Use of fibers during hthp sintering and their subsequent attachment to substrate

Abstract

A fiber-reinforced cutting element for a drill bit and method of manufacturing same is disclosed. A plurality of fibers are formed in and embedded between the PCD table and the attached substrate. The fibers enhance the thermo-mechanical integrity of the cutting element as well as its wear and abrasion resistance and also help to minimize the failure of the bond between the PCD table and the substrate. The fibers may be coated with a ceramic material to help withstand the high temperatures during the HTHP sintering process used to form the PCD table. The PCD table is leached following the HTHP press cycle thereby partially exposing the fibers. The PCD table with partially exposed fibers is then bonded to a substrate through an infiltration, hot pressing or sintering process. A binder may optionally be used to enhance the binding of the substrate to the PCD table.

Dependencies are inferred from the claim text.