# US 9,533,398 B2 · Positive relief forming of polycrystalline diamond structures and resulting cutting tools

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- Number: US 9,533,398 B2
- Document ID: US9533398B2
- Status: Granted
- Kind: B2
- Application number: 14/463,587
- Filed: 2014-08-19
- Published: 2016-02-25
- Granted: 2017-01-03
- Earliest claimed: 2014-08-19
- Assignees: US Synthetic Corporation
- Applicants: US Synthetic Corporation
- Inventors: David P. Miess
- Web page: https://patentgrep.com/patent/US9533398B2

## CPC

- B24D 18/0009: {using moulds or presses}
- B22F 3/14: simultaneously
- B22F 5/085: {with helical contours}
- B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)}
- B23C 5/10: Shank-type cutters, i.e. with an integral shaft
- B23G 5/06: Taps (chucks therefor B23B31/00)
- B24D 99/005: {Segments of abrasive wheels}
- C22C 26/00: Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes}
- E21B 10/573: characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element
- B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware}
- B23B 51/00: Tools for drilling machines
- B23B 2226/315: polycrystalline [PCD]
- B23C 2226/315: polycrystalline [PCD]
- B23G 2225/165: Polycrystalline diamond
- 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)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B23C: MILLING (broaching B23D; broach-milling in making gears B23F; arrangement for copying or controlling B23Q)
- B23G: THREAD CUTTING; WORKING OF SCREWS, BOLT HEADS, OR NUTS, IN CONJUNCTION THEREWITH (making helical grooves by turning B23B5/48, by milling B23C3/32, by forging, pressing, or hammering B21K1/56, by grinding B24B19/02; arrangements for copying or controlling B23Q; thread-forming by corrugating tubes B21D15/04, by rolling B21H3/02)
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- B23B: TURNING; BORING (arrangements for copying or controlling B23Q)

## Abstract

Embodiments of the invention relate to methods of making articles having portions of polycrystalline diamond bonded to a surface of a substrate and polycrystalline diamond compacts made using the same. In an embodiment, a molding technique is disclosed for forming cutting tools comprising polycrystalline diamond portions bonded to the outer surface of a substrate.

## Claims

### Claim 1

A method of making a polycrystalline diamond (“PCD”) structure, the method comprising:
providing a substrate having a surface;
positioning at least one diamond material flute volume including at least one diamond material tube including diamond particles, the at least one diamond material tube in contact with a portion of the surface of the substrate; and
subjecting the substrate and the at least one diamond material flute volume to a high-pressure/high-temperature (“HPHT”) process effective to sinter the diamond particles to form a PCD flute volume and bond the PCD flute volume.

### Claim 2 (depends on 1)

The method of claim 1, wherein the at least one diamond material tube includes a cobalt-containing tube.

### Claim 3 (depends on 1)

The method of claim 1, further comprising attaching at least one portion of the PCD flute volume to the substrate using at least one of induction heating, laser tacking, adhesive, or a binder material.

### Claim 4 (depends on 1)

The method of claim 1, wherein the at least one diamond material flute volume includes a plurality of shear compacted diamond particles.

### Claim 5 (depends on 1)

The method of claim 1, wherein positioning the at least one diamond material flute volume includes positioning at least one preformed diamond volume generally helically around at least a portion of the substrate.

### Claim 6 (depends on 1)

The method of claim 1, further comprising:
removing mold material from around the PCD flute volume and the substrate;
processing the PCD flute volume to a final dimension using at least one of milling, grinding, lapping, electro-discharge machining, or lasing; and
at least partially leaching the PCD flute volume to a selected depth therein.