# US 8,784,767 B2 · Polycrystalline diamond and method of manufacturing the same

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- Number: US 8,784,767 B2
- Document ID: US8784767B2
- Status: Granted
- Kind: B2
- Application number: 13/517,921
- Filed: 2011-08-10
- Published: 2012-10-11
- Granted: 2014-07-22
- Earliest claimed: 2010-08-19
- Assignees: Sumitomo Electric Industries, Ltd.
- Applicants: Hitoshi Sumiya; Katsuko Yamamoto; Takeshi Sato; Keiko Arimoto
- Inventors: Hitoshi Sumiya; Katsuko Yamamoto; Takeshi Sato; Keiko Arimoto
- Web page: https://patentgrep.com/patent/US8784767B2

## CPC

- B01J 3/062: {characterised by the composition of the materials to be processed}
- B24B 53/12: Dressing tools; Holders therefor
- B24D 3/00: Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- C01B 32/25: Diamond
- C01B 32/26: Preparation (by using ultra-high pressure B01J3/06; by crystal growth C30B29/04)
- C04B 35/528: obtained from carbonaceous particles with or without other non-organic components
- C04B 35/645: Pressure sintering
- B01J 2203/061: Graphite
- B01J 2203/0655: Diamond
- B01J 2203/068: Crystal growth
- B01J 2203/0685: Crystal sintering
- B23B 2226/315: polycrystalline [PCD]
- B23C 2226/315: polycrystalline [PCD]
- C04B 2235/425: Graphite
- C04B 2235/427: Diamond
- C04B 2235/5445: submicron sized, i.e. from 0,1 to 1 micron
- C04B 2235/762: Cubic symmetry, e.g. beta-SiC
- C04B 2235/96: Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- C04B 2235/963: Surface properties, e.g. surface roughness
- Y10T 83/0215: Including use of rotary scoring blade
- Y10T 83/0333: Scoring
- Y10T 83/0385: Rotary scoring blade
- Y10T 83/929: Tool or tool with support
- Y10T 83/9372: Rotatable type
- Y10T 428/24975: No layer or component greater than 5 mils thick
- Y10T 428/265: 1 mil or less
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B24B: MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING (grinding of gear teeth B23F, of screw-threads B23G1/36; by electro-erosion B23H; abrasive or related blasting B24C; tools for grinding, buffing or sharpening B24D; polishing compositions C09G1/00; abrasives C09K3/14; electrolytic etching or polishing C25F3/00; grinding arrangements for use on assembled railway tracks E01B31/17); DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- 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)
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B23B: TURNING; BORING (arrangements for copying or controlling B23Q)
- B23C: MILLING (broaching B23D; broach-milling in making gears B23F; arrangement for copying or controlling B23Q)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Polycrystalline diamond includes cubic diamond and hexagonal diamond, and a ratio of X-ray diffraction peak intensity of a (100) plane of the hexagonal diamond to X-ray diffraction peak intensity for a (111) plane of cubic diamond is not lower than 0.01%. In addition, a present method of manufacturing polycrystalline diamond includes the steps of preparing a non-diamond carbon material having a degree of graphitization not higher than 0.58 and directly converting the non-diamond carbon material to cubic diamond and hexagonal diamond and sintering the non-diamond carbon material, without adding any of a sintering agent and a binder, under pressure and temperature conditions at which diamond is thermodynamically stable.

## Claims

### Claim 1

Polycrystalline diamond, comprising:
cubic diamond; and
hexagonal diamond,
a ratio of X-ray diffraction peak intensity of a (100) plane of said hexagonal diamond to X-ray diffraction peak intensity for a (111) plane of said cubic diamond being not lower than 0.01% and not higher than 0.5%.

### Claim 2 (depends on 1)

The polycrystalline diamond according to claim 1, having rupture strength in a temperature range not lower than 800° C. and not higher than 1200° C., wherein the rupture strength in the temperature range not lower than 800° C. and not higher than 1200° C. is not lower than 90% of rupture strength at room temperature.

### Claim 3 (depends on 2)

The polycrystalline diamond according to claim 2, having rupture strength in a temperature range not lower than 1000° C. and not higher than 1200° C., wherein the rupture strength in the temperature range not lower than 1000° C. and not higher than 1200° C. is higher than the rupture strength at room temperature.

### Claim 4 (depends on 1)

The polycrystalline diamond according to claim 1, having hardness at 800° C., not lower than 80% of hardness at room temperature.

### Claim 5 (depends on 1)

A scribe tool, comprising a tip end portion composed of the polycrystalline diamond according to claim 1,
said tip end portion having three or four points.

### Claim 6 (depends on 1)

A scribing wheel, comprising a wheel composed of the polycrystalline diamond according to claim 1.

### Claim 7 (depends on 1)

A dresser, comprising a tip end portion composed of the polycrystalline diamond according to claim 1.

### Claim 8 (depends on 1)

A wire drawing die, comprising the polycrystalline diamond according to claim 1.

### Claim 9 (depends on 1)

A nozzle, comprising an orifice composed of the polycrystalline diamond according to claim 1.

### Claim 10 (depends on 1)

A grinding tool, comprising a grinding edge composed of the polycrystalline diamond according to claim 1.

### Claim 11 (depends on 1)

A cutting tool, comprising a cutting edge composed of the polycrystalline diamond according to claim 1.

### Claim 12 (depends on 1)

A rotary cutting tool, comprising a cutting edge composed of the polycrystalline diamond according to claim 1.

### Claim 13 (depends on 1)

A wire guide, composed of the polycrystalline diamond according to claim 1.

### Claim 14 (depends on 1)

A method of manufacturing polycrystalline diamond according to claim 1, comprising the steps of: preparing a non-diamond carbon material having a degree of graphitization not higher than 0.58; and directly converting said non-diamond carbon material into cubic diamond and hexagonal diamond and sintering the non-diamond carbon material, without adding any of a sintering agent and a binder, under pressure and temperature conditions at which diamond is thermodynamically stable.