Methods of forming and using three-dimensional structures with open pore networks to form sintered polycrystalline compacts, and compacts formed by such methods

Abstract

A method of forming a hard polycrystalline compact, such as a polycrystalline diamond compact, for use in an earth-boring tool includes forming a three-dimensional structure that has an open pore network. The three-dimensional structure includes at least one of a metal, metal alloy, or diamond grains. Particulate material is disposed within the three-dimensional structure. The particulate material also includes at least one of a metal, metal alloy, or diamond grains. The three-dimensional structure with the particulate material therein is then subjected to a high-temperature, high-pressure (HTHP) sintering process to form the hard polycrystalline compact.

Dependencies are inferred from the claim text.