Abstract: An enlarged diamond table for use as a cutter in rotating drill bits is provided by disposing a plurality of thermally stable or leached polycrystalline diamond (PCD) rod-like elements within a matrix body. In one embodiment the matrix body is impregnated with diamond grit and completely fills the interstitial spaces between the plurality of PCD elements. Generally, the PCD elements have their longitudinal axes arranged in a mutually parallel configuration. The bundle of rod-like diamond elements are in one embodiment in a compact touching array and in another embodiment in a spaced-apart array. In the illustrated embodiment, a bundle of rod-like diamond elements are disposed so that their end surfaces are exposed on the cutting face of the cutting slug. The slug is then in turn mounted on a stud or directly infiltrated into a matrix body bit.

Abstract: A diamond cutting table having the geometric characteristics of larger unleached diamond compact products and yet characterized by the physical properties of smaller leached diamond products is fabricated by forming a diamond cutter incorporating a plurality of polycrystalline diamond (PCD) leached disks. The PCD leached disks are disposed in array in a cutting slug formed of matrix material. The matrix material is disposed between and around the plurality of diamond disks and in one embodiment incorporates a volume distribution of diamond grit. The cutting slug is hot pressed or infiltrated to form an integral mass or table. The diamond table is then bonded to a cutter or directly molded into an integral tooth within a matrix body bit.

Abstract: A diamond cutter for use in a drill bit having a geometric size and shape normally characterized by unleached diamond product, such as STRATAPAX diamond cutters, can be fabricated by assembling a plurality of prefabricated leached polycrystalline diamond (PCD) elements in an array in a cutting slug. A cutting slug is formed of matrix material which in one embodiment is impregnated with diamond grit. The cutting face of the cutting slug is characterized by exposing at least one surface of each of the PCD elements disposed therein. The diamonds may be set within the cutting slug either in a compact touching array or in a spaced-apart relationship. More than one type of array may also be employed within a single cutting slug. The PCD elements can assume a variety of polyhedral shapes such as triangular prismatic elements, rectangular elements, hexagonal elements and the like. The plurality of diamond elements and the cutting slug are fabricated using hot pressing or infiltration techniques.

Abstract: A diamond cutter for use in a drill bit having a geometric size and shape normally characterized by unleached diamond product, such as STRATAPAX diamond cutters, can be fabricated by assembling a plurality of prefabricated leached polycrystalline diamond (PCD) elements in an array in a cutting slug. A cutting slug is formed of matrix material which in one embodiment is impregnated with diamond grit. The cutting face of the cutting slug is characterized by exposing at least one surface of each of the PCD elements disposed therein. The diamonds may be set within the cutting slug either in a compact touching array or in a spaced-apart relationship. More than one type of array may also be employed within a single cutting slug. The PCD elements can assume a variety of polyhedral shapes such as triangular prismatic elements, rectangular elements, hexagonal elements and the like. The plurality of diamond elements and the cutting slug are fabricated using hot pressing or infiltration techniques.

Abstract: The present invention is an improvement in the cutting tooth used in a rotating drilling bit wherein the cutting tooth incorporates a synthetic triangularly shaped prismatic diamond element. The polycrystalline diamond element is substantially exposed above the bit face of the bit and is supported and retained on the bit face by disposition within a tooth of matrix material integrally formed with the bit face. The tooth is particularly characterized by having a trailing support in the shape of a tapered teardrop with a leading face on the trailing support that is at least in part adjacent and contiguous to the trailing face of the diamond cutting element and is congruous at the plane of contact with the diamond cutting element and tapers thereafter to a point on the bit face to minimize the amount of matrix material in the tooth which must to be removed by wearing before a useful cutting surface of the polycrystalline diamond element can be exposed.