IP Library Granted Patent US 9,957,757
Granted Patent B2
US 9,957,757 · App. 14/659,983 · Granted May 1, 2018

Cutting elements for drill bits for drilling subterranean formations and methods of forming such cutting elements

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Quick Facts
Patent No.
US 9,957,757
App. No.
14/659,983
Granted
May 1, 2018
Kind
B2
Abstract

A cutting element for use in a drill bit for drilling subterranean formations includes a cutting body having a substrate, and a superabrasive layer overlying an upper surface of the substrate. The cutting element further includes a sleeve including another superabrasive layer and surrounding the peripheral side surface of the cutting body.

Claims (43)

1. A cutting element for use in a drill bit for drilling subterranean formations, comprising:

a cutting body comprising:

a substantially cylindrical substrate comprising an upper surface; and

a first superabrasive layer overlying the upper surface of the substrate; and

a sleeve comprising a second superabrasive layer surrounding the first superabrasive layer,

wherein the sleeve is mechanically connected to the cutting body by a connection selected from the group consisting of an interlocking fit connection, an interference fit connection, a grooved connection, a threaded connection, a taper lock connection, and combinations thereof, the connection configured to inhibit rotational movement of the cutting body relative to the sleeve.

2. The cutting element of claim 1 , further comprising an interface material directly radially between the first superabrasive layer and the second superabrasive layer.

3. The cutting element of claim 2 , wherein the interface material comprises a material selected from the group consisting of carbides, nitrides, borides, and oxides.

4. The cutting element of claim 2 , wherein the interface material comprises a metal or a metal alloy material.

5. The cutting element of claim 2 , wherein the interface material comprises abrasive grit within a matrix material.

6. The cutting element of claim 1 , wherein the first and second superabrasive layers are mutually concentrically oriented.

7. The cutting element of claim 1 , wherein the second superabrasive layer comprises a chamfered surface extending at an angle to an upper surface of the second superabrasive layer.

8. The cutting element of claim 1 , wherein the cutting element is mounted to a body of a rotary drill bit.

9. The cutting element of claim 1 , wherein an upper surface of the first superabrasive layer protrudes axially above an upper surface of the second superabrasive layer.

10. The cutting element of claim 1 , wherein an upper surface of the first superabrasive layer is recessed axially below an upper surface of the second superabrasive layer.

11. A method of forming a cutting element for use in a drill bit for drilling subterranean formations, comprising:

disposing a cutting body within a sleeve,

wherein the cutting body comprises:

a substantially cylindrical substrate;

a first superabrasive layer over a surface of the substrate; and

a peripheral side surface comprising a peripheral side surface of the substrate and a peripheral side surface of the first superabrasive layer;

wherein the sleeve comprises:

a sleeve body; and

a second superabrasive layer bonded to a surface of the sleeve body; and

providing at least one of a gap and an interface material directly radially between the first superabrasive layer and the second superabrasive layer;

wherein an upper surface of the first superabrasive layer is coplanar with or recessed below an upper surface of the second superabrasive layer.

12. The method of claim 11 , further comprising subjecting the cutting body to a high pressure, high temperature process.

13. The method of claim 11 , further comprising subjecting the sleeve to a high pressure, high temperature process.

14. The method of claim 11 , wherein providing at least one of the gap and the interface material directly radially between the first superabrasive layer and the second superabrasive layer comprises providing a material selected from the group consisting of carbides, nitrides, borides, oxides, and carbon-based materials directly radially between the first superabrasive layer and the second superabrasive layer.

15. The method of claim 11 , wherein disposing a cutting body within a sleeve comprises simultaneously forming the cutting body and the sleeve.

16. The method of claim 11 , further comprising forming chamfered surfaces on the cutting body and the sleeve.

17. The method of claim 11 , further comprising polishing the first superabrasive layer.

18. A cutting element for use in a drill bit for drilling subterranean formations, comprising:

a cutting body, comprising:

a substrate;

a first superabrasive layer overlying a surface of the substrate;

a second superabrasive layer overlying the surface of the substrate; and

an arresting layer disposed between an interior side surface of the first superabrasive layer and a peripheral side surface of the second superabrasive layer, the arresting layer configured to mitigate the transfer of mechanical strain between the first superabrasive layer and the second superabrasive layer;

wherein the cutting body comprises at least one peripheral side surface comprising a peripheral side surface of the substrate and a peripheral side surface of the first superabrasive layer; and

a sleeve comprising a third superabrasive layer;

wherein an interior side surface of the sleeve surrounds the cutting body such that at least one of a gap and an interface material is disposed directly radially between the first superabrasive layer and the third superabrasive layer.

19. The cutting element of claim 18 , wherein the sleeve comprises a first region having a first radial thickness and a second region having a second radial thickness, the second radial thickness different from the first radial thickness.

20. The cutting element of claim 18 , wherein the arresting layer comprises a material selected from the group consisting of carbides, nitrides, borides, oxides, and carbon-based materials.

Assignments (2)
CHANGE OF NAME Recorded Nov 30, 2022
From: BAKER HUGHES, A GE COMPANY, LLC
To: BAKER HUGHES HOLDINGS LLC
Reel/Frame 062020/0311 →
CHANGE OF NAME Recorded Sep 20, 2022
From: BAKER HUGHES INCORPORATED
To: BAKER HUGHES, A GE COMPANY, LLC.
Reel/Frame 061493/0542 →