Patents by Inventor Yahua Bao

Yahua Bao 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: 20170341147
    Abstract: A method of making a polycrystalline diamond compact includes forming a first layer of polycrystalline diamond precursor materials comprising diamond particles and a first concentration of catalyst, forming a second layer of polycrystalline diamond precursor materials comprising diamond particles and a second concentration of catalyst, and placing a layer of an infiltrant material in the proximity of the first or the second layer of polycrystalline diamond precursor materials. The second concentration of catalyst is greater than the first concentration of catalyst. The infiltrant material is a catalyst. The first layer and the second layer are sintered under high-pressure high-temperature conditions in the presence of the infiltrant material to form the polycrystalline diamond compact. At least a portion of the catalyst is leached from the polycrystalline diamond compact.
    Type: Application
    Filed: November 19, 2015
    Publication date: November 30, 2017
    Inventor: Yahua Bao
  • Patent number: 9670100
    Abstract: The present disclosure relates to the formation of polycrystalline diamond materials with fine diamond grains and nano-sized particles of a grain growth inhibitor. In one embodiment, a method of fabricating a polycrystalline diamond material is provided. The method includes providing a mixture of diamond particles with an average particle size of about 1 micron or less, distributing a plurality of nano-sized titanium-containing particles with the diamond mixture, to act as a grain growth inhibitor, and sintering the mixture of diamond particles and titanium-containing particles at high pressure and high temperature to create a polycrystalline structure of sintered diamond grains. The sintered diamond grains have an average size of about 1 micron or less.
    Type: Grant
    Filed: November 29, 2011
    Date of Patent: June 6, 2017
    Assignee: Element Six Limited
    Inventors: Yahua Bao, Xian Yao, Scott Horman
  • Publication number: 20170144273
    Abstract: A method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond with a first quantity of magnesium carbonate to form a first layer for forming a working surface, and combining a second quantity of magnesium carbonate to form a second layer adjacent to the first layer, forming an assembly. The method includes placing a quantity of silicon or aluminum in or adjacent to at least a portion of the assembly and sintering the assembly including the silicon or aluminum at high pressure and high temperature, causing the silicon or aluminum to infiltrate at least one layer of the assembly.
    Type: Application
    Filed: December 6, 2016
    Publication date: May 25, 2017
    Inventor: YAHUA BAO
  • Publication number: 20170122038
    Abstract: A method of making a polycrystalline diamond compact includes forming multiple layers of premixed diamond particles and carbonate material, where the carbonate material includes an alkaline earth metal carbonate, and where each layer has a weight percent ratio of diamond to carbonate that is different from adjacent layers. The layers are subjected to high pressure high temperature conditions to form polycrystalline diamond.
    Type: Application
    Filed: September 26, 2016
    Publication date: May 4, 2017
    Inventors: Yahua Bao, Anatoliy Garan, Michael David France, John Daniel Belnap
  • Publication number: 20170095906
    Abstract: A polycrystalline diamond body, and a method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond particles with a first quantity of magnesium carbonate to form a first layer in an enclosure, the first layer having a working surface, and placing a second quantity of magnesium carbonate in the enclosure forming a second layer, the first layer and the second layer forming an assembly. A quantity of at least one of silicon or aluminum is mixed in with or placed adjacent to at least one of the first layer or the second layer. The assembly, including the at least one of silicon or aluminum, is sintered at high pressure and high temperature, causing the at least one of silicon or aluminum to infiltrate at least one layer of the assembly, forming a polycrystalline diamond body.
    Type: Application
    Filed: December 19, 2016
    Publication date: April 6, 2017
    Inventor: YAHUA BAO
  • Patent number: 9586376
    Abstract: A high-pressure high-temperature cell including two or more thermal insulation layers is described. A high-pressure high-temperature cell including a current path through a thermal insulation layer, the current path being electrically connected to a heating element and having an indirect path through the thermal insulation layer, is also described. High-pressure high-temperature press systems including the foregoing high-pressure high-temperature cells alone or in combination are also disclosed.
    Type: Grant
    Filed: March 15, 2013
    Date of Patent: March 7, 2017
    Assignee: SMITH INTERNATIONAL, INC.
    Inventors: Stewart N. Middlemiss, Yahua Bao, Lan Carter
  • Patent number: 9539703
    Abstract: A method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond with a first quantity of magnesium carbonate to form a first layer for forming a working surface, and combining a second quantity of magnesium carbonate to form a second layer adjacent to the first layer, forming an assembly. The method includes placing a quantity of silicon or aluminum in or adjacent to at least a portion of the assembly and sintering the assembly including the silicon or aluminum at high pressure and high temperature, causing the silicon or aluminum to infiltrate at least one layer of the assembly.
    Type: Grant
    Filed: March 14, 2014
    Date of Patent: January 10, 2017
    Assignee: Smith International, Inc.
    Inventor: Yahua Bao
  • Patent number: 9539704
    Abstract: A polycrystalline diamond body, and a method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond particles with a first quantity of magnesium carbonate to form a first layer in an enclosure, the first layer having a working surface, and placing a second quantity of magnesium carbonate in the enclosure forming a second layer, the first layer and the second layer forming an assembly. A quantity of at least one of silicon or aluminum is mixed in with or placed adjacent to at least one of the first layer or the second layer. The assembly, including the at least one of silicon or aluminum, is sintered at high pressure and high temperature, causing the at least one of silicon or aluminum to infiltrate at least one layer of the assembly, forming a polycrystalline diamond body.
    Type: Grant
    Filed: March 13, 2014
    Date of Patent: January 10, 2017
    Assignee: Smith International, Inc.
    Inventor: Yahua Bao
  • Patent number: 9475176
    Abstract: A method of making a polycrystalline diamond compact includes forming multiple layers of premised diamond particles and carbonate material, where the carbonate material includes an alkaline earth metal, carbonate, and where each layer has a weight percent ratio of diamond to carbonate that is different from adjacent layers. The layers are subjected to high pressure high temperature conditions to form polycrystalline diamond.
    Type: Grant
    Filed: November 14, 2013
    Date of Patent: October 25, 2016
    Assignee: Smith International, Inc.
    Inventors: Yahua Bao, Anatoliy Garan, Michael David France, J. Daniel Belnap
  • Publication number: 20160303827
    Abstract: The present invention relates to tungsten-rhenium coated compounds, materials formed from tungsten-rhenium coated compounds, and to methods of forming the same. In embodiments, tungsten and rhenium are coated on ultra hard material particles to form coated ultra hard material particles, and the coated ultra hard material particles are sintered at high temperature and high pressure.
    Type: Application
    Filed: June 30, 2016
    Publication date: October 20, 2016
    Inventors: Yahua Bao, Scott L. Horman
  • Patent number: 9422770
    Abstract: A method for making a diamond compact includes pre-heating a diamond body which includes a carbonate catalyst to convert at least a portion of the carbonate catalyst into an oxide, assembling the diamond body and a substrate, providing a braze material between the diamond body and the substrate to form a diamond compact, heating the braze material to melt the braze material and form a braze joint between the diamond body and the substrate, and cooling the braze material after increasing the pressure. A bit having a diamond compact including a carbonate catalyst and a metal oxide mounted thereon.
    Type: Grant
    Filed: December 27, 2012
    Date of Patent: August 23, 2016
    Assignee: Smith International, Inc.
    Inventors: J. Daniel Belnap, Yahua Bao, Youhe Zhang, Liang Zhao, Zhijun Lin
  • Patent number: 9382602
    Abstract: The present invention relates to tungsten-rhenium coated compounds, materials formed from tungsten-rhenium coated compounds, and to methods of forming the same. In embodiments, tungsten and rhenium are coated on ultra hard material particles to form coated ultra hard material particles, and the coated ultra hard material particles are sintered at high temperature and high pressure.
    Type: Grant
    Filed: August 30, 2012
    Date of Patent: July 5, 2016
    Assignee: Smith International, Inc.
    Inventors: Yahua Bao, Scott L. Horman
  • Publication number: 20160168919
    Abstract: Methods for joining an ultra-hard body, such as a thermally stable polycrystalline diamond (TSP) body, to a substrate and mitigating the formation of high stress concentration regions between the ultra-hard body and the substrate. One method includes covering at least a portion of the ultra-hard body with an intermediate layer, placing the ultra-hard body and the intermediate layer in a mold, filling a remaining portion of mold with a substrate material including a matrix material and a binder material such that the intermediate layer is disposed between the ultra-hard body and the substrate material, and heating the mold to an infiltration temperature configured to melt the binder material and form the substrate.
    Type: Application
    Filed: December 3, 2015
    Publication date: June 16, 2016
    Inventors: Liang Zhao, Xiaoge Gan, Yahua Bao, Yuri Y. Burhan, Youhe Zhang, J. Daniel Belnap, Zhijun Lin
  • Patent number: 9089951
    Abstract: Polycrystalline diamond compacts for cutting tools and rock drilling tools, and more particularly to very fine polycrystalline diamond compacts with a grain growth inhibitor layer and reduced abnormal grain growth. A method of fabricating such polycrystalline diamond material includes placing a powder layer of nano-sized grain growth inhibitor particles next to a mixture of diamond particles having an average particle size of about 1 micron or less and sintering at high pressure and high temperature to create a polycrystalline structure of sintered diamond grains. The sintered diamond grains have an average size of about 1 micron or less.
    Type: Grant
    Filed: August 23, 2012
    Date of Patent: July 28, 2015
    Assignee: Element Six Limited
    Inventors: Yahua Bao, Scott L. Horman
  • Publication number: 20150183091
    Abstract: A method for treating a polycrystalline diamond material includes subjecting the polycrystalline diamond material to a leaching process and to a thermal decomposition process.
    Type: Application
    Filed: December 10, 2014
    Publication date: July 2, 2015
    Inventors: Yahua Bao, J. Daniel Belnap, Liang Zhao
  • Publication number: 20150183092
    Abstract: A method of forming a cutting element may include subjecting a first press containing at least a diamond powder-containing container and a volume of a high melting temperature non-reactive material to a first high pressure high temperature sintering condition to form a sintered polycrystalline diamond wafer including a diamond matrix of diamond grains bonded together and a plurality of interstitial spaces between the bonded together diamond grains; and subjecting a second press containing the sintered polycrystalline diamond wafer and a substrate to a second high temperature high pressure condition, thereby attaching the wafer to the substrate to form a cutting element having a polycrystalline diamond layer on the substrate.
    Type: Application
    Filed: December 10, 2014
    Publication date: July 2, 2015
    Inventors: Yahua Bao, Ronald K. Eyre
  • Patent number: 9028573
    Abstract: The present disclosure relates to cubic boron nitride (cBN) cutting elements that have high cBN content and that are cuttable by electric discharge machining (EDM). A cutting element according to an embodiment includes a self-sintered polycrystalline cubic boron nitride (PCBN) compact, having a first phase of cubic boron nitride (cBN) particles and a ceramic binder phase with titanium compounds. The first phase occupies greater than 80% by volume of the self-sintered PCBN compact. The self-sintered PCBN compact has an electrical conductivity sufficient to be cuttable by electrical discharge machining.
    Type: Grant
    Filed: September 8, 2011
    Date of Patent: May 12, 2015
    Assignee: Element Six Limited
    Inventors: Yahua Bao, Scott Horman, Xian Yao, Qingyuan Liu
  • Patent number: 9028575
    Abstract: The present disclosure relates to cubic boron nitride (cBN) cutting elements that have high cBN content and that are cuttable by electric discharge machining (EDM). A cutting element according to an embodiment includes a self-sintered polycrystalline cubic boron nitride (PCBN) compact, having a first phase of cubic boron nitride (cBN) particles and a ceramic binder phase with titanium compounds. The first phase occupies greater than 80% by volume of the self-sintered PCBN compact. The self-sintered PCBN compact has an electrical conductivity sufficient to be cuttable by electrical discharge machining.
    Type: Grant
    Filed: September 8, 2011
    Date of Patent: May 12, 2015
    Assignee: Element Six Limited
    Inventors: Yahua Bao, Scott Horman, Xian Yao, Qingyuan Liu
  • Publication number: 20150068817
    Abstract: A method of making a cutting element includes subjecting a mixture of diamond particles and a carbonate material to high-pressure high-temperature sintering conditions to form a sintered carbonate-polycrystalline diamond body having a diamond matrix of diamond grains bonded together and carbonates residing in the interstitial regions between the diamond grains, the carbonate material having a non-uniform distribution throughout the diamond matrix. The carbonate-polycrystalline diamond body is subjected to a controlled temperature, a controlled pressure condition or a combination thereof, to effect an at least partial decomposition of the carbonate material.
    Type: Application
    Filed: September 9, 2014
    Publication date: March 12, 2015
    Inventors: YAHUA BAO, LIANG ZHAO, J. DANIEL BELNAP, ZHIJUN LIN
  • Publication number: 20140259963
    Abstract: A polycrystalline diamond body, and a method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond particles with a first quantity of magnesium carbonate to form a first layer in an enclosure, the first layer having a working surface, and placing a second quantity of magnesium carbonate in the enclosure forming a second layer, the first layer and the second layer forming an assembly. A quantity of at least one of silicon or aluminum is mixed in with or placed adjacent to at least one of the first layer or the second layer. The assembly, including the at least one of silicon or aluminum, is sintered at high pressure and high temperature, causing the at least one of silicon or aluminum to infiltrate at least one layer of the assembly, forming a polycrystalline diamond body.
    Type: Application
    Filed: March 13, 2014
    Publication date: September 18, 2014
    Applicant: SMITH INTERNATIONAL, INC.
    Inventor: YAHUA BAO