# US 11,111,728 B2 · Super hard constructions and methods of making same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,111,728 B2 - Document ID: US11111728B2 - Status: Granted - Kind: B2 - Application number: 16/066,469 - Filed: 2016-12-19 - Published: 2019-01-17 - Granted: 2021-09-07 - Earliest claimed: 2015-12-31 - Assignees: Element Six (UK) Limited - Applicants: Element Six (UK) Limited - Inventors: David Christian Bowes - Web page: https://patentgrep.com/patent/US11111728B2 ## CPC - C22C 26/00: Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} - B22F 3/1103: {with particular physical characteristics} - B22F 7/008: {characterised by the composition} - B22F 7/062: {involving the connection or repairing of preformed parts} - E21B 10/08: Roller bits (E21B10/26 takes precedence; roller core bits E21B10/06; characterised by wear resisting parts E21B10/50) - E21B 10/5735: {Interface between the substrate and the cutting element} - B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware} - B22F 2005/005: {Article surface comprising protrusions} - B22F 2302/253: Aluminum oxide (Al2O3) - B22F 2302/406: Diamond - C22C: ALLOYS (treatment of alloys C21D, C22F) - 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 - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS ## Abstract A super hard construction comprises a substrate comprising a peripheral surface, an interface surface and a longitudinal axis extending in a plane and a super hard material layer formed over the substrate and having an exposed outer surface, a peripheral surface extending therefrom and an interface surface. One of the interface surface of the substrate or the interface surface of the super hard material layer comprises one or more projections arranged to project from the interface surface, the one or more projections being spaced from the peripheral surface of the substrate and a peripheral flange extending between the peripheral side edge and the interface surface. The peripheral flange is inclined at an angle of between around 5 degrees to around 30 degrees to a plane substantially perpendicular to the plane through which the longitudinal axis extends. ## Claims ### Claim 1 A super hard construction comprising: a substrate comprising a peripheral surface, an interface surface and a longitudinal axis extending in a plane; and a super hard material layer formed over the substrate and having an exposed outer surface, a peripheral surface extending therefrom and an interface surface; wherein the interface surface of the substrate comprises: one or more projections arranged to project from the interface surface in a first direction along the longitudinal axis; the one or more projections being spaced from the peripheral surface of the substrate; and a peripheral flange extending between a peripheral side edge and the interface surface, the peripheral flange being inclined at an angle of between around 5 degrees to around 30 degrees to a plane substantially perpendicular to the plane through which the longitudinal axis extends and directed away from the plane substantially perpendicular to the plane through which the longitudinal axis extends in a second direction opposite the first direction; wherein the flange is spaced from the peripheral side edge by a shoulder portion, the shoulder portion extending a radial distance of between around 0.2 to around 0.8 mm from the peripheral side edge in a plane substantially perpendicular to the plane through which the longitudinal axis of the substrate extends. ### Claim 2 (depends on 1) The super hard construction of claim 1, wherein the peripheral flange is substantially concentric with the substrate. ### Claim 3 (depends on 1) The super hard construction of claim 1, wherein the thickness of the super hard material layer about the longitudinal axis of the substrate is substantially the same as the thickness of the super hard material layer at the peripheral surface. ### Claim 4 (depends on 1) The super hard construction of claim 1, wherein the super hard material layer comprises polycrystalline diamond. ### Claim 5 (depends on 1) The super hard construction of claim 1, wherein the shoulder portion extends a radial distance of between around 0.3 to around 0.5 mm from the peripheral side edge in the plane substantially perpendicular to the plane through which the longitudinal axis of the substrate extends. ### Claim 6 (depends on 1) The super hard construction of claim 1, wherein the interface surface of the substrate is a negative or reversal of the interface surface of the super hard material layer such that the two interface surfaces form a matching fit. ### Claim 7 (depends on 1) The super hard construction of claim 1, wherein the super hard construction is a cutter element. ### Claim 8 (depends on 1) The super hard construction of claim 1, wherein the projections are arranged such that there is reflective symmetry along a plane through the longitudinal axis. ### Claim 9 (depends on 1) The super hard construction of claim 1, the angle at which the peripheral flange is inclined to the plane substantially perpendicular to the plane through which the longitudinal axis extends is between around 5 degrees to around 20 degrees. ### Claim 10 (depends on 1) The super hard construction of claim 1, the angle at which the peripheral flange is inclined to the plane substantially perpendicular to the plane through which the longitudinal axis extends is between around 5 degrees to around 15 degrees. ### Claim 11 (depends on 1) The super hard construction of claim 1, the angle at which the peripheral flange is inclined to the plane substantially perpendicular to the plane through which the longitudinal axis extends is between around 5 degrees to around 10 degrees. ### Claim 12 (depends on 1) The super hard construction of claim 1, wherein the one or more projections are arranged in two arrays disposed in two concentric and substantially circular paths. ### Claim 13 (depends on 12) The super hard construction of claim 12, wherein the one or more projections of a first array are arranged staggered with the one or more projections of a second array. ### Claim 14 (depends on 1) The super hard construction of claim 1, wherein the interface surface is substantially planar and the one or more projections each have a non-parallel surface opposite the interface surface. ### Claim 15 (depends on 14) The super hard construction of claim 14, wherein each non-parallel surface of the one or more projections is not substantially parallel to a cutting face. ### Claim 16 (depends on 1) The super hard construction of claim 1, wherein the one or more projections are each trapezoidal in shape. ### Claim 17 (depends on 1) An earth boring drill bit comprising a body having the super hard construction of claim 1 mounted thereon as a cutter element.