Patents by Inventor Debkumar Mukhopadhyay

Debkumar Mukhopadhyay 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).

  • Patent number: 10773480
    Abstract: Embodiments disclosed herein relate to cell assemblies for fabricating superhard materials (e.g., used in a high-pressure cubic press) and methods of using the same. The disclosed cell assemblies include a plurality of internal anvils, at least some of which are positioned internally relative to a cell pressure medium of the cell assembly. Such a configuration for the cell assemblies may enable one or more of intensifying cell pressure, reducing processing time, or reducing costs for fabricating such superhard materials.
    Type: Grant
    Filed: October 1, 2019
    Date of Patent: September 15, 2020
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Kenneth E. Bertagnolli, Michael A. Vail, Jiang Qian, Jason K. Wiggins, Mark P. Chapman, Arnold D. Cooper, Debkumar Mukhopadhyay, Amy Leigh Rodriguez, Stephen Rudger Adams
  • Publication number: 20200256133
    Abstract: Embodiments disclosed herein relate to superabrasive compacts, methods of making the same, and drill bits incorporating the same. For example, embodiments of a superabrasive compact disclosed herein (e.g., a PDC) may be formed by providing a superabrasive compact. The superabrasive compact includes a superabrasive body and a cemented carbide substrate bonded to the superabrasive body. The cemented carbide substrate includes a base surface, an interfacial surface bonded to the superabrasive body, and at least one peripheral surface extending between the base surface and the interfacial surface.
    Type: Application
    Filed: February 11, 2020
    Publication date: August 13, 2020
    Inventors: Anne-Grethe Slotnaes, Daniel Scott, Debkumar Mukhopadhyay, Jeremy B. Lynn, Jiang Qian
  • Patent number: 10703681
    Abstract: Embodiments of the invention relate to polycrystalline diamond (“PCD”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PCD includes a plurality of diamond grains defining a plurality of interstitial regions. A metal-solvent catalyst occupies at least a portion of the plurality of interstitial regions. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit a coercivity of about 115 Oersteds (“Oe”) or more and a specific magnetic saturation of about 15 Gauss·cm3/grams (“G·cm3/g”) or less. Other embodiments are directed to polycrystalline diamond compacts (“PDCs”) employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.
    Type: Grant
    Filed: February 21, 2018
    Date of Patent: July 7, 2020
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Kenneth E. Bertagnolli, Jiang Qian, Jason Wiggins, Michael Vail, Debkumar Mukhopadhyay
  • Publication number: 20200141189
    Abstract: In an embodiment, a method of fabricating a polycrystalline diamond compact is disclosed. The method includes sintering a plurality of diamond particles in the presence of a metal-solvent catalyst to form a polycrystalline diamond body; leaching the polycrystalline diamond body to at least partially remove the metal-solvent catalyst therefrom, thereby forming an at least partially leached polycrystalline diamond body; and subjecting an assembly of the at least partially leached polycrystalline diamond body and a cemented carbide substrate to a high-pressure/high-temperature process at a pressure to infiltrate the at least partially leached polycrystalline diamond body with an infiltrant. The pressure of the high-pressure/high-temperature process is less than that employed in the act of sintering of the plurality of diamond particles.
    Type: Application
    Filed: October 29, 2019
    Publication date: May 7, 2020
    Inventors: Kenneth E. Bertagnolli, David P. Miess, Jiang Qian, Jason K. Wiggins, Michael A. Vail, Debkumar Mukhopadhyay
  • Publication number: 20200130141
    Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDC”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, a PDC includes a polycrystalline diamond (“PCD”) table bonded to a substrate. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The plurality of interstitial regions includes a metal-solvent catalyst. The plurality of diamond grains exhibit an average grain size of about 30 ?m or less. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit an average electrical conductivity of less than about 1200 S/m. Other embodiments are directed to PCD, employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.
    Type: Application
    Filed: October 29, 2019
    Publication date: April 30, 2020
    Inventors: Kenneth E. Bertagnolli, Jiang Qian, Jason K. Wiggins, Michael A. Vail, Debkumar Mukhopadhyay, Brandon P. Linford
  • Patent number: 10612313
    Abstract: Embodiments relate to a polycrystalline diamond compact (“PDC”) including a polycrystalline diamond (“PCD”) table bonded to a cemented carbide substrate including tungsten carbide grains having a fine average grain size to provide one or more of enhanced wear resistance, corrosion resistance, or erosion resistance, and a PDC with enhanced impact resistance. In an embodiment, a PDC includes a cemented carbide substrate having a cobalt-containing cementing constituent cementing tungsten carbide grains together exhibiting an average grain size of about 1.5 ?m or less. The 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. The PDC includes a PCD table bonded to the interfacial surface of the substrate. The PCD table includes diamond grains bonded together exhibiting an average grain size of about 40 ?m or less.
    Type: Grant
    Filed: July 13, 2017
    Date of Patent: April 7, 2020
    Assignee: US SYNTHETIC CORPORATION
    Inventor: Debkumar Mukhopadhyay
  • Publication number: 20200031076
    Abstract: Embodiments disclosed herein relate to cell assemblies for fabricating superhard materials (e.g., used in a high-pressure cubic press) and methods of using the same. The disclosed cell assemblies include a plurality of internal anvils, at least some of which are positioned internally relative to a cell pressure medium of the cell assembly. Such a configuration for the cell assemblies may enable one or more of intensifying cell pressure, reducing processing time, or reducing costs for fabricating such superhard materials.
    Type: Application
    Filed: October 1, 2019
    Publication date: January 30, 2020
    Inventors: Kenneth E. Bertagnolli, Michael A. Vail, Jiang Qian, Jason K. Wiggins, Mark P. Chapman, Arnold D. Cooper, Debkumar Mukhopadhyay, Amy Leigh Rodriguez, Stephen Rudger Adams
  • Publication number: 20200024905
    Abstract: 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: Application
    Filed: August 26, 2019
    Publication date: January 23, 2020
    Inventors: Cody William Knuteson, Paul Douglas Jones, Brandon P. Linford, Brent R. Eddy, Kenneth E. Bertagnolli, Debkumar Mukhopadhyay
  • Patent number: 10508502
    Abstract: In an embodiment, a method of fabricating a polycrystalline diamond compact is disclosed. The method includes sintering a plurality of diamond particles in the presence of a metal-solvent catalyst to form a polycrystalline diamond body; leaching the polycrystalline diamond body to at least partially remove the metal-solvent catalyst therefrom, thereby forming an at least partially leached polycrystalline diamond body; and subjecting an assembly of the at least partially leached polycrystalline diamond body and a cemented carbide substrate to a high-pressure/high-temperature process at a pressure to infiltrate the at least partially leached polycrystalline diamond body with an infiltrant. The pressure of the high-pressure/high-temperature process is less than that employed in the act of sintering of the plurality of diamond particles.
    Type: Grant
    Filed: March 19, 2019
    Date of Patent: December 17, 2019
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Kenneth E. Bertagnolli, David P. Miess, Jiang Qian, Jason K. Wiggins, Michael A. Vail, Debkumar Mukhopadhyay
  • Patent number: 10507565
    Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDC”) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, a PDC includes a polycrystalline diamond (“PCD”) table bonded to a substrate. At least a portion of the PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The plurality of interstitial regions includes a metal-solvent catalyst. The plurality of diamond grains exhibit an average grain size of about 30 ?m or less. The plurality of diamond grains and the metal-solvent catalyst collectively exhibit an average electrical conductivity of less than about 1200 S/m. Other embodiments are directed to PCD, employing such PCD, methods of forming PCD and PDCs, and various applications for such PCD and PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.
    Type: Grant
    Filed: March 24, 2016
    Date of Patent: December 17, 2019
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Kenneth E. Bertagnolli, Jiang Qian, Jason K. Wiggins, Michael A. Vail, Debkumar Mukhopadhyay, Brandon P. Linford
  • Patent number: 10493598
    Abstract: 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: Grant
    Filed: April 3, 2014
    Date of Patent: December 3, 2019
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli
  • Patent number: 10494874
    Abstract: 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: Grant
    Filed: June 25, 2018
    Date of Patent: December 3, 2019
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Debkumar Mukhopadhyay, Greg Carlos Topham, Renato Ventura
  • Patent number: 10464273
    Abstract: Embodiments disclosed herein relate to cell assemblies for fabricating superhard materials (e.g., used in a high-pressure cubic press) and methods of using the same. The disclosed cell assemblies include a plurality of internal anvils, at least some of which are positioned internally relative to a cell pressure medium of the cell assembly. Such a configuration for the cell assemblies may enable one or more of intensifying cell pressure, reducing processing time, or reducing costs for fabricating such superhard materials.
    Type: Grant
    Filed: January 10, 2017
    Date of Patent: November 5, 2019
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Kenneth E. Bertagnolli, Michael A. Vail, Jiang Qian, Jason K. Wiggins, Mark P. Chapman, Arnold D. Cooper, Debkumar Mukhopadhyay, Amy Leigh Rodriguez, Stephen Rudger Adams
  • Patent number: 10435952
    Abstract: 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: Grant
    Filed: March 2, 2018
    Date of Patent: October 8, 2019
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson, Kevin Duy Nguyen
  • Patent number: 10428589
    Abstract: 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: Grant
    Filed: August 22, 2017
    Date of Patent: October 1, 2019
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Cody William Knuteson, Paul Douglas Jones, Brandon P. Linford, Brent R. Eddy, Kenneth E. Bertagnolli, Debkumar Mukhopadhyay
  • Publication number: 20190242193
    Abstract: In an embodiment, a polycrystalline diamond compact includes a substrate, and a polycrystalline diamond (“PCD”) table bonded to the substrate and including an exterior working surface, at least one lateral surface, and a chamfer extending between the exterior working surface and the at least one lateral surface. The PCD table includes bonded diamond grains defining interstitial regions. The PCD table includes a first region adjacent to the substrate and a second leached region adjacent to the first region and extending inwardly from the exterior working surface to a selected depth. At least a portion of the interstitial regions of the first region include an infiltrant disposed therein. The interstitial regions of the second leached region are substantially free of metal-solvent catalyst. The second region is defined by the exterior working surface, the lateral surface, the chamfer, and a generally horizontal boundary located below the chamfer.
    Type: Application
    Filed: April 16, 2019
    Publication date: August 8, 2019
    Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Jair J. Gonzalez
  • Publication number: 20190211629
    Abstract: In an embodiment, a method of fabricating a polycrystalline diamond compact is disclosed. The method includes sintering a plurality of diamond particles in the presence of a metal-solvent catalyst to form a polycrystalline diamond body; leaching the polycrystalline diamond body to at least partially remove the metal-solvent catalyst therefrom, thereby forming an at least partially leached polycrystalline diamond body; and subjecting an assembly of the at least partially leached polycrystalline diamond body and a cemented carbide substrate to a high-pressure/high-temperature process at a pressure to infiltrate the at least partially leached polycrystalline diamond body with an infiltrant. The pressure of the high-pressure/high-temperature process is less than that employed in the act of sintering of the plurality of diamond particles.
    Type: Application
    Filed: March 19, 2019
    Publication date: July 11, 2019
    Inventors: Kenneth E. Bertagnolli, David P. Miess, Jiang Qian, Jason K. Wiggins, Michael A. Vail, Debkumar Mukhopadhyay
  • Patent number: 10315288
    Abstract: In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table bonded to the substrate. The table includes bonded diamond grains defining interstitial regions. The table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending therebetween. The table includes a first region extending inwardly from the upper surface and the lateral surface. The first region exhibits a first interstitial region concentration and includes at least one interstitial constituent disposed therein, which may be present in at least a residual amount and includes at least one metal carbonate and/or at least one metal oxide. The table includes a second bonding region adjacent to the substrate that extends inwardly from the back surface. The second bonding region exhibits a second interstitial region concentration that is greater than the first interstitial region concentration and includes a metallic infiltrant therein.
    Type: Grant
    Filed: February 10, 2016
    Date of Patent: June 11, 2019
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Jiang Qian, C. Eugene McMurray, Debkumar Mukhopadhyay, Jason K. Wiggins, Michael A. Vail, Kenneth E. Bertagnolli
  • Patent number: 10309158
    Abstract: In an embodiment, a method of fabricating a polycrystalline diamond compact (“PDC”) includes forming a polycrystalline diamond (“PCD”) table in the presence of a metal-solvent catalyst in a first high-pressure/high-temperature (“HPHT”) process. The PCD table includes bonded diamond grains defining interstitial regions, with the metal-solvent catalyst disposed therein. The method includes at least partially leaching the PCD table to remove at least a portion of the metal-solvent catalyst therefrom. The method includes subjecting the at least partially leached PCD table and a substrate to a second HPHT process under diamond-stable temperature-pressure conditions to partially infiltrate the at least partially leached PCD table with an infiltrant. A maximum temperature (T), a total process time (t), and a maximum pressure (P) of the second HPHT process are chosen so that ? is about 2° Celsius·hours/gigapascals (“° C.·h/GPa”) to about 325° C.·h/GPa, with ? represented as ?=T·t/P.
    Type: Grant
    Filed: December 7, 2010
    Date of Patent: June 4, 2019
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Jair J. Gonzalez
  • Patent number: 10301882
    Abstract: In an embodiment, a polycrystalline diamond compact includes a substrate, and a polycrystalline diamond (“PCD”) table bonded to the substrate and including an exterior working surface, at least one lateral surface, and a chamfer extending between the exterior working surface and the at least one lateral surface. The PCD table includes bonded diamond grains defining interstitial regions. The PCD table includes a first region adjacent to the substrate and a second leached region adjacent to the first region and extending inwardly from the exterior working surface to a selected depth. At least a portion of the interstitial regions of the first region include an infiltrant disposed therein. The interstitial regions of the second leached region are substantially free of metal-solvent catalyst. The second region is defined by the exterior working surface, the lateral surface, the chamfer, and a generally horizontal boundary located below the chamfer.
    Type: Grant
    Filed: February 11, 2014
    Date of Patent: May 28, 2019
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Jair J. Gonzalez