Polycrystalline super hard construction & method of making 机翻标题: 暂无翻译,请尝试点击翻译按钮。

公开号/公开日
WO2015091635 A1 2015-06-25 [WO201591635] / 2015-06-25
申请号/申请日
2014WO-EP78203 / 2014-12-17
发明人
NILEN ROGER WILLIAM NIGEL;CAN NEDRET;SITHEBE HUMPHREY;BOWES DAVID;NELMS DEREK;
申请人
BAKER HUGHES;ELEMENT SIX;
主分类号
IPC分类号
C04B-037/00E21B-004/00E21B-010/573
摘要
(WO201591635) A polycrystalline superhard construction comprises a body of polycrystalline superhard material having two or more layers.  A first layer differs from a second layer in one or more characteristics.  The body has a thickness of greater than around 1.8 mm.  A substrate is bonded to at least one of said layers, and one of the interface surface of the substrate or the body comprises one or more projections arranged to project from the interface surface, the height of the projection(s)being between around 0.2mm to around 2.0mm measured from the lowest point on the interface surface from which the one or more projections extend.  At least a portion of the body of superhard material is substantially free of a catalyst material for the superhard material, and forms a thermally stable region extending a depth of at least around 300 microns from the working surface of the body of superhard material.
机翻摘要
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地址
代理人
代理机构
;
优先权号
2013US-61917189 2013-12-17
主权利要求
(WO201591635)  Claims:   1 .  A polycrystalline super hard construction comprising:    a body of polycrystalline super hard material, the body of super hard material comprising:    two or more layers comprising a respective mass of super hard grains exhibiting inter-granular bonding and defining a plurality of interstitial regions therebetween; a first layer of said two or more layers differing from a second layer of said two or more layers differing in one or more characteristics; the body of polycrystalline super hard material having a thickness of greater than around 1 .8 mm and having an exposed outer surface forming a working surface, a peripheral surface extending therefrom and an interface surface; a substrate bonded to at least one of said two or more layers along an interface surface; the substrate comprising a peripheral surface, an interface surface and having a longitudinal axis; wherein one of the interface surface of the substrate or the interface surface of the body of polycrystalline super hard material comprises one or more projections arranged to project from the interface surface, the height of the one or more projections being between around 0.2mm to around 2.0mm measured from the lowest point on the interface surface from which the one or more projections extend; and wherein at least a portion of the body of polycrystalline super hard material is substantially free of a catalyst material for the superhard material, said portion forming a thermally stable region extending a depth of at least around 300 microns from the working surface of the body of polycrystalline super hard material.   2. The polycrystalline super hard construction of claim 1 , wherein the body of polycrystalline super hard material has a thickness of between around 2.2 to around 4mm.    3. The polycrystalline super hard construction of claim 2, wherein the body of polycrystalline super hard material has a thickness of between around 3.0 mm to around 4.0 mm.   4. The polycrystalline super hard construction of any one of the preceding claims, wherein the one or more characteristics comprise one or more of average grain size of the super hard material, coefficient of thermal expansion, super hard material grain size distribution, and super hard material composition.   5. The polycrystalline super hard construction of any one of the preceding claims, wherein the first layer includes the working surface of the body of polycrystalline super hard material and comprises polycrystalline super hard material having a smaller average grain size than the average grain size of the super hard material of the second layer.   6. The polycrystalline super hard construction of claim 5 wherein the average grain size of the superhard material in the first layer is less than around 20 microns and the average grain size of the superhard material in the second layer is greater than around 20 microns.   7. The polycrystalline super hard construction according to any one of the preceding claims, wherein the super hard grains comprise natural and/or synthetic diamond grains, the super hard polycrystalline construction forming a polycrystalline diamond construction.   8. The polycrystalline super hard construction according to any one of the preceding claims, wherein the thermally stable region extends a depth of at least around between around 300 to around 1000 microns from the working surface of the body of polycrystalline super hard material.   9. The polycrystalline super hard construction according to any one of the preceding claims, wherein the thermally stable region extends a depth of at least around between around 350 to around 700 microns from the working surface of the body of polycrystalline super hard material.    10. The polycrystalline super hard construction according to any one of claims 1 to 7, wherein the thermally stable region extends a depth of at least around between around 500 to around 1000 microns from the working surface of the body of polycrystalline super hard material.   1 1 .  The polycrystalline super hard construction according to any one of claims 1 to 7, wherein the thermally stable region extends a depth of at least around 700 microns from the working surface of the body of polycrystalline super hard material.   12. The polycrystalline super hard construction according to any one of the preceding claims, wherein the height of the one or more projections is between around 0.3mm to around 1 .0mm.   13. The polycrystalline super hard construction of any one of the preceding claims, wherein the projections are arranged in one or more substantially radial arrays around the central longitudinal axis of the substrate.   14. The polycrystalline superhard construction of claim 13, wherein the projections are arranged in a first array and a second array, the second array being positioned radially within the first array.   15. The polycrystalline superhard construction of claim 14, wherein the first and second arrays are substantially concentric with the substrate.   16. The polycrystalline superhard construction of any of claims 14 or 15, wherein the first array comprises substantially double the number of projections than the second array.   17.  The polycrystalline superhard construction of any one of claims 14 to  16, wherein the projections in the first and second arrays are staggered relative to each other.   18.  The polycrystalline super hard construction of any one of claims 13 to  17, wherein the projections are arranged in a substantially annular discontinuous first array around the central longitudinal axis and spaced from    the peripheral surface of the substrate by a distance of between around 1 mm to around 1 .5mm and a second substantially annular discontinuous array of projections radially within the first array; the projections in the second array being positioned to radially align with spaces between the projections in the first array; the interface surface between the projections being substantially planar; and wherein the projections in the first array are of a greater height than the projections in the second array.   19. The polycrystalline super hard construction of any one of claims 1 to 17, wherein all or a majority of the interface surface between the spaced-apart projections is non-curved and extends in one or more planes which are not substantially parallel to the plane of the exposed outer surface of the super hard material layer.   20. The polycrystalline super hard construction of any one of the preceding claims 1 to 17 or 19, wherein all or a majority of the interface surface between the spaced-apart projections extends in one or more planes which are not substantially parallel to a plane through which the central longitudinal axis of the substrate extends.   21 .  The polycrystalline super hard construction of any one of the preceding claims, wherein one or more of the surfaces of all or a majority of the projections extend in one or more planes which are not substantially parallel to the plane of the exposed outer surface of the super hard material layer and/or in one or more planes which are not substantially parallel to a plane through which the central longitudinal axis of the substrate extends.   22. The polycrystalline superhard construction of any one of the preceding claims, wherein the thickness of the super hard material layer about the central longitudinal axis of the substrate is substantially the same as the thickness of the super hard material layer at the peripheral surface.    23. The polycrystalline superhard construction of any one of claims 1 to 12, wherein the projections are randomly arranged on one of the interface surface of the substrate or the interface surface of the super hard material layer.   24. The polycrystalline super hard construction according to any one of the preceding claims, wherein the substrate comprises a cemented carbide particles bonded together by a binder material, the binder material forming between around 9 to around 1 1 wt% of the substrate.   25. The polycrystalline super hard construction according to any one of the preceding claims, wherein the substrate comprises cemented tungsten carbide.   26. The polycrystalline super hard construction according to any one of the preceding claims, wherein the substrate comprises comprising a binder material comprising Co and/or an alloy of Co, Ni and Cr.   27. The polycrystalline super hard construction according to any one of the preceding claims, wherein the polycrystalline superhard construction comprises one or more of: up to 20 wt% nanodiamond additions in the form of nanodiamond powder grains; salts; borides or metal carbides of at least one of Ti, V, or Nb; or at least one of the metals Pd or Ni.   28. A polycrystalline super hard construction for a rotary shear bit for boring into the earth, or for a percussion drill bit, comprising the polycrystalline super hard construction as claimed in any one of the preceding claims bonded to a cemented carbide support body.    29. A tool comprising a polycrystalline super hard construction according to any one of claims 1 to 27, the tool being for cutting, milling, grinding, drilling, earth boring, rock drilling or other abrasive applications.   30. A tool according to claim 29, wherein the tool comprises a drill bit for earth boring or rock drilling.   31 .  A tool according to claim 29, wherein the tool comprises a rotary fixed- cutter bit for use in oil and gas drilling.   32. A tool according to claim 29, wherein the tool is a rolling cone drill bit, a hole opening tool, an expandable tool, a reamer or other earth boring tools.   33. A drill bit or a cutter or a component therefor comprising the polycrystalline super hard construction according to any one of claims 1 to 27.   34.  A method of forming a polycrystalline super hard construction, comprising:   providing a first mass of grains of super hard material; providing a second mass of grains of super hard material; the first mass of grains differing in one or more characteristics from the second mass of grains; providing a substrate, the substrate comprising a peripheral surface, an interface surface and having a longitudinal axis; treating the pre-sinter assembly in the presence of a catalyst/solvent material for the super hard grains at an ultra-high pressure of around 5.5 GPa or greater and a temperature at which the super hard material is more thermodynamically stable than graphite to sinter together the grains of super hard material to form a polycrystalline super hard construction comprising a body of superhard material formed of the first and second mass of grains in adjacent regions, the super hard grains exhibiting inter-granular bonding and    defining a plurality of interstitial regions therebetween, a non-super hard phase at least partially filling a plurality of the interstitial regions; the body of polycrystalline super hard material having a thickness of greater than around 1 .8 mm and having an exposed outer surface forming a working surface, a peripheral surface extending therefrom and an interface surface; wherein one of the interface surface of the substrate or the interface surface of the body of polycrystalline super hard material comprises one or more projections arranged to project from the interface surface, the height of the one or more projections being between around 0.2mm to around 2.0mm measured from the lowest point on the interface surface from which the one or more projections extend; and treating at least a portion of the body of polycrystalline super hard material to remove residual catalyst/binder from the interstitial spaces to form a region substantially free of the catalyst/binder material for the superhard material, said portion forming a thermally stable region extending a depth of at least around 300 microns from the working surface of the body of polycrystalline super hard material.   35. The method of claim 34, wherein the body of polycrystalline super hard material has a thickness of between around 2.2 to around 4mm.   36. The method of claim 34, wherein the body of polycrystalline super hard material has a thickness of between around 3.0 mm to around 4.0 mm.   37. The method of any one of claims 34 to 36, wherein the one or more characteristics comprise one or more of average grain size of the super hard material, coefficient of thermal expansion, super hard material grain size distribution, and super hard material composition.   38. The method of any one of claims 34 to 37, wherein the first mass of super hard grains once sintered forms a layer comprising the working surface of the body of polycrystalline super hard material; and wherein the step of providing the first mass of grains comprises proving grains for forming the first    mass having a smaller average grain size than the average grain size of the super hard material of the second mass of grains.   39. The method of claim 38 wherein the step of providing the first mass of grains comprises providing super hard grains having an average grain size less than around 20 microns; and the step of providing a second mass of grains comprises providing super hard grains having an average grain size greater than around 20 microns.   40. The method of any one of claims 34 to 39, wherein the super hard grains comprise natural and/or synthetic diamond grains, the super hard polycrystalline construction forming a polycrystalline diamond construction.   41 .  The method of any one of claims 34 to 40, wherein the step of treating comprises creating the thermally stable region to extend a depth of between around 300 to around 1000 microns from the working surface of the body of polycrystalline super hard material.   42. The method of any one of claims 34 to 40, wherein the step of treating comprises creating the thermally stable region to extend a depth of between around 350 to around 700 microns from the working surface of the body of polycrystalline super hard material.   43. The method of any one of claims 34 to 40, wherein the step of treating comprises creating the thermally stable region to extend a depth of between around 500 to around 1000 microns from the working surface of the body of polycrystalline super hard material.   44. The method of any one of claims 34 to 40, wherein the step of treating comprises creating the thermally stable region to extend a depth of at least around 700 microns from the working surface of the body of polycrystalline super hard material.   45. The method of any one of claims 34 to 44, wherein the height of the one or more projections is between around 0.3mm to around 1 .0mm.    46. The method of any one of claims 34 to 45, wherein the projections are arranged in a substantially annular discontinuous first array around the central longitudinal axis and spaced from the peripheral surface of the substrate by a distance of between around 1 mm to around 1 .5mm and a second substantially annular discontinuous array of projections radially within the first array; the projections in the second array being positioned to radially align with spaces between the projections in the first array; the interface surface between the projections being substantially planar; and wherein the projections in the first array are of a greater height than the projections in the second array.   47. The method of any one of claims 34 to 46, wherein the step of providing a substrate comprises providing a substrate comprising cemented carbide particles bonded together by a binder material, the binder material forming between around 9 to around 1 1 wt% of the substrate.   48. The method of any one of claims 34 to 47, wherein the step of subjecting the super hard grains to a pressure comprises subjecting the grains to a pressure of greater than around 6.8 GPa.   49. A polycrystalline super hard construction substantially as hereinbefore described with reference to any one embodiment as that embodiment is illustrated in the accompanying drawings.   50. A method of forming a polycrystalline super hard construction substantially as hereinbefore described with reference to any one embodiment as that embodiment is illustrated in the accompanying drawings.
法律状态
(WO201591635) LEGAL DETAILS FOR WO2015091635  Actual or expected expiration date=2017-06-17    Legal state=ALIVE    Status=PENDING     Event publication date=2014-12-17  Event code=WO/APP  Event indicator=Pos  Event type=Examination events  Application details  Application country=WO WOEP2014078203  Application date=2014-12-17  Standardized application number=2014WO-EP78203     Event publication date=2015-06-25  Event code=WO/A1  Event type=Examination events  Published application with search report  Publication country=WO  Publication number=WO2015091635  Publication stage Code=A1  Publication date=2015-06-25  Standardized publication number=WO201591635  LEGAL DETAILS FOR DESIGNATED STATE CN106029608  Actual or expected expiration date=2034-12-17    Legal state=ALIVE    Status=PENDING   Corresponding cc:  Designated or member state=CN Corresponding appl: CN201480075757  Application date in the designated or member state=2014-12-17   Application number in the designated or member state=2014CN-80075757 Corresponding cc:  Designated or member state=CN Corresponding pat: CN106029608  Publication stage code in the designated or member state=A  Publication date in the designated or member state=2016-10-12   Publication number in the designated or member state=CN106029608 LEGAL DETAILS FOR DESIGNATED STATE DE  Actual or expected expiration date=2016-06-17    Legal state=DEAD    Status=LAPSED   Corresponding cc:  Designated or member state=DE     Event publication date=2016-06-17  Event code=WO/NENP  Event type=Event indicating Not In Force  Non-entry into the national phase in: Corresponding cc:  Designated or member state=DE     Event publication date=2016-06-17  Event code=WO/NENP  Event type=Event indicating Not In Force  Non-entry into the national phase in: Corresponding cc:  Designated or member state=DE  LEGAL DETAILS FOR DESIGNATED STATE EP  Actual or expected expiration date=2017-01-11    Legal state=DEAD    Status=LAPSED   Corresponding cc:  Designated or member state=EP Corresponding appl: EP14821591    Event publication date=2015-08-05  Event code=WO/121  Event type=Designated states  EP: The EPO has been informed by wipo that ep was designated in this application Corresponding cc:  Designated or member state=EP     Event publication date=2015-08-05  Event code=WO/121  Event type=Designated states  EP: The EPO has been informed by wipo that ep was designated in this application Corresponding cc:  Designated or member state=EP     Event publication date=2017-01-11  Event code=WO/122  Event indicator=Neg  Event type=Event indicating Not In Force  EP: PCT  app. not ent. europ. phase EP: PCT anmeldung nicht in europaeische phase eingetreten Corresponding cc:  Designated or member state=EP  LEGAL DETAILS FOR DESIGNATED STATE US2016312542  Actual or expected expiration date=2034-12-17    Legal state=ALIVE    Status=PENDING   Corresponding cc:  Designated or member state=US Corresponding appl: US15105163  Application date in the designated or member state=2014-12-17   Application number in the designated or member state=2014US-15105163 Corresponding cc:  Designated or member state=US Corresponding pat: US2016312542  Publication stage code in the designated or member state=A1  Publication date in the designated or member state=2016-10-27   Publication number in the designated or member state=US20160312542    Event publication date=2016-06-16  Event code=WO/WWE  Event indicator=Pos  Event type=Entry into national phase  Wipo information: entry into national phase Corresponding cc:  Designated or member state=US     Event publication date=2016-06-16  Event code=WO/WWE  Event indicator=Pos  Event type=Entry into national phase  Wipo information: entry into national phase Corresponding cc:  Designated or member state=US
专利类型码
A1
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