond layer as in claim 1, wherein the diamond constituents comprise micrometer-sized monocrystalline diamond particles, wherein the particle size is between 1 μm-40 μm.

### Claim 3 (depends on 1)

The polycrystalline diamond layer as in claim 1, wherein the binder material is a metallic catalyst material selected from the group consisting of cobalt, nickel, iron and alloys thereof.

### Claim 4 (depends on 1)

The polycrystalline diamond layer as in claim 1, wherein the binder material is a non-metallic material selected from the group consisting of silicon, silicon carbide, magnesium carbonate and calcium carbonate.

### Claim 5 (depends on 1)

A fixed cutter drill bit comprising:
a fixed cutter drill bit body;
at least one polycrystalline diamond compact mounted on the body as claimed in claim 1 comprising:
a tungsten carbide substrate;
a polycrystalline diamond layer formed over the substrate comprising:
diamond constituents comprising nanostructured polycrystalline diamond particles or aggregates, wherein the particle size is between 1 μm-40 μm, wherein the particles or aggregates consist of nanometer-sized diamond grains; and
binder material, wherein the binder material is located at the interstitial spaces among the diamond constituents.

### Claim 6 (depends on 5)

The polycrystalline diamond layer as in claim 5, wherein the diamond constituents comprise micrometer-scale monocrystalline diamond particles, wherein the particle size is between 1 μm-40 μm.

### Claim 7 (depends on 5)

The polycrystalline diamond layer as in claim 5, wherein the binder material is a metallic catalyst material selected from the group consisting of cobalt, nickel, iron and alloys thereof.

### Claim 8 (depends on 5)

The polycrystalline diamond layer as in claim 5, wherein the binder material is a non-metallic material selected from the group consisting of silicon, silicon carbide, magnesium carbonate and calcium carbonate.

### Claim 9 (depends on 3)

The polycrystalline diamond layer as in claim 3, wherein the polycrystalline diamond layer with an exterior surface consists of a first volume remote from the exterior surface and a second volume adjacent to the exterior surface, wherein the first volume contains the metallic catalyst material, and at least a portion of the second volume is substantially free of the metallic catalyst material to a depth of at least 10 μm from the exterior surface.

### Claim 10 (depends on 7)

The polycrystalline diamond layer as in claim 7, wherein the polycrystalline diamond layer with an exterior surface consists of a first volume remote from the exterior surface and a second volume adjacent to the exterior surface, wherein the first volume contains the metallic catalyst material, and at least a portion of the second volume is substantially free of the metallic catalyst material to a depth of at least 10 μm from the exterior surface.