# US 12,005,548 B2 · Methods of cleaning and/or neutralizing an at least partially leached polycrystalline diamond body and resulting polycrystalline diamond compacts > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,005,548 B2 - Document ID: US12005548B2 - Status: Granted - Kind: B2 - Application number: 18/097,398 - Filed: 2023-01-16 - Published: 2023-05-18 - Granted: 2024-06-11 - Earliest claimed: 2014-10-10 - Assignees: US Synthetic Corporation - Applicants: US Synthetic Corporation - Inventors: Julie Ann Kidd; Heather Marie Schaefer; Jason K. Wiggins; Cody Frisby - Web page: https://patentgrep.com/patent/US12005548B2 ## CPC - B24D 3/10: for porous or cellular structure, e.g. for use with diamonds as abrasives - B24D 99/005: {Segments of abrasive wheels} - E21B 10/42: Rotary drag type drill bits with teeth, blades or like cutting elements, e.g. fork-type bits, fish tail bits (characterised by wear resisting parts E21B10/46; by conduits or nozzles for drilling fluid E21B10/60; by detachable or adjustable parts E21B10/62) - E21B 10/567: with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts - 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 Embodiments relate to polycrystalline diamond compacts (“PDCs”), methods of fabricating PDCs, and applications for such PDCs. In an embodiment, a method includes providing an at least partially leached polycrystalline diamond (“PCD”) body. A residual amount of acid may remain in and/or on the at least partially leached PCD body. The method further includes removing and/or neutralizing at least some of the residual amount of acid from the at least partially leached PCD body and/or a substrate to which the at least partially leached PCD body is attached. ## Claims ### Claim 1 A polycrystalline diamond compact, comprising: a substrate; and a polycrystalline diamond body including an interfacial surface bonded to the substrate and a working surface generally opposing the interfacial surface, the polycrystalline diamond body including a first leached volume extending inwardly from the working surface and a second volume at least proximate to the substrate that includes at least one interstitial material therein, wherein the first leached volume is substantially free of a residual amount of acid, wherein the polycrystalline diamond body exhibits a concentration of anions of one of 2 parts per million to 3 parts per million or 1 part per million to 2 parts per million, and wherein the polycrystalline diamond body exhibits a pH of about 5 to about 9. ### Claim 2 (depends on 1) The polycrystalline diamond compact of claim 1, wherein the residual amount of acid includes at least one of hydrochloric acid, nitric acid, phosphoric acid, acetic acid, or hydrofluoric acid. ### Claim 3 (depends on 1) The polycrystalline diamond compact of claim 1, wherein the polycrystalline diamond body exhibits the concentration of anions comprising 1 part per million to 2 parts per million. ### Claim 4 (depends on 1) The polycrystalline diamond compact of claim 1, wherein the first leached volume has been subjected to a neutralization process after a leaching of the first leached volume, and wherein the pH and/or the concentration of anions of the polycrystalline diamond body has been monitored during the neutralization process to provide the pH and/or the concentration of anions. ### Claim 5 (depends on 1) The polycrystalline diamond compact of claim 1, wherein the polycrystalline diamond body exhibits a pH of about 6.5 to about 7.5. ### Claim 6 (depends on 1) The polycrystalline diamond compact of claim 1, wherein the first leached volume has been subjected to a neutralization process after a leaching of the first leached volume. ### Claim 7 (depends on 6) The polycrystalline diamond compact of claim 6, wherein the first leached volume has been subjected to the neutralization process after the leaching of the first leached volume, the neutralization process comprising a thermal process to remove at least some of the residual amount of acid. ### Claim 8 (depends on 6) The polycrystalline diamond compact of claim 6, wherein the first leached volume has been subjected to the neutralization process after the leaching of the first leached volume, the neutralization process comprising a rinsing process to remove at least some of the residual amount of acid. ### Claim 9 (depends on 6) The polycrystalline diamond compact of claim 6, wherein the first leached volume has been subjected to the neutralization process after the leaching of the first leached volume, the neutralization process comprising exposing the first leached volume to a base material to remove at least some of the residual amount of acid. ### Claim 10 (depends on 6) The polycrystalline diamond compact of claim 6, wherein the first leached volume has been subjected to the neutralization process after the leaching of the first leached volume, the neutralization process comprising a pressurizing process or a vacuum process to remove at least some of the residual amount of acid. ### Claim 11 A polycrystalline diamond compact, comprising: a polycrystalline diamond body comprising: a first leached volume extending inwardly from a working surface of polycrystalline diamond body; and a second volume configured to be located proximate to a substrate that includes at least one interstitial material therein; wherein the first leached volume is substantially free of a residual amount of acid; wherein the first leached volume has been subjected to a residual acid removal and/or neutralization process after a leaching of the first leached volume; and wherein the polycrystalline diamond body exhibits a concentration of anions of 1 part per million to 3 parts per million. ### Claim 12 (depends on 11) The polycrystalline diamond compact of claim 11, wherein the concentration of anions of the polycrystalline diamond body has been monitored during the residual acid removal and/or neutralization process to provide the concentration of anions 1 part per million to 3 parts per million. ### Claim 13 (depends on 11) The polycrystalline diamond compact of claim 11, wherein the polycrystalline diamond body exhibits a concentration of anions between 1 parts per million and 2 parts per million. ### Claim 14 (depends on 11) The polycrystalline diamond compact of claim 11, wherein the polycrystalline diamond body exhibits a pH of about 5 to about 9. ### Claim 15 A polycrystalline diamond compact produced by a process comprising: providing a polycrystalline diamond body including a plurality of diamond grains defining a plurality of interstitial regions having at least one interstitial material occupying at least a portion of the plurality of interstitial regions; at least partially leaching at least some of the at least one interstitial material from the polycrystalline diamond body to form an at least partially leached polycrystalline diamond body including a residual amount of acid; and removing and/or neutralizing at least a portion of the residual amount of acid to remove at least some of the residual amount of acid in the at least partially leached polycrystalline diamond body, wherein the polycrystalline diamond body exhibits a concentration of anions greater than zero and less than 3 parts per million. ### Claim 16 (depends on 15) The polycrystalline diamond compact of claim 15, wherein the process further comprises monitoring the polycrystalline diamond body during the removing and/or neutralizing to produce the polycrystalline diamond body exhibiting the concentration of anions less than 3 parts per million. ### Claim 17 (depends on 15) The polycrystalline diamond compact of claim 15, wherein the process further comprises monitoring the polycrystalline diamond body during the removing and/or neutralizing to produce the polycrystalline diamond body exhibiting a pH of about 5 to about 9. ### Claim 18 (depends on 15) The polycrystalline diamond compact of claim 15, wherein the process further comprises, after removing and/or neutralizing the at least a portion of the residual amount of acid, subjecting the at least partially leached polycrystalline diamond body to another process to remove and/or neutralize an additional portion of the residual amount of acid. ### Claim 19 (depends on 1) A rotary drill bit, comprising: a bit body including a leading end structure configured to facilitate drilling a subterranean formation; and a plurality of cutting elements affixed to the bit body, at least one of the plurality of cutting elements including the polycrystalline diamond compact of claim 1.