公开(公告)号：US20120222363A1

公开(公告)日：2012-09-06

申请号：US13040861

申请日：2011-03-04

申请人： Anthony A. DiGiovanni ,  Nicholas J. Lyons ,  Derek L. Nelms ,  Danny E. Scott

发明人： Anthony A. DiGiovanni ,  Nicholas J. Lyons ,  Derek L. Nelms ,  Danny E. Scott

IPC分类号： B01J3/06 ,  B24B3/00

CPC分类号： E21B10/5735 ,  B22F7/08 ,  B22F2005/001 ,  B24D3/14 ,  B24D18/0009 ,  B24D99/005 ,  C04B35/52 ,  C04B35/58 ,  C04B35/583 ,  C04B35/5831 ,  C04B35/6303 ,  C04B35/638 ,  C04B35/645 ,  C04B37/001 ,  C04B37/021 ,  C04B2235/3856 ,  C04B2235/386 ,  C04B2235/405 ,  C04B2235/427 ,  C04B2235/602 ,  C04B2235/608 ,  C04B2235/61 ,  C04B2235/661 ,  C04B2237/36 ,  C04B2237/361 ,  C04B2237/363 ,  C04B2237/401 ,  C22C26/00 ,  C22C2204/00 ,  E21B10/50 ,  E21B10/55 ,  E21B10/5673 ,  F16C33/043

摘要： Methods of forming a polycrystalline table comprise disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles is partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate is removed from the brown polycrystalline table and catalyst material is removed from the brown polycrystalline table. The brown polycrystalline table is then fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate comprising a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table comprises a plurality of interbonded grains of a superabrasive material.

摘要翻译： 形成多晶台的方法包括在模具中设置包括超硬磨料材料的多个颗粒，包含硬质材料的底物和催化剂材料。 多个颗粒在催化剂材料的存在下被部分烧结，以形成一个棕色多晶表，其具有附着在基底端部的第一渗透性。 从棕色多晶表中除去底物，从棕色多晶表中除去催化剂材料。 然后将棕色多晶表完全烧结以形成具有减小的第二渗透性的多晶台。 在将多晶台附着到包括基本上完全浸出的棕色多晶表的基板的过程中形成的中间结构。 基本上完全浸出的棕色多晶表包括多个超级磨料材料的接合晶粒。

公开(公告)号：US09243452B2

公开(公告)日：2016-01-26

申请号：US13477905

申请日：2012-05-22

申请人： Anthony A. DiGiovanni ,  Yavuz Kadioglu ,  Danny E. Scott ,  Matthew J. Meiners ,  Rudolf Carl Pessier ,  Nicholas J. Lyons ,  Clement D. van der Riet ,  Donald Royceton Herschell ,  Cornelis Roelof Jonker ,  Roger William Nigel Nilen ,  Gerard Peter Dolan

发明人： Anthony A. DiGiovanni ,  Yavuz Kadioglu ,  Danny E. Scott ,  Matthew J. Meiners ,  Rudolf Carl Pessier ,  Nicholas J. Lyons ,  Clement D. van der Riet ,  Donald Royceton Herschell ,  Cornelis Roelof Jonker ,  Roger William Nigel Nilen ,  Gerard Peter Dolan

IPC分类号： E21B10/567 ,  E21B7/00 ,  E21B10/573 ,  E21B10/60 ,  B22F5/00 ,  B23P15/28

CPC分类号： E21B10/5673 ,  B22F2005/001 ,  B23P15/28 ,  B24D18/00 ,  E21B7/00 ,  E21B10/573 ,  E21B10/60

摘要： Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body.

摘要翻译： 用于钻孔工具的切割元件包括在一体积的超级磨料材料的切割面中的一个或多个凹部和/或一个或多个突起。 超研磨材料可以设置在基材上。 切割面可以是非平面的。 凹部和/或突起可以包括一个或多个线性段。 凹部和/或突起可以包括彼此横向隔离的离散特征。 凹部和/或突起可以具有螺旋形构造。 超级磨料材料的体积可以包括多个薄层，其中至少两个可以在至少一个特征上不同。 形成切割元件的方法包括在一定体积的超级磨料材料的切割面中和/或之上形成这样的凹部和/或突起。 钻孔工具包括这样的切割元件，并且形成钻孔工具的方法包括将这样的切割元件附接到工具主体。

公开(公告)号：US10099347B2

公开(公告)日：2018-10-16

申请号：US13040921

申请日：2011-03-04

申请人： Nicholas J. Lyons ,  Danny E. Scott ,  Anthony A. DiGiovanni ,  Derek L. Nelms

发明人： Nicholas J. Lyons ,  Danny E. Scott ,  Anthony A. DiGiovanni ,  Derek L. Nelms

IPC分类号： B24D3/00 ,  B24B1/00 ,  B24D18/00 ,  B24D99/00

摘要： Polycrystalline elements include a substrate and a polycrystalline table attached to an end of the substrate. The polycrystalline table includes a first region of superabrasive material having a first permeability and at least a second region of superabrasive material having a second, lesser permeability, the at least a second region being interposed between the substrate and the first region. Methods of forming a polycrystalline element involve attaching a polycrystalline table including a first region of superabrasive material having a first permeability and at least a second region of superabrasive material having a second, lesser permeability to an end of a substrate, the at least a second region being interposed between the first region and the substrate. Catalyst material is removed from at least the first region of the polycrystalline table.

公开(公告)号：US20130068538A1

公开(公告)日：2013-03-21

申请号：US13477905

申请日：2012-05-22

申请人： Anthony A. DiGiovanni ,  Yavuz Kadioglu ,  Danny E. Scott ,  Matthew J. Meiners ,  Rudolf Carl Pessier ,  Nicholas J. Lyons ,  Clement D. van der Riet ,  Donald Royceton Herschell ,  Cornelis Roelof Jonker ,  Roger William Nigel Nilen ,  Gerard Peter Dolan

发明人： Anthony A. DiGiovanni ,  Yavuz Kadioglu ,  Danny E. Scott ,  Matthew J. Meiners ,  Rudolf Carl Pessier ,  Nicholas J. Lyons ,  Clement D. van der Riet ,  Donald Royceton Herschell ,  Cornelis Roelof Jonker ,  Roger William Nigel Nilen ,  Gerard Peter Dolan

IPC分类号： E21B10/573

CPC分类号： E21B10/5673 ,  B22F2005/001 ,  B23P15/28 ,  B24D18/00 ,  E21B7/00 ,  E21B10/573 ,  E21B10/60

摘要： Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body.

摘要翻译： 用于钻孔工具的切割元件包括在一定体积的超级磨料材料的切割面中的一个或多个凹部和/或一个或多个突起。 超研磨材料可以设置在基材上。 切割面可以是非平面的。 凹部和/或突起可以包括一个或多个线性段。 凹部和/或突起可以包括彼此横向隔离的离散特征。 凹部和/或突起可以具有螺旋形构造。 超级磨料材料的体积可以包括多个薄层，其中至少两个可以在至少一个特征上不同。 形成切割元件的方法包括在一定体积的超级磨料材料的切割面中和/或之上形成这种凹陷和/或突起。 钻孔工具包括这种切割元件，并且形成钻孔工具的方法包括将这样的切割元件附接到工具主体。

公开(公告)号：US08292006B2

公开(公告)日：2012-10-23

申请号：US12508440

申请日：2009-07-23

申请人： Danny E. Scott ,  Nicholas J. Lyons

发明人： Danny E. Scott ,  Nicholas J. Lyons

IPC分类号： E21B10/46

CPC分类号： E21B10/56 ,  B22F2999/00 ,  B24D3/10 ,  C22C26/00 ,  C22C2204/00 ,  B22F2207/03

摘要： Cutting elements for use in earth-boring applications include a substrate, a transition layer, and a working layer. The transition layer and the working layer comprise a continuous matrix phase and a discontinuous diamond phase dispersed throughout the matrix phase. The concentration of diamond in the working layer is higher than in the transition layer. Earth-boring tools include at least one such cutting element. Methods of making cutting elements and earth-boring tools include mixing diamond crystals with matrix particles to form a mixture. The mixture is formulated in such a manner as cause the diamond crystals to comprise about 50% or more by volume of the solid matter in the mixture. The mixture is sintered to form a working layer of a cutting element that is at least substantially free of polycrystalline diamond material and that includes the diamond crystals dispersed within a continuous matrix phase formed from the matrix particles.

摘要翻译： 用于镗孔应用的切割元件包括基底，过渡层和工作层。 过渡层和工作层包括分散在整个基质相中的连续的基质相和不连续的金刚石相。 工作层中金刚石的浓度高于过渡层。 钻孔工具包括至少一个这样的切割元件。 制造切割元件和钻孔工具的方法包括将金刚石晶体与基质颗粒混合以形成混合物。 混合物配制成使金刚石晶体占混合物中固体物质的约50％或更多的体积。 混合物被烧结以形成至少基本上不含多晶金刚石材料的切割元件的工作层，并且包括分散在由基质颗粒形成的连续基质相中的金刚石晶体。

公开(公告)号：US20110017517A1

公开(公告)日：2011-01-27

申请号：US12508440

申请日：2009-07-23

申请人： Danny E. Scott ,  Nicholas J. Lyons

发明人： Danny E. Scott ,  Nicholas J. Lyons

IPC分类号： E21B10/567 ,  B24D3/04 ,  B24D3/10 ,  E21B10/42 ,  E21B10/16 ,  E21B10/52 ,  E21B10/55

CPC分类号： E21B10/56 ,  B22F2999/00 ,  B24D3/10 ,  C22C26/00 ,  C22C2204/00 ,  B22F2207/03

摘要： Cutting elements for use in earth-boring applications include a substrate, a transition layer, and a working layer. The transition layer and the working layer comprise a continuous matrix phase and a discontinuous diamond phase dispersed throughout the matrix phase. The concentration of diamond in the working layer is higher than in the transition layer. Earth-boring tools include at least one such cutting element. Methods of making cutting elements and earth-boring tools include mixing diamond crystals with matrix particles to form a mixture. The mixture is formulated in such a manner as cause the diamond crystals to comprise about 50% or more by volume of the solid matter in the mixture. The mixture is sintered to form a working layer of a cutting element that is at least substantially free of polycrystalline diamond material and that includes the diamond crystals dispersed within a continuous matrix phase formed from the matrix particles.

摘要翻译： 用于镗孔应用的切割元件包括基底，过渡层和工作层。 过渡层和工作层包括分散在整个基质相中的连续的基质相和不连续的金刚石相。 工作层中金刚石的浓度高于过渡层。 钻孔工具包括至少一个这样的切割元件。 制造切割元件和钻孔工具的方法包括将金刚石晶体与基质颗粒混合以形成混合物。 混合物配制成使金刚石晶体占混合物中固体物质的约50％或更多的体积。 混合物被烧结以形成至少基本上不含多晶金刚石材料的切割元件的工作层，并且包括分散在由基质颗粒形成的连续基质相中的金刚石晶体。

公开(公告)号：US09074435B2

公开(公告)日：2015-07-07

申请号：US13098123

申请日：2011-04-29

申请人： Danny E. Scott ,  Nicholas J. Lyons ,  Juan Miguel Bilen ,  Oliver Matthews ,  Rudolf Carl Pessier

发明人： Danny E. Scott ,  Nicholas J. Lyons ,  Juan Miguel Bilen ,  Oliver Matthews ,  Rudolf Carl Pessier

IPC分类号： E21B10/567 ,  E21B10/46 ,  E21B10/42

CPC分类号： E21B10/55 ,  E21B10/42 ,  E21B10/46 ,  E21B10/5673

摘要： Cutting elements include a volume of superabrasive material. The volume of superabrasive material comprises a front-cutting surface, an end-cutting surface, a cutting edge, and lateral side surfaces extending between and intersecting each of the front-cutting surface and the end-cutting surface. An earth-boring tool may comprise a bit body and at least one cutting element attached to the bit body. Methods of forming cutting elements comprise forming a volume of superabrasive material comprising forming a front-cutting surface, an end-cutting surface, a cutting edge, and lateral side surfaces extending between and intersecting each of the front-cutting surface and the end-cutting surface. Methods of forming earth-boring tools comprise forming a cutting element and attaching the cutting element to an earth-boring tool.

摘要翻译： 切割元件包括一定量的超级磨料。 超硬材料的体积包括前切割表面，端切割表面，切割边缘和在每个前切割表面和端切割表面之间延伸并在其之间交叉的横向侧表面。 钻孔工具可以包括钻头体和附接到钻头体的至少一个切割元件。 形成切割元件的方法包括形成一定体积的超级磨料，包括形成前切割表面，端切割表面，切割边缘以及在每个前切割表面和末端切割之间延伸并与之相交的横向侧表面 表面。 形成钻孔工具的方法包括形成切割元件并将切割元件附接到钻孔工具。

公开(公告)号：US08505634B2

公开(公告)日：2013-08-13

申请号：US12793396

申请日：2010-06-03

申请人： Nicholas J. Lyons ,  Danny E. Scott ,  Rudolf Carl Pessier ,  David Gavia ,  Juan Miguel Bilen

发明人： Nicholas J. Lyons ,  Danny E. Scott ,  Rudolf Carl Pessier ,  David Gavia ,  Juan Miguel Bilen

IPC分类号： E21B10/43

CPC分类号： E21B10/55 ,  E21B10/43 ,  E21B10/54

摘要： Earth-boring tools include combinations of shearing cutting elements and gouging cutting elements on a blade of the earth-boring tools. In some embodiments, a gouging cutting element may be disposed adjacent to a shearing cutting element on a blade of an earth-boring tool. Methods of forming earth-boring tools include providing such combination of at least one shearing cutting element and at least one gouging cutting element on a blade of an earth-boring tool.

摘要翻译： 钻孔工具包括剪切元件和钻孔刀具刀片上的气刨切割元件的组合。 在一些实施例中，气蚀切割元件可以布置成与钻孔工具的刀片上的剪切切割元件相邻。 形成钻孔工具的方法包括在钻孔工具的刀片上提供至少一个剪切切割元件和至少一个气刨切割元件的组合。

公开(公告)号：US20120056022A1

公开(公告)日：2012-03-08

申请号：US13297040

申请日：2011-11-15

申请人： Nicholas J. Lyons ,  Danny E. Scott

发明人： Nicholas J. Lyons ,  Danny E. Scott

IPC分类号： B02C11/08 ,  B23K35/22

CPC分类号： E21B10/55 ,  B22F2005/001 ,  B23K35/0261 ,  B23K35/24 ,  B23K35/36 ,  B23K35/365 ,  B24D3/10 ,  C22C26/00 ,  E21B10/42 ,  E21B10/46 ,  E21B10/50 ,  E21B10/54 ,  Y10T428/25

摘要： Hardfacing materials include particles of polycrystalline diamond (PCD) material embedded within a matrix material. The PCD particles comprise a plurality of inter-bonded diamond grains. Material compositions and structures used to apply a hardfacing material to an earth-boring tool (e.g., welding rods) include PCD particles. Earth-boring tools include a hardfacing material comprising PCD particles embedded within a matrix material on at least a portion of a surface of a body of the tools. Methods of forming a hardfacing material include subjecting diamond grains to elevated temperatures and pressures to diamond-to-diamond bonds between the diamond grains and form a PCD material. The PCD material is broken down to form PCD particles that include a plurality of inter-bonded diamond grains. Methods of hardfacing tools include bonding PCD particles to surfaces of the tools using a metal matrix material.

摘要翻译： 表面材料包括嵌入基质材料中的多晶金刚石（PCD）材料颗粒。 PCD颗粒包括多个相互结合的金刚石晶粒。 用于将表面硬化材料施加到钻孔工具（例如焊条）上的材料组成和结构包括PCD颗粒。 钻孔工具包括硬化材料，其包含嵌入在基体材料中的工具主体表面的至少一部分上的PCD颗粒。 形成表面硬化材料的方法包括对金刚石晶粒进行金刚石晶粒之间的金刚石 - 金刚石键的升高温度和压力，并形成PCD材料。 PCD材料被分解以形成包括多个相互结合的金刚石晶粒的PCD颗粒。 硬化工具的方法包括使用金属基质材料将PCD颗粒粘合到工具的表面上。

公开(公告)号：US10113368B2

公开(公告)日：2018-10-30

申请号：US13245102

申请日：2011-09-26

申请人： Nicholas J. Lyons ,  Danny E. Scott

发明人： Nicholas J. Lyons ,  Danny E. Scott

IPC分类号： E21B10/573 ,  B23B27/20 ,  B24D3/00 ,  B23B27/14 ,  B24D99/00 ,  B22F3/14 ,  B22F7/06 ,  C22C26/00 ,  C22C29/08 ,  B23B27/18 ,  C09K3/14 ,  B01J3/06 ,  B24D18/00 ,  B22F5/00

摘要： Cutting elements include a substrate, a thermally stable polycrystalline table comprising a superhard material secured to the substrate, and a layer of metal interposed between, and attaching the substrate and the thermally stable polycrystalline table. Methods of forming a cutting element include providing a thermally stable polycrystalline table in a mold, providing a layer of metal on the thermally stable polycrystalline table, distributing a mixture of particles comprising a plurality of hard particles and a plurality of particles comprising a matrix material on the layer of metal, and heating the mold while applying pressure to the mixture of particles to cause the mixture of particles to coalesce and form a substrate and at least partially melt the layer of metal to flow and wet the thermally stable polycrystalline table and the substrate to form an attachment therebetween.