# US 11,306,542 B2 · Thermally stable polycrystalline diamond and methods of making the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,306,542 B2 - Document ID: US11306542B2 - Status: Granted - Kind: B2 - Application number: 14/481,570 - Filed: 2014-09-09 - Published: 2015-03-12 - Granted: 2022-04-19 - Earliest claimed: 2013-09-11 - Assignees: Schlumberger Technology Corporation - Applicants: Smith International, Inc. - Inventors: Yahua Bao; Liang Zhao; J. Daniel Belnap; Zhijun Lin - Web page: https://patentgrep.com/patent/US11306542B2 ## CPC - B01J 3/062: {characterised by the composition of the materials to be processed} - B24D 3/04: and being essentially inorganic - B24D 3/10: for porous or cellular structure, e.g. for use with diamonds as abrasives - B24D 18/0009: {using moulds or presses} - B24D 99/005: {Segments of abrasive wheels} - E21B 10/567: with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts - E21B 10/5735: {Interface between the substrate and the cutting element} - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS - B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11) - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS ## Abstract A method of making a cutting element includes subjecting a mixture of diamond particles and a carbonate material to high-pressure high-temperature sintering conditions to form a sintered carbonate-polycrystalline diamond body having a diamond matrix of diamond grains bonded together and carbonates residing in the interstitial regions between the diamond grains, the carbonate material having a non-uniform distribution throughout the diamond matrix. The carbonate-polycrystalline diamond body is subjected to a controlled temperature, a controlled pressure condition or a combination thereof, to effect an at least partial decomposition of the carbonate material. ## Claims ### Claim 1 A method of making a cutting element, comprising: subjecting at least one layer comprising a premixture of diamond particles and a carbonate material throughout the at least one layer to high-pressure high-temperature sintering conditions, the at least one layer having a non-uniform distribution of diamond particles and carbonate material in the premixture through a thickness of the at least one layer, to form a sintered carbonate-polycrystalline diamond body having a diamond matrix of diamond grains bonded together and carbonates residing in the interstitial regions between the diamond grains, the carbonates having a non-uniform distribution throughout the diamond matrix such that a first region and a second region are formed; and subjecting the carbonate-polycrystalline diamond body further to a controlled temperature, a controlled pressure, or a combination thereof, to effect an at least partial decomposition of the carbonate material. ### Claim 2 (depends on 1) The method of claim 1, wherein partial decomposition of the carbonate material to metal oxides results in formation of channels distributed through the matrix. ### Claim 3 (depends on 2) The method of claim 2, wherein the channels formed after the decomposition of the carbonate material have a non-uniform distribution. ### Claim 4 (depends on 1) The method of claim 1, wherein the carbonate material comprises SiO2 as an impurity. ### Claim 5 (depends on 4) The method of claim 4, wherein during the partial decomposition of the carbonate material to at least one metal oxide, the at least one metal oxide reacts with SiO2 present as an impurity in the carbonate material, thereby resulting in the formation of at least one metal silicate. ### Claim 6 (depends on 1) The method of claim 1, wherein the carbonate material comprises an alkaline earth metal carbonate. ### Claim 7 (depends on 6) The method of claim 6, wherein the carbonate material comprises at least one of magnesium carbonate or calcium carbonate. ### Claim 8 (depends on 1) The method of claim 1, wherein a height of the carbonate-polycrystalline diamond high-pressure high-temperature sintered body is smaller than a diameter of the carbonate-polycrystalline diamond high-pressure high-temperature sintered body. ### Claim 9 (depends on 1) The method of claim 1, wherein the first region of the carbonate-based polycrystalline diamond body comprises from about 0 to 5 percent by weight of the carbonate material. ### Claim 10 (depends on 1) The method of claim 1, wherein the second region of the carbonate-based polycrystalline diamond body comprises from about 2 to 9 percent by weight of the carbonate material. ### Claim 11 A method of making a cutting element, comprising: subjecting at least one layer comprising a premixture of diamond particles and a carbonate material throughout the at least one layer to high-pressure high-temperature sintering conditions, the at least one layer having a non-uniform distribution of diamond particles and carbonate material in the premixture through an area of the layer, to form a sintered carbonate-polycrystalline diamond body having a diamond matrix of diamond grains bonded together and carbonates residing in the interstitial regions between the diamond grains, the carbonates having a non-uniform distribution throughout the diamond matrix such that a first region and a second region are formed; and subjecting the carbonate-polycrystalline diamond body further to a controlled temperature, a controlled pressure, or a combination thereof, to effect an at least partial decomposition of the carbonate material. ### Claim 12 (depends on 11) The method of claim 11, wherein partial decomposition of the carbonate material to metal oxides results in formation of channels distributed through the matrix. ### Claim 13 (depends on 12) The method of claim 12, wherein the channels formed after the decomposition of the carbonate material have a non-uniform distribution. ### Claim 14 (depends on 11) The method of claim 11, wherein the carbonate material comprises SiO2 as an impurity. ### Claim 15 (depends on 14) The method of claim 14, wherein during the partial decomposition of the carbonate material to at least one metal oxide, the at least one metal oxide reacts with SiO2 present as an impurity in the carbonate material, thereby resulting in the formation of at least one metal silicate. ### Claim 16 (depends on 11) The method of claim 11, wherein the carbonate material comprises an alkaline earth metal carbonate. ### Claim 17 (depends on 16) The method of claim 16, wherein the carbonate material comprises at least one of magnesium carbonate or calcium carbonate. ### Claim 18 (depends on 11) The method of claim 11, wherein a height of the carbonate-polycrystalline diamond high-pressure high-temperature sintered body is smaller than a diameter of the carbonate-polycrystalline diamond high-pressure high-temperature sintered body. ### Claim 19 (depends on 11) The method of claim 11, wherein the first region of the carbonate-based polycrystalline diamond body comprises from about 0 to 5 percent by weight of the carbonate material. ### Claim 20 (depends on 11) The method of claim 11, wherein the second region of the carbonate-based polycrystalline diamond body comprises from about 2 to 9 percent by weight of the carbonate material. ### Claim 21 (depends on 1) The method of claim 1, wherein the carbonate-polycrystalline diamond body comprises the first region forming and proximate a circumferential cutting edge and the second region extending axially, radially or a combination of both away from the first region, wherein the second region has a higher concentration of carbonates than the first region, and the first region extending a height ranging from 15 to 50% of a circumferential side surface. ### Claim 22 (depends on 11) The method of claim 11, wherein the second region has a higher concentration of carbonates, and the first region extending at least 30% of the distance between a circumferential side surface and a radial center of the body. ### Claim 23 (depends on 1) The method of claim 1, wherein the sintered carbonate-polycrystalline diamond body has a first exposed face and a second exposed face, opposite the first exposed face, wherein the first region extends to the first exposed face and the second region extends to the second exposed face. ### Claim 24 (depends on 11) The method of claim 11, wherein the sintered carbonate-polycrystalline diamond body has a first exposed face, a second exposed face opposite the first exposed face, and circumferential side surface extending between the first exposed face and the second exposed face, wherein the first region extends to the circumferential side surface, and the second region is at a radial center of the body.