Patents by Inventor Cody William Knuteson
Cody William Knuteson has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20230017882Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a diamond grain size distribution selected for improving performance and/or leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween. Other embodiments are directed to methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.Type: ApplicationFiled: July 20, 2022Publication date: January 19, 2023Inventors: Brandon Paul Linford, Cody William Knuteson, Jason Dean Blackburn, Daniel Call Mortensen, Steven Swan
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Patent number: 11525309Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.Type: GrantFiled: August 26, 2019Date of Patent: December 13, 2022Assignee: US Synthetic CorporationInventors: Cody William Knuteson, Paul Douglas Jones, Brandon P. Linford, Brent R. Eddy, Kenneth E. Bertagnolli, Debkumar Mukhopadhyay
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Patent number: 11421485Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a diamond grain size distribution selected for improving performance and/or leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween. The plurality of diamond grains includes a first amount being about 5 weight % to about 65 weight % of the plurality of diamond grains and a second amount being about 18 weight % to about 95 weight % of the plurality of diamond grains. The first amount exhibits a first average grain size of about 0.5 ?m to about 30 ?m. The second amount exhibits a second average grain size that is greater than the first average grain size and is about 10 ?m to about 65 ?m. Other embodiments are directed to methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.Type: GrantFiled: December 9, 2019Date of Patent: August 23, 2022Assignee: US Synthetic CorporationInventors: Brandon Paul Linford, Cody William Knuteson, Jason Dean Blackburn, Daniel Call Mortensen, Steven Swan
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Patent number: 11235435Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a diamond grain size distribution selected for improving leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes diamond grains exhibiting diamond-to-diamond bonding therebetween. The diamond grains includes a first amount being about 30 to about 65 volume % of the diamond grains and a second amount being about 18 to about 65 volume % of the diamond grains. The first amount exhibits a first average grain size of about 8 ?m to about 22 ?m. The second amount exhibits a second average grain size that is greater than the first average grain size and is about 15 ?m to about 50 ?m. 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: September 10, 2019Date of Patent: February 1, 2022Assignee: US SYNTHETIC CORPORATIONInventors: Brandon Paul Linford, Cody William Knuteson
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Patent number: 10858892Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability and/or wear resistance of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element such as phosphorous.Type: GrantFiled: July 12, 2018Date of Patent: December 8, 2020Assignee: US SYNTHETIC CORPORATIONInventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson
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Publication number: 20200024905Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.Type: ApplicationFiled: August 26, 2019Publication date: January 23, 2020Inventors: Cody William Knuteson, Paul Douglas Jones, Brandon P. Linford, Brent R. Eddy, Kenneth E. Bertagnolli, Debkumar Mukhopadhyay
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Patent number: 10501998Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a diamond grain size distribution selected for improving performance and/or leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween. The plurality of diamond grains includes a first amount being about 5 weight % to about 65 weight % of the plurality of diamond grains and a second amount being about 18 weight % to about 95 weight % of the plurality of diamond grains. The first amount exhibits a first average grain size of about 0.5 ?m to about 30 ?m. The second amount exhibits a second average grain size that is greater than the first average grain size and is about 10 ?m to about 65 ?m. Other embodiments are directed to methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.Type: GrantFiled: February 20, 2015Date of Patent: December 10, 2019Assignee: US SYNTHETIC CORPORATIONInventors: Brandon Paul Linford, Cody William Knuteson, Jason Dean Blackburn, Daniel Call Mortensen, Steven Swan
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Patent number: 10449658Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a diamond grain size distribution selected for improving leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes diamond grains exhibiting diamond-to-diamond bonding therebetween. The diamond grains includes a first amount being about 30 to about 65 volume % of the diamond grains and a second amount being about 18 to about 65 volume % of the diamond grains. The first amount exhibits a first average grain size of about 8 ?m to about 22 ?m. The second amount exhibits a second average grain size that is greater than the first average grain size and is about 15 ?m to about 50 ?m. 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: April 21, 2016Date of Patent: October 22, 2019Assignee: US SYNTHETIC CORPORATIONInventors: Brandon Paul Linford, Cody William Knuteson
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Patent number: 10435952Abstract: Polycrystalline diamond compacts (“PDCs”) include a polycrystalline diamond (“PCD”) table in which cobalt is alloyed with phosphorous to improve the thermal stability of the PCD table. The PDC includes a substrate and a PCD table including an upper surface spaced from an interfacial surface that is bonded to the substrate. The PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The PCD table further includes an alloy comprising at least one Group VIII metal and phosphorous. The alloy is disposed in at least a portion of the plurality of interstitial regions.Type: GrantFiled: March 2, 2018Date of Patent: October 8, 2019Assignee: US SYNTHETIC CORPORATIONInventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson, Kevin Duy Nguyen
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Patent number: 10428589Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.Type: GrantFiled: August 22, 2017Date of Patent: October 1, 2019Assignee: US SYNTHETIC CORPORATIONInventors: Cody William Knuteson, Paul Douglas Jones, Brandon P. Linford, Brent R. Eddy, Kenneth E. Bertagnolli, Debkumar Mukhopadhyay
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Patent number: 10240398Abstract: The present disclosure relates to an industrial device, such as a drill bit including a thermally stable polycrystalline diamond (TSP) table coupled to a substrate via an attachment joint, with at least one attachment material located in the attachment joint. At least one of the attachment materials includes a metal or metal alloy and an additive material having a hardness higher than the metal or metal alloy or a coefficient of thermal expansion lower than that of the metal or metal alloy.Type: GrantFiled: December 23, 2013Date of Patent: March 26, 2019Assignee: Halliburton Energy Services, Inc.Inventors: Seth Garrett Anderle, Cody William Knuteson
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Publication number: 20180328115Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability and/or wear resistance of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element such as phosphorous.Type: ApplicationFiled: July 12, 2018Publication date: November 15, 2018Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson
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Publication number: 20180238116Abstract: Polycrystalline diamond compacts (“PDCs”) include a polycrystalline diamond (“PCD”) table in which cobalt is alloyed with phosphorous to improve the thermal stability of the PCD table. For example, a PDC includes a substrate and a PCD table including an upper surface spaced from an interfacial surface that is bonded to the substrate. The PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The PCD table further includes an alloy comprising at least one Group VIII metal and phosphorous. The alloy is disposed in at least a portion of the plurality of interstitial regions.Type: ApplicationFiled: March 2, 2018Publication date: August 23, 2018Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson, Kevin Duy Nguyen
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Patent number: 10047568Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability and/or wear resistance of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element such as phosphorous.Type: GrantFiled: April 2, 2015Date of Patent: August 14, 2018Assignee: US SYNTHETIC CORPORATIONInventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson
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Patent number: 10022843Abstract: Embodiments of the invention relate to methods of forming polycrystalline diamond compacts (“PDCs”), wherein the PDC includes a polycrystalline diamond (“PCD”) table in which at least one Group VIII metal is at least partially alloyed with phosphorus and/or at least one other alloying element to improve the thermal stability of the PCD table. The disclosed PDCs may be used in a variety of applications, such as rotary drill bits, machining equipment, and other articles and apparatuses.Type: GrantFiled: February 24, 2017Date of Patent: July 17, 2018Assignee: US SYNTHETIC CORPORATIONInventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson
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Patent number: 9945186Abstract: Polycrystalline diamond compacts (“PDCs”) include a polycrystalline diamond (“PCD”) table in which cobalt is alloyed with phosphorous to improve the thermal stability of the PCD table. For example, a PDC includes a substrate and a PCD table including an upper surface spaced from an interfacial surface that is bonded to the substrate. The PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The PCD table further includes an alloy comprising at least one Group VIII metal and phosphorous. The alloy is disposed in at least a portion of the plurality of interstitial regions.Type: GrantFiled: June 13, 2014Date of Patent: April 17, 2018Assignee: US SYNTHETIC CORPORATIONInventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson, Kevin Duy Nguyen
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Publication number: 20170370158Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.Type: ApplicationFiled: August 22, 2017Publication date: December 28, 2017Inventors: Cody William Knuteson, Paul Douglas Jones, Brandon P. Linford, Brent R. Eddy, Kenneth E. Bertagnolli, Debkumar Mukhopadhyay
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Patent number: 9765572Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.Type: GrantFiled: November 21, 2013Date of Patent: September 19, 2017Assignee: US SYNTHETIC CORPORATIONInventors: Cody William Knuteson, Paul Douglas Jones, Brandon P. Linford, Brent R. Eddy, Kenneth E. Bertagnolli, Debkumar Mukhopadhyay
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Publication number: 20170157746Abstract: Embodiments of the invention relate to methods of forming polycrystalline diamond compacts (“PDCs”), wherein the PDC includes a polycrystalline diamond (“PCD”) table in which at least one Group VIII metal is at least partially alloyed with phosphorus and/or at least one other alloying element to improve the thermal stability of the PCD table. The disclosed PDCs may be used in a variety of applications, such as rotary drill bits, machining equipment, and other articles and apparatuses.Type: ApplicationFiled: February 24, 2017Publication date: June 8, 2017Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson
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Patent number: D984500Type: GrantFiled: June 21, 2019Date of Patent: April 25, 2023Assignee: US Synthetic CorporationInventor: Cody William Knuteson