Patents Assigned to US SYNTHETICS CORPORATION
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Patent number: 11958133Abstract: In one or more embodiments, a method includes selecting a cemented carbide substrate from a plurality of cemented carbide substrates in a substrate inventory. Each of the plurality of cemented carbide substrates have a substantially planar top surface. The method also includes emitting a plurality of laser pulses from a laser towards at least the substantially planar top surface of the cemented carbide substrate to ablate selected regions of the cemented carbide substrate thereby forming the cemented carbide substrate into a selected shape.Type: GrantFiled: December 31, 2019Date of Patent: April 16, 2024Assignee: US SYNTHETIC CORPORATIONInventors: Paul Douglas Jones, Benjamin Michael Spencer, Brent Richard Eddy, Mark Pehrson Chapman
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Patent number: 11946320Abstract: Polycrystalline diamond may include a working surface and a peripheral surface extending around an outer periphery of the working surface. The polycrystalline diamond includes a first volume including an interstitial material and a second volume having a leached region that includes boron and titanium. A method of fabricating a polycrystalline diamond element may include positioning a first volume of diamond particles adjacent to a substrate, the first volume of diamond particles including a material that includes a group 13 element, and positioning a second volume of diamond particles adjacent to the first volume of diamond particles such that the first volume of diamond particles is disposed between the second volume of diamond particles and the substrate, the second volume of diamond particles having a lower concentration of material including the group 13 element than the first volume of diamond particles.Type: GrantFiled: January 9, 2021Date of Patent: April 2, 2024Assignee: US Synthetic CorporationInventors: Daren Nathaniel Heaton, Jeremy Brett Lynn
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Patent number: 11926972Abstract: This disclosure relates to a system for removing road material. In an embodiment, the system may include a milling drum and at least one pick mounted on the milling drum. Furthermore, the pick may include polycrystalline diamond at least partially forming one or more working surfaces of the pick.Type: GrantFiled: April 19, 2021Date of Patent: March 12, 2024Assignee: US Synthetic CorporationInventors: Regan Leland Burton, Andrew E. Dadson, Mohammad N. Sani
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Patent number: 11878485Abstract: Embodiments of the present invention include a press base assembly, a strengthening ring for use with press bases and related methods. In one embodiment, a press base assembly includes a press base having a body that includes a piston cavity at one end. The body, at a second end opposite that of the piston cavity, may exhibit a desired geometry. A strengthening ring may be shaped, sized and configured to substantially mate with the geometry of the second end of the body and be placed thereover. For example, the geometry of the second end may be substantially circular exhibiting a particular diameter and circumference. The strengthening ring may have substantially circular internal surface sized and configured such that the strengthening ring is positioned on the second end of the body in a manner that results in an interference fit between the two components.Type: GrantFiled: June 1, 2022Date of Patent: January 23, 2024Assignee: US Synthetic CorporationInventor: Shelby M. Shreve
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Patent number: 11865672Abstract: PDCs, methods of fabricating the PDCs, and methods of using the PDCs are disclosed herein. The PDCs include a PCD table bonded to a substrate. The PCD table includes an upper surface having a plurality of recessed features formed therein. The plurality of recessed features are configured to attract at least some cracks that form in the PCD table. As such, the plurality of recessed features limit or prevent crack propagation into other portions of the PCD table and limit a volume of the PCD table that spalls. Methods of fabricating the PDCs include partially leaching the PCD table and, after leaching the PCD table, forming the plurality of recessed features in the upper surface thereof. Method of using the PDCs include rotating a PDC that has spalled relative to a rotary drill bit such that a portion of the upper surface of the PDC that has not spalled forms a cutting surface thereof.Type: GrantFiled: July 22, 2019Date of Patent: January 9, 2024Assignee: US Synthetic CorporationInventors: Daniel Call Mortensen, Lindsay Sue Patton, Trevor Allen Olsen, Casey Wade Swan, Shawn Casey Scott, Matthew Kimball Baker, Anne-Grethe Slotnaes, Kenneth E. Bertagnolli, Jiang Qian, Jason Lott, Joshua Adam Hawks
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Patent number: 11858230Abstract: In an example, a cubic press is described having press bases with spacers disposed between adjacent press bases. Sets of two or more tie bars are also disposed between adjacent press bases. The tie bars are placed in a state of compression while the spacers are placed in a state of compression. During operation, the press bases may become displaced relative to one another such that additional tension is experienced by the tie bars while the amount of compression experienced by the spacer is reduced. The tie bars exhibit a relatively small cross-sectional area as compared to the cross-sectional area of the spacer.Type: GrantFiled: October 30, 2018Date of Patent: January 2, 2024Assignee: US SYNTHETIC CORPORATIONInventor: Shelby M. Shreve
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Patent number: 11859660Abstract: Embodiments of the invention relate to bearing apparatuses in which one bearing surface of the bearing apparatus includes diamond, while another bearing surface includes a non-diamond superhard material (e.g., silicon carbide). For example, a bearing apparatus may include a bearing stator assembly and a bearing rotor assembly. The bearing stator assembly and bearing rotor assembly each include a support ring and one or more superhard bearing elements generally opposed to one another. The bearing surface(s) of the rotor or stator may include diamond, while the bearing surface(s) of the other of the rotor or stator do not include diamond. Another bearing apparatus may include both thrust- and radial bearing components. The generally opposed thrust-bearing elements may include diamond, while the generally opposed radial bearing elements may not include diamond, but include a non-diamond superhard material, such as silicon carbide.Type: GrantFiled: August 17, 2022Date of Patent: January 2, 2024Assignee: US SYNTHETIC CORPORATIONInventor: Jair J. Gonzalez
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Patent number: 11845137Abstract: A heating apparatus for induction heating is disclosed. The heating apparatus may comprise a bearing ring, at least one bearing element disposed in the bearing ring, and a braze material adjacent to the at least one bearing element and the bearing ring. The heating apparatus may additionally comprise an inductor positioned radially adjacent to at least a portion of the bearing ring. A current source may be electrically coupled to the inductor. A bearing orienting member may also abut a surface of the at least one bearing element. The bearing orienting member may orient a surface of the at least one bearing element. A heating method is also disclosed.Type: GrantFiled: December 17, 2019Date of Patent: December 19, 2023Assignee: US SYNTHETIC CORPORATIONInventors: S. Barrett Peterson, Timothy N. Sexton, Curtis M. Simons, Troy C. Campbell
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Patent number: 11839917Abstract: Embodiments disclosed herein relate to polycrystalline diamond compacts that have a substrate including a cementing constituent constituting less than 13 weight percent (wt %) of the substrate, the cementing constituent including a cobalt alloy having and at least one alloying element, wherein the at least one alloying element constitutes less than 12 wt % of the substrate and wherein the cobalt constitutes less than 12 wt % of the substrate; and methods of making the same.Type: GrantFiled: September 11, 2019Date of Patent: December 12, 2023Assignee: US SYNTHETIC CORPORATIONInventor: Debkumar Mukhopadhyay
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Patent number: 11814902Abstract: Bearing assemblies, apparatuses, systems, and methods include bearing assemblies where one of the bearing assemblies may include bearing surfaces defining an at least partially conical surface.Type: GrantFiled: March 24, 2023Date of Patent: November 14, 2023Assignee: US Synthetic CorporationInventors: Tyler Kolste, Daryl Wise, S. Barrett Peterson
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Patent number: 11773654Abstract: Embodiments of the invention relate to polycrystalline diamond compact (“PDC”) including a polycrystalline diamond (“PCD”) table that bonded to a cobalt-nickel alloy cemented carbide substrate. The cobalt-nickel alloy cemented carbide substrate provides both erosion resistance and corrosion resistance to the cemented carbide substrate. In an embodiment, a PDC includes a cemented carbide substrate including cobalt-nickel alloy cementing constituent. The PDC further includes a PCD table bonded to the cemented carbide substrate.Type: GrantFiled: December 14, 2021Date of Patent: October 3, 2023Assignee: US SYNTHETIC CORPORATIONInventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli
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Patent number: 11766761Abstract: A method of processing a superabrasive element includes providing a superabrasive element including a polycrystalline diamond table that includes a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table. The polycrystalline diamond table includes a superabrasive face and a superabrasive side surface extending around an outer periphery of the superabrasive face. The method also includes leaching the metallic material from at least a volume of the polycrystalline diamond table to produce a leached volume in the polycrystalline diamond table by (1) exposing at least a portion of the polycrystalline diamond table to a processing solution, (2) exposing an electrode to the processing solution, and (3) applying a charge to the electrode such that a voltage is generated between the polycrystalline diamond table and the electrode and the voltage is applied to the processing solution.Type: GrantFiled: August 13, 2020Date of Patent: September 26, 2023Assignee: US Synthetic CorporationInventors: Daniel Marin Scott, Daren Nathaniel Heaton, Jeremy Brett Lynn, Mark Pehrson Chapman, Oakley D. Bond
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Patent number: 11767717Abstract: Rotary drill bits may include on or more cutting element assemblies which include a cutter and a mounting system. In one embodiment, the mounting system includes a housing, a first bearing component disposed within the housing, and a second bearing component associated with the cutting element. In certain embodiments, the bearing components may comprise a table of superhard material bonded with a substrate. In one or more embodiments, the bearing components may include bearing surfaces that are arcuate. For example, the bearing surfaces may be substantially spherical (a portion of a sphere). The bearing components may be arranged to act as a radial bearing as well as a thrust bearing for the cutting element, enabling the cutting element to rotate about a longitudinal axis of the cutter, relative to the housing, while also enabling the longitudinal axis of the cutter to be displaced (change angles) relative to the housing.Type: GrantFiled: June 28, 2021Date of Patent: September 26, 2023Assignee: US Synthetic CorporationInventors: Craig H. Cooley, Keith Baskett
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Patent number: 11753873Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a structure for enhancing at least one of abrasion resistance, thermal stability, or impact resistance. In an embodiment, a PDC includes a PCD table. The PCD table includes a lower region including a plurality of diamond grains exhibiting a lower average grain size and at least an upper region adjacent to the lower region and including a plurality of diamond grains exhibiting an upper average grain size. The lower average grain size may be at least two times greater than that of the upper average grain size. The PDC includes a substrate having an interfacial surface that is bonded to the lower region of the PCD table. Other embodiments are directed methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.Type: GrantFiled: May 18, 2021Date of Patent: September 12, 2023Assignee: US SYNTHETIC CORPORATIONInventors: Greg Carlos Topham, Renato Ventura
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Patent number: 11746601Abstract: Embodiments relate to a polycrystalline diamond compact (“PDC”) including a polycrystalline diamond (“PCD”) table having at least two regions and being bonded to a fine grained cemented tungsten carbide substrate. In an embodiment, a PDC includes a cemented carbide substrate having a cobalt-containing cementing constituent cementing tungsten carbide grains together that exhibit an average grain size of about 1.5 ?m or less, and a PCD table having at least one upper region including diamond grains exhibiting an upper average grain size and at least one lower region adjacent to the upper region a lower average grain size that may be at least two times greater than the upper average grain size. The cemented carbide substrate includes an interfacial surface and a depletion zone depleted of the cementing constituent that extends inwardly from the interfacial surface to a depth of, for example, about 30 ?m to about 60 ?m.Type: GrantFiled: September 27, 2019Date of Patent: September 5, 2023Assignee: US SYNTHETIC CORPORATIONInventors: Debkumar Mukhopadhyay, Greg Carlos Topham, Renato Ventura
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Patent number: 11738315Abstract: In an embodiment, a polycrystalline diamond table includes a plurality of bonded diamond grains and a plurality of interstitial regions defined by the plurality of bonded diamond grains. The polycrystalline diamond table may be at least partially leached such that at least a portion of at least one interstitial constituent has been removed from at least a portion of the plurality of interstitial regions by exposure to a leaching agent. The leaching agent may include a mixture having a ratio of weight % hydrofluoric acid to weight % nitric acid of about 1.0 to about 2.4, and water in a concentration of about 50 weight % to about 85 weight %. Various other materials, articles, and methods are also disclosed.Type: GrantFiled: September 20, 2021Date of Patent: August 29, 2023Assignee: US Synthetic CorporationInventors: Julie Ann Kidd, Heather Marie Schaefer, Chengkun Xu, Jason K. Wiggins, Matthew Brown, Cody Frisby
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Patent number: 11703083Abstract: Bearing assemblies and methods of using bearings are provided in the present disclosure. In one embodiment, a bearing ring is provided having a plurality of carrier components removably coupled therewith. Each carrier component may carry one or more bearing elements. Upon wearing of the bearing elements beyond a desired amount, the carrier components may be removed from the bearing ring and installed in a different bearing ring to place the mearing elements at their original bearing surface radius. In another embodiment, individual bearing elements may be radially adjustable relative to the bearing ring to define and redefine the radius of a radial bearing surface.Type: GrantFiled: June 28, 2022Date of Patent: July 18, 2023Assignee: US Synthetic CorporationInventors: Jair J. Gonzalez, Leonidas C. Leite
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Patent number: 11686347Abstract: Embodiments disclosed herein relate to bearing assemblies and methods of manufacturing. In an embodiment, a bearing assembly includes a support ring and bearing elements. The bearing elements are mounted to and distributed circumferentially about an axis of the support ring. At least one of the bearing elements includes a polycrystalline diamond table, a substrate bonded to the polycrystalline diamond table, bonding region defined by the substrate and the polycrystalline diamond table, and a corrosion resistant region. The corrosion resistant region includes a corrosion resistant material that covers at least a portion of at least one lateral surface of the bonding region. The corrosion resistant region prevents corrosion of at least some material in the bonding region covered by the corrosion resistant region (e.g., during use). Other embodiments employ one or more sacrificial anodes as an alternative to or in combination with the corrosion resistant region.Type: GrantFiled: January 13, 2021Date of Patent: June 27, 2023Assignee: US SYNTHETIC CORPORATIONInventor: Jair Jahaziel Gonzalez
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Patent number: D1026979Type: GrantFiled: December 3, 2020Date of Patent: May 14, 2024Assignee: US Synthetic CorporationInventor: Jarrett Meier
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Patent number: D1026982Type: GrantFiled: March 15, 2022Date of Patent: May 14, 2024Assignee: US Synthetic CorporationInventor: Daniel Call Mortensen