Superabrasive elements and related methods for processing and manufacturing using protective layers

1 . A method of processing a polycrystalline diamond element, the method comprising:

forming a protective layer over a selected portion of a polycrystalline diamond element, the polycrystalline diamond element comprising a polycrystalline diamond table comprising:

a superabrasive face;

a superabrasive side surface; and

a chamfer extending between the superabrasive face and the superabrasive side surface; and

exposing at least a portion of the polycrystalline diamond element to a leaching solution such that the leaching solution contacts an exposed surface region of the polycrystalline diamond table and at least a portion of the protective layer;

wherein:

a portion of the superabrasive side surface is covered by the protective layer; and

the protective layer is not formed over the chamfer.

2 . The method of claim 1 , further comprising covering at least a portion of a surface of a substrate bonded to the polycrystalline diamond table with the protective layer.

3 . The method of claim 1 , further comprising selecting the protective layer to comprise a substantially inert material.

4 . The method of claim 1 , further comprising selecting the protective layer to be substantially impermeable to the leaching solution.

5 . The method of claim 1 , wherein forming the protective layer over the selected portion of the polycrystalline diamond element comprises exposing the protective layer to an elevated temperature of about 50° C. or higher and an elevated pressure of about 1000 psi or higher.

6 . The method of claim 1 , further comprising defining an intercalated hybrid layer at an interface between the protective layer and the polycrystalline diamond element.

7 . The method of claim 1 , further comprising selecting the protective layer to comprise at least one of a metallic material, a thermoplastic material, a glass sealant, or graphite.

8 . The method of claim 1 , further comprising positioning an intermediate liner between the polycrystalline diamond element and the protective layer.

9 . The method of claim 8 , further comprising selecting the protective layer to comprise a polymer material and the intermediate liner to comprise a metallic material.

10 . The method of claim 1 , further comprising leaching the polycrystalline diamond element to produce a leached volume and an unleached volume, a portion of the unleached volume defining an outer circumferential surface of the polycrystalline diamond table.

11 . The method of claim 1 , wherein:

the protective layer comprises a thermosetting material; and

forming the protective layer over the selected portion of the polycrystalline diamond element comprises curing the thermosetting material.

12 . The method of claim 1 , further comprising, prior to exposing at least a portion of the polycrystalline diamond element to the leaching solution:

forming the protective layer over the selected portion of the polycrystalline diamond element; and

partially removing the protective layer from the selected portion of the polycrystalline diamond element.

13 . The method of claim 1 , further comprising forming an outer layer on at least a portion of an outer surface of the protective layer.

14 . The method of claim 1 , further comprising covering a portion of the superabrasive side surface proximate to the chamfer with the protective layer.

15 . A method of processing a polycrystalline diamond element, the method comprising:

positioning a protective layer over a selected portion of a polycrystalline diamond element, the polycrystalline diamond element comprising a polycrystalline diamond table comprising:

a superabrasive face;

a superabrasive side surface; and

a chamfer extending between the superabrasive face and the superabrasive side surface;

covering a portion of the superabrasive side surface with the protective layer; and

exposing at least a portion of the polycrystalline diamond element including the chamfer to a leaching solution such that the leaching solution contacts an exposed surface region of the polycrystalline diamond table.

16 . The method of claim 15 , wherein covering the portion of the superabrasive side surface by the protective layer comprises covering a majority of the superabrasive side surface while the chamfer remains exposed.

17 . A method of processing a polycrystalline diamond element, the method comprising:

defining a protective layer over a selected portion of a polycrystalline diamond element, the polycrystalline diamond element comprising a polycrystalline diamond table including a superabrasive face, a superabrasive side surface, and a chamfer extending between the superabrasive face and the superabrasive side surface;

covering at least a portion of the superabrasive side surface with the protective layer while at least a portion of the chamfer remains exposed; and

exposing at least a portion of the polycrystalline diamond element including the chamfer to a leaching solution such that the leaching solution contacts an exposed surface region of the polycrystalline diamond table.

18 . The method of claim 17 , further comprising positioning an intermediate liner between the polycrystalline diamond element and the protective layer.

19 . The method of claim 18 , further comprising selecting the protective layer to comprise a polymer material and the intermediate liner to comprise a metallic material.

20 . The method of claim 19 , further comprising leaching the polycrystalline diamond element to produce a leached volume and an unleached volume, a portion of the unleached volume defining an outer circumferential surface of the polycrystalline diamond table.