Complex polycrystalline diamond compact

Abstract

A new type of polycrystalline diamond composite drill bit insert comprising a polycrystalline diamond layer and a cemented carbide matrix; the polycrystalline diamond having a top surface formed at two different heights. The polycrystalline diamond composite comprises at least one upper surface that is higher than the top surface of the primary layer of the polycrystalline diamond composite; where the primary layer forms an interface with the cemented carbide insert and the upper layer is formed on, or above, the primary layer. The cutting profile, or cutting area, of the upper layer is reduced from the cutting profile of the primary layer. The surface shape or area of the upper polycrystalline diamond is different from that of the lower primary surface layer and can form more than one vertex. The variable surface heights, and the reduced cutting profile of the upper layer of polycrystalline diamond composite, allows for the insert to cut or plough through rock or concrete more easily and efficiently, than a conventional, single layer polycrystalline diamond compact.

Dependencies are inferred from the claim text.