Patents by Inventor Kenneth E. Bertagnolli

Kenneth E. Bertagnolli 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).

  • Publication number: 20180179114
    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: Application
    Filed: February 21, 2018
    Publication date: June 28, 2018
    Inventors: Kenneth E. Bertagnolli, Jiang Qian, Jason Wiggins, Michael Vail, Debkumar Mukhopadhyay
  • Patent number: 9951566
    Abstract: Methods of manufacturing a superabrasive element are disclosed. In one embodiment, a substrate and a preformed superabrasive volume may be at least partially surrounded by an enclosure and the enclosure may be sealed in an inert environment. Further, the enclosure may be exposed to an elevated pressure and preformed superabrasive volume may be affixed to the substrate. Polycrystalline diamond elements are disclosed. In one embodiment, a polycrystalline diamond element may comprise a preformed polycrystalline diamond volume bonded to a substrate by a braze material. Optionally, such a polycrystalline diamond element may exhibit a compressive stress. Rotary drill bit for drilling a subterranean formation and including at least one superabrasive element are also disclosed.
    Type: Grant
    Filed: October 30, 2013
    Date of Patent: April 24, 2018
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Kenneth E. Bertagnolli, David P. Miess
  • Patent number: 9945186
    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. 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: Grant
    Filed: June 13, 2014
    Date of Patent: April 17, 2018
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson, Kevin Duy Nguyen
  • Patent number: 9932274
    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: August 16, 2016
    Date of Patent: April 3, 2018
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Kenneth E. Bertagnolli, Jiang Qian, Jason Wiggins, Michael Vail, Debkumar Mukhopadhyay
  • Publication number: 20170370158
    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 22, 2017
    Publication date: December 28, 2017
    Inventors: Cody William Knuteson, Paul Douglas Jones, Brandon P. Linford, Brent R. Eddy, Kenneth E. Bertagnolli, Debkumar Mukhopadhyay
  • Patent number: 9765572
    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: November 21, 2013
    Date of Patent: September 19, 2017
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Cody William Knuteson, Paul Douglas Jones, Brandon P. Linford, Brent R. Eddy, Kenneth E. Bertagnolli, Debkumar Mukhopadhyay
  • Patent number: 9719307
    Abstract: A polycrystalline diamond compact useful for wear, cutting, drilling, drawing and like applications is provided with a first diamond region remote from the working surface which has a metallic catalyzing material and a second diamond region adjacent to or including the working surface containing a non-metallic catalyst and the method of making such a compact is provided. This compact is particularly useful in high temperature operations, such as hard rock drilling because of the improved thermal stability at the working surface.
    Type: Grant
    Filed: October 6, 2014
    Date of Patent: August 1, 2017
    Assignee: U.S. Synthetic Corporation
    Inventors: Kenneth E. Bertagnolli, Michael A. Vail
  • Publication number: 20170210081
    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: January 10, 2017
    Publication date: July 27, 2017
    Inventors: Kenneth E. Bertagnolli, Michael A. Vail, Jiang Qian, Jason K. Wiggins, Mark P. Chapman, Arnold D. Cooper, Debkumar Mukhopadhyay, Amy Leigh Rodriguez, Steven Rudger Adams
  • Publication number: 20170157746
    Abstract: 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: Application
    Filed: February 24, 2017
    Publication date: June 8, 2017
    Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson
  • Patent number: 9657529
    Abstract: Embodiments of the invention relate to thermally-stable polycrystalline diamond compacts (“PDCs”), and methods of fabricating such PDCs. In an embodiment, a PDC includes a substrate and a pre-sintered polycrystalline diamond (“PCD”) table bonded to the substrate. The pre-sintered PCD table includes bonded diamond grains defining a plurality of interstitial regions. The pre-sintered PCD table further including a first region remote from the substrate including a nonmetallic catalyst and a metallic catalyst each of which is disposed interstitially between the bonded diamond grains thereof, and a second region bonded to the substrate including a metallic-catalyst infiltrant disposed interstitially between the bonded diamond grains thereof. A nonplanar boundary is located between the first region and the second region.
    Type: Grant
    Filed: July 15, 2015
    Date of Patent: May 23, 2017
    Assignee: US SYNTHETICS CORPORATION
    Inventors: Kenneth E. Bertagnolli, Michael A. Vail
  • Patent number: 9650839
    Abstract: In an embodiment, a superabrasive compact is disclosed in which a heat-absorbing material having a phase-transition temperature lower than a peak operating temperature of a superabrasive table of the superabrasive compact is positioned in the superabrasive compact. In some embodiments, the heat-absorbing material positioned between the substrate and the superabrasive table. In another embodiment, a rotary drill bit is also disclosed including a bit body and at least one cutting element including a substrate and a superabrasive table bonded to the substrate. At least one heat-absorbing material is positioned within the bit body at least proximate to the at least one cutting element.
    Type: Grant
    Filed: January 6, 2016
    Date of Patent: May 16, 2017
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Kenneth E. Bertagnolli, Jason Wiggins, Shawn C. Scott
  • Patent number: 9643373
    Abstract: In an embodiment, a cell assembly for use in a high-pressure cubic press may include at least one can assembly containing a diamond volume. The at least one can assembly may include an end surface in proximity to the diamond volume. The cell assembly may include at least one heating element including a major surface generally opposing and positioned adjacent to the end surface of the at least one can assembly. The at least one heating element may be positioned and configured to heat the diamond volume. The cell assembly may include at least one pressure transmitting medium extending about the at least one can assembly, and a gasket medium that defines a receiving space configured to receive the at least one can assembly, the one or more heating elements, and the at least one pressure transmitting medium.
    Type: Grant
    Filed: January 8, 2013
    Date of Patent: May 9, 2017
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Kenneth E Bertagnolli, Michael A Vail, Arnold D Cooper, Paul Douglas Jones, Damon B Crocket
  • Patent number: 9623542
    Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) comprising a polycrystalline diamond (“PCD”) table including a thermally-stable region having at least one low-carbon-solubility material disposed interstitially between bonded diamond grains thereof, and methods of fabricating such PDCs. In an embodiment, a PDC includes a substrate, and a PCD table bonded to the substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions. The PCD table further includes at least one low-carbon-solubility material disposed in at least a portion of the plurality of interstitial regions. The at least one low-carbon-solubility material exhibits a melting temperature of about 1300° C. or less and a bulk modulus at 20° C. of less than about 150 GPa.
    Type: Grant
    Filed: December 15, 2014
    Date of Patent: April 18, 2017
    Assignee: US SYNTHETIC CORPORATION
    Inventors: David P. Miess, Michael A. Vail, Kenneth E. Bertagnolli, C. Eugene McMurray, Paul Douglas Jones
  • Patent number: 9610555
    Abstract: 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: Grant
    Filed: April 2, 2015
    Date of Patent: April 4, 2017
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Debkumar Mukhopadhyay, Kenneth E. Bertagnolli, Cody William Knuteson
  • Publication number: 20160355440
    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: Application
    Filed: August 16, 2016
    Publication date: December 8, 2016
    Inventors: Kenneth E. Bertagnolli, Jiang Qian, Jason Wiggins, Michael Vail, Debkumar Mukhopadhyay
  • Patent number: 9459236
    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 Oersteads (“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: August 18, 2010
    Date of Patent: October 4, 2016
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Kenneth E. Bertagnolli, Jiang Qian, Jason Wiggins, Michael A. Vail, Debkumar Mukhopadhyay
  • Patent number: 9453270
    Abstract: Embodiments relate to PDCs, methods of fabricating PDCs, and applications for such PDCs. In an embodiment, a PDC includes a substrate and a pre-sintered PCD table including an interfacial surface that is bonded to the substrate. The pre-sintered PCD table may be substantially free of leaching by-products in a region at least proximate to the interfacial surface. In an embodiment, a method of fabricating a PDC includes providing an at least partially leached PCD including an interfacial surface. The method includes removing at least some leaching by-products from the at least partially leached PCD table. After removing the at least some leaching by-products, the method includes bonding the interfacial surface of the at least partially leached PCD table to a substrate to form a PDC.
    Type: Grant
    Filed: July 15, 2014
    Date of Patent: September 27, 2016
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Michael A. Vail, Kenneth E. Bertagnolli
  • Publication number: 20160263727
    Abstract: Embodiments of the invention relate to methods of fabricating polycrystalline diamond compacts (“PDCs”) and applications for such PDCs. In an embodiment, a method of fabricating a PDC includes providing a polycrystalline diamond (“PCD”) table in which a catalyst is disposed throughout, leaching the PCD table with a gaseous leaching agent to remove catalyst from the PCD table and bonding the at least partially leached PCD table to a substrate to form a PDC.
    Type: Application
    Filed: September 22, 2014
    Publication date: September 15, 2016
    Inventors: Julie Ann Kidd, Michael A. Vail, Kenneth E. Bertagnolli
  • Publication number: 20160263725
    Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) comprising a polycrystalline diamond (“PCD”) table including a thermally-stable region having at least one low-carbon-solubility material disposed interstitially between bonded diamond grains thereof, and methods of fabricating such PDCs. In an embodiment, a PDC includes a substrate, and a PCD table bonded to the substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions. The PCD table further includes at least one low-carbon-solubility material disposed in at least a portion of the plurality of interstitial regions. The at least one low-carbon-solubility material exhibits a melting temperature of about 1300° C. or less and a bulk modulus at 20° C. of less than about 150 GPa.
    Type: Application
    Filed: February 26, 2015
    Publication date: September 15, 2016
    Inventors: David P. Miess, Michael A. Vail, Kenneth E. Bertagnolli, C. Eugene McMurray, Paul Douglas Jones
  • Patent number: 9443042
    Abstract: Embodiments of systems and methods are disclosed for evaluating a superabrasive material by a three-dimensional model generated using a computed tomography scanner. The model is analyzed to identify a superabrasive matrix within the model and at least one performance characteristic of the superabrasive material is determined according to at least one property of the superabrasive matrix. Methods are also disclosed for characterizing crystal-to-crystal bonding regions and non-superabrasive material within an interstitial matrix of the superabrasive matrix.
    Type: Grant
    Filed: February 20, 2015
    Date of Patent: September 13, 2016
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Craig H. Cooley, Debkumar Mukhopadhyay, Kenneth E. Bertagnolli