Laminating Patents (Class 51/297)
  • Patent number: 10315175
    Abstract: A method of forming a polycrystalline diamond body includes mixing a sintering agent with diamond powder to form a premixed layer, the sintering agent including at least one alkaline eat mewl carbonate; forming an infiltration layer adjacent to the premixed layer, the infiltration layer including an infiltrant material including at least one alkaline earth metal carbonate; and subjecting the premixed layer and the infiltration layer to high pressure high temperature conditions.
    Type: Grant
    Filed: November 14, 2013
    Date of Patent: June 11, 2019
    Assignee: SMITH INTERNATIONAL, INC.
    Inventors: Yahua Bao, J. Daniel Belnap, Anatoliy Garan, Michael David France
  • Patent number: 9868100
    Abstract: Superabrasive tools and methods for the making thereof are disclosed and described. In one aspect, superabrasive particles are chemically bonded to a matrix support material according to a predetermined pattern by a braze alloy. The brazing alloy may be provided as a powder, thin sheet, or sheet of amorphous alloy. A template having a plurality of apertures arranged in a predetermined pattern may be used to place the superabrasive particles on a given substrate or matrix support material.
    Type: Grant
    Filed: June 3, 2011
    Date of Patent: January 16, 2018
    Inventor: Chien-Min Sung
  • Patent number: 9718168
    Abstract: Embodiments disclosed herein involve polycrystalline diamond (“PCD”) tables and polycrystalline diamond compacts (“PDCs”) that include PCD tables as well as methods and apparatuses for manufacturing thereof. Some embodiments include a canister assembly that may be used in a high-pressure/high-temperature (“HPHT”) process or other heating process to manufacture the PCD tables and/or the PDCs.
    Type: Grant
    Filed: April 2, 2015
    Date of Patent: August 1, 2017
    Assignee: US SYNTHETIC CORPORATION
    Inventors: Debkumar Mukhopadhyay, Robert J. Farr, Ronald W. Ward, Edwin Sean Cox, Damon Bart Crockett, Daniel Preston Wilding
  • Patent number: 9539694
    Abstract: A chemical mechanical polishing pad is provided containing: a polishing layer having a polishing surface; wherein the polishing layer comprises a first continuous non-fugitive polymeric phase and a second continuous non-fugitive polymeric phase; wherein the first continuous non-fugitive polymeric phase has a plurality of interconnected periodic recesses; wherein the plurality of interconnected periodic recesses are occupied with the second continuous non-fugitive polymeric phase; wherein the first continuous non-fugitive polymeric phase has an open cell porosity of ?6 vol %; wherein the second continuous non-fugitive polymeric phase contains an open cell porosity of ?10 vol %; and, wherein the polishing surface is adapted for polishing a substrate.
    Type: Grant
    Filed: June 26, 2015
    Date of Patent: January 10, 2017
    Assignee: Rohm and Haas Electronic Materials CMP Holdings, Inc.
    Inventors: Julia Kozhukh, Teresa Brugarolas Brufau, Bainian Qian
  • Patent number: 9463552
    Abstract: A superabrasive tools having uniformly leveled superabrasive particles and associated methods are provided. In one aspect, for example, a superabrasive can include a metal matrix configured for bonding superabrasive particles and a plurality of superabrasive particles held in the metal matrix at specific positions according to a predetermined pattern, wherein tips of each of the plurality of the superabrasive particles protrude from the metal matrix to a uniform height.
    Type: Grant
    Filed: May 23, 2011
    Date of Patent: October 11, 2016
    Inventor: Chien-Min Sung
  • Patent number: 9457449
    Abstract: A chemical mechanical polishing pad is provided containing: a polishing layer having a polishing surface; wherein the polishing layer comprises a continuous non-fugitive polymeric phase and a discontinuous non-fugitive polymeric phase; wherein the continuous non-fugitive polymeric phase has a plurality of periodic recesses; wherein the plurality of periodic recesses are occupied with the discontinuous non-fugitive polymeric phase; wherein the continuous non-fugitive polymeric phase has an open cell porosity of ?6 vol %; wherein the discontinuous non-fugitive polymeric phase contains an open cell porosity of ?10 vol %; and, wherein the polishing surface is adapted for polishing a substrate.
    Type: Grant
    Filed: June 26, 2015
    Date of Patent: October 4, 2016
    Assignee: Rohm and Haas Electronic Materials CMP Holdings, Inc.
    Inventors: Teresa Brugarolas Brufau, Julia Kozhukh, Bainian Qian
  • Patent number: 9168637
    Abstract: A vitrified superabrasive grain grinding stone includes superabrasive grains including a CBN abrasive grain as a main abrasive grain and a diamond abrasive grain as an auxiliary abrasive grain bonded together by use of a vitrified bond. The auxiliary abrasive grain has an average grain diameter equal to ½ to 1/10 of that of the main abrasive grain, and the auxiliary abrasive grain has a toughness value of 0.4 to 1 when that of the main abrasive grain is given as 1.
    Type: Grant
    Filed: January 18, 2013
    Date of Patent: October 27, 2015
    Assignee: NORITAKE CO., LIMITED
    Inventors: Akihiro Mizuno, Norio Imai, Kouichi Yoshimura, Takeshi Mishima
  • Patent number: 9126303
    Abstract: Disclosed is a method for production of a laminate polishing pad which comprises a reduced number of steps and is excellent in productivity rate, and which causes no detachment between a polishing layer and a cushion layer and can prevent the groove clogging caused by a slurry or the like. Also disclosed is a laminate polishing pad produced by the method. A method for production of a laminate polishing pad, comprising the steps of: preparing a cell-dispersed urethane composition by a mechanical frothing process; ejecting the cell-dispersed urethane composition onto a cushion layer continuously while feeding the cushion layer; curing the cell-dispersed urethane composition while controlling the thickness of the composition evenly to form a polishing layer made of a polyurethane foam, thereby producing a long laminate sheet; and cutting the long laminate sheet.
    Type: Grant
    Filed: August 25, 2006
    Date of Patent: September 8, 2015
    Assignee: Toyo Tire & Rubber Co., Ltd.
    Inventors: Junji Hirose, Masato Doura
  • Patent number: 9108301
    Abstract: A polycrystalline diamond compact (PDC) is fabricated using a process of delayed diffusion of a diffusion species (e.g., a metalloid) introduced from the back side of a cemented carbide further away from the diamond grit or from the flank side of the cemented carbide, as opposed to the side of the cemented carbide adjacent to the diamond grit. The process of fabricating the PDC includes depositing, in a metal container, a diamond grit, a cemented carbide, and a diffusion species, then applying a high pressure and high temperature (HPHT) to the contents of the metal container wherein (1) the binder of cemented carbide diffuses across the diamond grit, and (2) the diffusion species diffuses through the cemented carbide, and then through the diamond grit, thus providing a protective coating to the diamond grains of the PDC.
    Type: Grant
    Filed: March 15, 2013
    Date of Patent: August 18, 2015
    Assignee: Diamond Innovations, Inc.
    Inventors: Gary Martin Flood, Joel Vaughn
  • Publication number: 20150121768
    Abstract: Cutting elements for use with earth-boring tools include a cutting table having a base surface and a substrate having a support surface. An intermediate structure and an adhesion layer extend between the base surface of the cutting table and the support surface of the substrate. Earth-boring tools include such cutting elements. Methods for fabricating cutting elements for use with earth-boring tools include forming an intermediate structure on and extending from a support surface of a substrate and adhering a cutting table comprising a superabrasive material to the support surface of the substrate.
    Type: Application
    Filed: January 16, 2015
    Publication date: May 7, 2015
    Inventor: Nicholas J. Lyons
  • Publication number: 20150113881
    Abstract: A layer of matrix powder is deposited within a mold opening. A layer of super-abrasive particles is then deposited over the matrix powder layer. The super-abrasive particles have a non-random distribution, such as being positioned at locations set by a regular and repeating distribution pattern. A layer of matrix powder is then deposited over the super-abrasive particles. The particle and matrix powder layer deposition process steps are repeated to produce a cell having alternating layers of matrix powder and non-randomly distributed super-abrasive particles. The cell is then fused, for example using an infiltration, hot isostatic pressing or sintering process, to produce an impregnated structure. A working surface of the impregnated structure that is oriented non-parallel (and, in particular, perpendicular) to the super-abrasive particle layers is used as an abrading surface for a tool.
    Type: Application
    Filed: January 6, 2015
    Publication date: April 30, 2015
    Inventor: Michel De Reynal
  • Patent number: 8999025
    Abstract: Embodiments of the invention relate to methods of fabricating a polycrystalline diamond compacts and applications for such polycrystalline diamond compacts. In an embodiment, a method of fabricating a polycrystalline diamond body includes mechanically milling non-diamond carbon and a sintering aid material for a time and aggressiveness sufficient to form a plurality of carbon-saturated sintering aid particles and sintering a plurality of diamond particles in the presence of the plurality of carbon-saturated sintering aid particles to form the polycrystalline diamond body.
    Type: Grant
    Filed: February 16, 2012
    Date of Patent: April 7, 2015
    Assignee: US Synthetic Corporation
    Inventors: David P. Miess, Michael A. Vail, C. Eugene McMurray
  • Patent number: 8997897
    Abstract: A layer of matrix powder is deposited within a mold opening. A layer of super-abrasive particles is then deposited over the matrix powder layer. The super-abrasive particles have a non-random distribution, such as being positioned at locations set by a regular and repeating distribution pattern. A layer of matrix powder is then deposited over the super-abrasive particles. The particle and matrix powder layer deposition process steps are repeated to produce a cell having alternating layers of matrix powder and non-randomly distributed super-abrasive particles. The cell is then fused, for example using an infiltration, hot isostatic pressing or sintering process, to produce an impregnated structure. A working surface of the impregnated structure that is oriented non-parallel (and, in particular, perpendicular) to the super-abrasive particle layers is used as an abrading surface for a tool.
    Type: Grant
    Filed: June 8, 2012
    Date of Patent: April 7, 2015
    Assignee: Varel Europe S.A.S.
    Inventor: Michel De Reynal
  • Publication number: 20150090502
    Abstract: A shear claw drill bit includes a bit body and a plurality of pick receptacles fixedly attached to the bit body. Each pick receptacle has a pick cavity. The shear claw drill bit further includes a plurality of picks. Each pick has a cutter cavity. The shear claw drill bit also includes a plurality of polycrystalline diamond compact (PDC) cutters. Each PDC cutter is disposed in the cutter cavity of a respective pick of the plurality of picks. A portion of each PDC cutter protrudes out of the cutter cavity of the respective pick.
    Type: Application
    Filed: October 2, 2014
    Publication date: April 2, 2015
    Applicant: VAREL INTERNATIONAL IND., L.P.
    Inventor: William W. King
  • Publication number: 20150089880
    Abstract: A method of manufacturing PDC drill bits includes inspecting a plurality of cutters. The method further includes inspecting a plurality of pockets of a bit body. A cutter of the plurality of cutters is assigned to a pocket of the plurality of pockets based on the inspection of the plurality of cutters and the inspection of the plurality of cutter pockets. A robot positions the cutter inside the pocket and applies heat to a brazing material to produce a molten brazing material within the pocket.
    Type: Application
    Filed: September 27, 2013
    Publication date: April 2, 2015
    Applicant: VAREL EUROPE S.A.S.
    Inventors: Alfazazi Dourfaye, Gary M. Thigpen
  • Patent number: 8986406
    Abstract: A polycrystalline diamond (PCD) with diamond grains includes a first zone of the diamond grains and a second zone of the diamond grains. The first zone forms a working surface and a first catalyzing material is disposed within voids of the diamond grains in the first zone. A second catalyzing material is bonded to the diamond grains disposed in the second zone. The first catalyzing material in the first zone is connected to the diamond grains disposed in the first zone less intimately than the second catalyzing material is bonded to the diamond grains in the second zone.
    Type: Grant
    Filed: December 6, 2013
    Date of Patent: March 24, 2015
    Inventor: Rusty Petree
  • Patent number: 8986408
    Abstract: Embodiments of the invention relate to polycrystalline diamond (“PCD”) fabricated by sintering a mixture including diamond particles and a selected amount of graphite particles, polycrystalline diamond compacts (“PDCs”) having a PCD table comprising such PCD, and methods of fabricating such PCD and PDCs. In an embodiment, a method includes providing a mixture including graphite particles present in an amount of about 0.1 weight percent (“wt %”) to about 20 wt % and diamond particles. The method further includes subjecting the mixture to a high-pressure/high-temperature process sufficient to form PCD.
    Type: Grant
    Filed: October 3, 2008
    Date of Patent: March 24, 2015
    Assignee: US Synthetic Corporation
    Inventor: Mohammad N. Sani
  • Publication number: 20150075082
    Abstract: A cutting element for an earth-boring drill bit may include a thermally stable cutting table comprising a polycrystalline diamond material. The polycrystalline diamond material may consist essentially of a matrix of diamond particles bonded to one another and a silicon, silicon carbide, or silicon and silicon carbide material located within interstitial spaces among interbonded diamond particles of the matrix of diamond particles. The cutting table may be at least substantially free of Group VIII metal or alloy catalyst material. The cutting element may further include a substrate and an adhesion material between and bonded to the cutting table and the substrate. The adhesion material may include diamond particles bonded to one another and to the cutting table and the substrate after formation of the preformed cutting table.
    Type: Application
    Filed: September 10, 2014
    Publication date: March 19, 2015
    Inventor: Danny E. Scott
  • Publication number: 20150075878
    Abstract: A cutting element for a cutting tool. The cutting element may be at least partially made from a composite material including a carbide material, a binder material, and a plurality of diamond particles. The carbide material may be from 55 wt % to 97 wt % of a total weight of the composite material. The binder material may be from 3 wt % to 20 wt % of the total weight of the composite material. The plurality of diamond particles may be from 0.1% to 25% of the total weight of the composite material. The carbide material and the binder material may be combined and sintered together prior to being combined with the plurality of diamond particles, such that the carbide material and the binder material form a plurality of pellets having an average cross-sectional length from 10 ?m to 250 ?m.
    Type: Application
    Filed: September 16, 2014
    Publication date: March 19, 2015
    Inventors: SIKE XIA, XIN DENG
  • Publication number: 20150072601
    Abstract: Superabrasive tools and methods for making and using the same are provided. In one aspect, for example, a CMP pad dresser includes a first monolayer of superabrasive particles disposed on and coupled to one side of a metal support layer and a second monolayer of superabrasive particles disposed on and coupled to the metal support layer on an opposite side from the first monolayer. The superabrasive particles of the second monolayer are positioned to have substantially the same distribution as the superabrasive particles of the first monolayer.
    Type: Application
    Filed: July 15, 2014
    Publication date: March 12, 2015
    Inventor: Chien-Min Sung
  • Publication number: 20150072595
    Abstract: Methods and systems for evaluating and/or increasing CMP pad dresser performance are provided. In one aspect, for example, a method of identifying overly-aggressive superabrasive particles in a CMP pad dresser can include positioning a CMP pad dresser having a plurality of superabrasive particles on an indicator substrate such that at least a portion of the plurality of superabrasive particles of the CMP pad dresser contact the indicator substrate, and moving the CMP pad dresser across the indicator substrate in a first direction such that the portion of the plurality of superabrasive particles create a first marking pattern on the substrate, wherein the first marking pattern identifies a plurality of working superabrasive particles from among the plurality of superabrasive particles.
    Type: Application
    Filed: March 24, 2014
    Publication date: March 12, 2015
    Inventor: Chien-Min Sung
  • Patent number: 8968435
    Abstract: A coated abrasive product including green, unfired abrasive aggregates having a generally spheroidal or toroidal shape, the aggregates formed from a composition comprising abrasive grit particles and a nanoparticle binder, wherein the abrasive aggregates are dispersed within a polymer resin coating, and wherein the coated abrasive product is capable of polishing an optical component, including ophthalmic lenses without the need to apply an abrasive slurry.
    Type: Grant
    Filed: March 29, 2013
    Date of Patent: March 3, 2015
    Assignees: Saint-Gobain Abrasives, Inc., Saint-Gobain Abrasifs
    Inventors: James J. Manning, Mark E. Sternberg, Jianna Wang
  • Patent number: 8961719
    Abstract: A method for making a treated super-hard structure, the method including providing a super-hard structure comprising super-hard material selected from polycrystalline cubic boron nitride (PCBN) material or thermally stable polycrystalline diamond (PCD) material; subjecting the super-hard structure to heat treatment at a treatment temperature of greater than 700 degrees centigrade at a treatment pressure at which the super-hard material is not thermodynamically stable, for a treatment period of at least about 5 minutes to produce the treated super-hard structure.
    Type: Grant
    Filed: May 25, 2012
    Date of Patent: February 24, 2015
    Assignee: Element Six Limited
    Inventors: Stig Åke Andersin, Bernd Heinrich Ries, Frank Friedrich Lachmann, Lars-Ivar Nilsson
  • Patent number: 8945252
    Abstract: A coated abrasive laminate disc (100) has a backing (120) with glass (125) and woven fabrics (124) laminated with a thermoplastic adhesive (122) having a melting onset temperature in a range of from about 140° C. to 190° C. and comprising polyamide and/or polyurethane. Methods of making are the coated abrasive laminate discs (100) are also disclosed.
    Type: Grant
    Filed: August 7, 2008
    Date of Patent: February 3, 2015
    Assignee: 3M Innovative Properties Company
    Inventor: Steven J. Keipert
  • Publication number: 20150027788
    Abstract: Cutters mounted on bits for advancing boreholes are subject to extreme forces that can separate the cutter from the bit. A cutter backing element with a rearward extending lug and forward face can provide support to the cutter. The backing element is attached to the back face of the cutter and the lug of the backing element is received in a recess of the bit. The backing element can be brazed to the bit and the cutter. The lug is offset from a longitudinal axis of the backing element. Forces applied to the front of the cutter during drilling operations are transferred through the cutter to the backing element and to the bit through the offset lug.
    Type: Application
    Filed: July 23, 2014
    Publication date: January 29, 2015
    Inventor: Jason Maw
  • Patent number: 8932376
    Abstract: Thermally stable diamond-bonded compacts include a diamond-bonded body having a thermally stable region extending a distance below a diamond-bonded body surface. The thermally stable region comprises a matrix first phase of bonded together diamond crystals, and a second phase interposed within the matrix phase. At least some population of the second phase comprises a reaction product formed between an infiltrant material and the diamond crystals at high pressure/high temperature conditions. The diamond bonded body further includes a polycrystalline diamond region that extends a depth from the thermally stable region and has a microstructure comprising a polycrystalline diamond matrix phase and a catalyst material disposed within interstitial regions of the matrix phase. The compact includes a substrate attached to the diamond-bonded body.
    Type: Grant
    Filed: June 1, 2010
    Date of Patent: January 13, 2015
    Assignee: Smith International, Inc.
    Inventor: Stewart N. Middlemiss
  • Publication number: 20150007505
    Abstract: A method of making a combination tool including a mining drill bit and reamer. The combination tool includes drill bit body having a plurality of cutting segments attached thereto, a reamer body having a plurality of reaming segments attached thereto, and the drill bit body and the reamer body being configured to selectively attach to the one another. The cutting segments and reamer segments being attached by laser welding to the drill bit body and reamer body, respectively.
    Type: Application
    Filed: June 27, 2014
    Publication date: January 8, 2015
    Inventors: Karl H. Moller, Thomas G. Ruffner
  • Publication number: 20150004879
    Abstract: A method for producing a laminated polishing pad, which is free from warpage and does not cause peeling between a polishing layer and a cushion layer during polishing, includes the steps of: laminating a hot-melt adhesive sheet to a surface of a cushion layer with a base material in which a thermoplastic resin base material is provided peelably on one surface of the cushion layer, on which the thermoplastic resin base material is not provided; heating the laminated hot-melt adhesive sheet to be melted or softened; laminating a polishing layer on the melted or softened hot-melt adhesive to prepare a laminate; cutting the laminate to the size of the polishing layer to prepare a laminated polishing sheet; and peeling the thermoplastic resin base material from the laminated polishing sheet.
    Type: Application
    Filed: January 9, 2013
    Publication date: January 1, 2015
    Inventor: Yoshiyuki Nakai
  • Publication number: 20150000201
    Abstract: A method of attaching a pre-sintered body of polycrystalline diamond material to a substrate along an interface therebetween, the substrate being formed of cemented carbide and a metal binder phase dispersed therein, comprises placing a layer comprising one or more elements or alloys thereof on the interface on one or other of the body of polycrystalline diamond material or substrate; the one or more elements being selected to form a eutectic mixture with the metal in the binder phase, the eutectic mixture having a lower melting point than the melting point of the metal in the binder phase of the substrate.
    Type: Application
    Filed: December 13, 2012
    Publication date: January 1, 2015
    Inventor: Kaveshini Naidoo
  • Publication number: 20150000988
    Abstract: Position indication in multiplexed downhole well tools. A method of selectively actuating and indicating a position in a well includes selecting at least one well tool from among multiple well tools for actuation by flowing direct current in one direction through a set of conductors in the well, the well tool being deselected for actuation when direct current flows through the set of conductors an opposite direction; and detecting a varying resistance across the set of conductors as the selected well tool is actuated, the variation in resistance providing an indication of a position of a portion of the selected well tool.
    Type: Application
    Filed: September 10, 2013
    Publication date: January 1, 2015
    Inventor: Shilin Chen
  • Publication number: 20140378032
    Abstract: The purpose of the present invention is to provide a laminated polishing pad that can be flatly bonded to a polishing platen even if it is large in size. This laminated polishing pad, comprising a polishing layer and a support layer with an adhesive member interposed therebetween, wherein the polishing layer contains 0.5 to 5% by weight of a hydrophilic substance; the support layer is a layer obtained by integrally molding a cushion layer and a resin film having a thermal dimensional change rate of 1.3 to 12.6%; the laminated polishing pad has a concavely warped form in the polishing layer side; and the laminated polishing pad has an average warp amount of 3 to 50 mm at the peripheral edge of the pad.
    Type: Application
    Filed: December 6, 2012
    Publication date: December 25, 2014
    Inventor: Atsushi Kazuno
  • Publication number: 20140357170
    Abstract: A chemical mechanical polishing pad is provided containing: a polishing layer; a plug in place endpoint detection window block; a rigid layer; and, a hot melt adhesive bonding the polishing layer to the rigid layer; wherein the polishing layer comprises the reaction product of ingredients, including: a polyfunctional isocyanate; and, a curative package; wherein the curative package contains an amine initiated polyol curative and a high molecular weight polyol curative; wherein the polishing layer exhibits a density of greater than 0.6 g/cm3; a Shore D hardness of 5 to 40; an elongation to break of 100 to 450%; and, a cut rate of 25 to 150 ?m/hr; and, wherein the polishing layer has a polishing surface adapted for polishing the substrate. Also provide are methods of making and using the chemical mechanical polishing pad.
    Type: Application
    Filed: May 31, 2013
    Publication date: December 4, 2014
    Inventors: Bainian Qian, Michelle K. Jensen, Marty W. DeGroot, Angus Repper, James Murnane, Jeffrey James Hendron, John G. Nowland, David B. James, Fengji Yeh
  • Publication number: 20140353040
    Abstract: Cutting elements for use with earth-boring tools include a cutting table having at least two sections where a boundary between the at least two sections is at least partially defined by a discontinuity formed in the cutting table. Earth-boring tools including a tool body and a plurality of cutting elements carried by the tool body. The cutting elements include a cutting table secured to a substrate. The cutting table includes a plurality of adjacent sections, each having a discrete cutting edge where at least one section is configured to be selectively detached from the substrate in order to substantially expose a cutting edge of an adjacent section. Methods for fabricating cutting elements for use with an earth-boring tool including forming a cutting table comprising a plurality of adjacent sections.
    Type: Application
    Filed: August 15, 2014
    Publication date: December 4, 2014
    Inventors: Danny E. Scott, Timothy K. Marvel, Yavuz Kadioglu, Michael R. Wells
  • Patent number: 8883288
    Abstract: An abrasive article includes a backing having a major surface, an adhesion promoting layer overlying the major surface of the backing, and a make layer directly contacting the adhesion promoting layer. The adhesion promoting layer has a thickness of at least about 10 microns and is formed of a polar thermoplastic material, a cross-linkable polymer, or blends thereof.
    Type: Grant
    Filed: August 1, 2008
    Date of Patent: November 11, 2014
    Assignees: Saint-Gobain Abrasives, Inc., Saint-Gobain Abrasifs
    Inventors: Anthony C. Gaeta, Paul S. Goldsmith, Kamran Khatami, Pranjal Shah
  • Patent number: 8882868
    Abstract: A bond matrix for metal bonded abrasive tools includes a metal bond system, porosity and an optional filler. Tools according to embodiments of the invention exhibit long tool life, produce an acceptable quality of cut and can have self-dressing properties. The bond matrix can be used, for example, in abrasives tools configured for the electronics industry, such as 1A8 wheels for slicing ball grid arrays (BGAs) and other such slicing operations.
    Type: Grant
    Filed: June 30, 2009
    Date of Patent: November 11, 2014
    Assignees: Saint-Gobain Abrasives, Inc., Saint-Gobain Abrasifs
    Inventors: Parul Walia, Srinivasan Ramanath, Richard W. Hall
  • Publication number: 20140318024
    Abstract: Partially formed earth-boring rotary drill bits comprise a first less than fully sintered particle-matrix component having at least one recess, and at least a second less than fully sintered particle-matrix component disposed at least partially within the at least one recess. Each less than fully sintered particle-matrix component comprises a green or brown structure including compacted hard particles, particles comprising a metal alloy matrix material, and an organic binder material. The at least a second less than fully sintered particle-matrix component is configured to shrink at a slower rate than the first less than fully sintered particle-matrix component due to removal of organic binder material from the less than fully sintered particle-matrix components in a sintering process to be used to sinterbond the first less than fully sintered particle-matrix component to the first less than fully sintered particle-matrix component.
    Type: Application
    Filed: July 7, 2014
    Publication date: October 30, 2014
    Inventors: Redd H. Smith, Nicholas J. Lyons
  • Patent number: 8871331
    Abstract: A coated abrasive article includes a backing having a surface, a plurality of abrasive regions overlying the surface in each of the first and second portions, and at least one macro-channel. The surface of the backing has a shape defined by an outer contour. A bisecting axis divides the shape into first and second portions. Each abrasive region includes a binder and a plurality of abrasive grains in contact with the binder. The abrasive grains have an average grain size of not greater than about 200 microns. The at least one macro-channel defines a passageway extending between a pair of adjacent abrasive regions and terminating at openings at the outer contour within each of the first and second portions. The macro-channel has an average channel width of between about 0.1 millimeters to about 5 millimeters and is substantially free of the binder and the abrasive grains.
    Type: Grant
    Filed: December 22, 2010
    Date of Patent: October 28, 2014
    Assignees: Saint-Gobain Abrasives, Inc., Saint-Gobain Abrasifs
    Inventor: Anuj Seth
  • Patent number: 8858870
    Abstract: A method of making an article of manufacture includes positioning a cemented carbide piece comprising at least 5% of the total volume of the article of manufacture, and, optionally, a non-cemented carbide piece in a void of a mold in predetermined positions to partially fill the void and define an unoccupied space. Inorganic particles are added to the mold to partially fill the unoccupied space and provide a remainder space. The cemented carbide piece, the non-cemented carbide piece if present, and the hard particles are heated and infiltrated with a molten metal or a metal alloy. The melting temperature of the molten metal or the metal alloy is less than the melting temperature of the inorganic particles. The molten metal or metal alloy in the remainder space solidifies and binds the cemented carbide piece, the non-cemented carbide piece if present, and the inorganic particles to form the article of manufacture.
    Type: Grant
    Filed: June 8, 2012
    Date of Patent: October 14, 2014
    Assignee: Kennametal Inc.
    Inventors: Prakash K. Mirchandani, Morris E. Chandler, Michale E. Waller, Heath C. Coleman
  • Patent number: 8858663
    Abstract: Methods of forming cutting elements for earth-boring tools include providing a barrier material between a first powder and a second powder each comprising diamond grains, and subjecting the powders and barrier material to high temperature and high pressure conditions to form polycrystalline diamond material. The formation of the polycrystalline diamond material is catalyzed, and catalytic material may be hindered from migrating across the layer of barrier material. Cutting elements for use in earth-boring tools include a barrier material disposed between a first layer of polycrystalline diamond material and a second layer of polycrystalline diamond material. Earth-boring tools include one or more such cutting elements for cutting an earth formation.
    Type: Grant
    Filed: March 26, 2012
    Date of Patent: October 14, 2014
    Assignee: Baker Hughes Incorporated
    Inventors: Kurtis Schmitz, Danny E. Scott
  • Publication number: 20140299387
    Abstract: A cutting element for use in a drilling bit and/or a milling bit having a cutter body made of a substrate having an upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further includes a sleeve extending around a portion of a side surface of the superabrasive layer and a side surface of the substrate, wherein the sleeve exerts a radially compressive force on the superabrasive layer.
    Type: Application
    Filed: June 18, 2014
    Publication date: October 9, 2014
    Inventors: Anthony A. DiGiovanni, Nicholas J. Lyons, Matthew S. Hale, Konstantin E. Morozov, John H. Liversage, Danny E. Scott, L. Allen Sinor
  • Publication number: 20140298862
    Abstract: Provided are a pressure-sensitive adhesive tape, a polishing pad, a method of manufacturing the same, a polishing device and a method of manufacturing a glass substrate. The illustrative pressure-sensitive adhesive tape may be a pressure-sensitive adhesive tape for a polishing material. The pressure-sensitive adhesive tape may be effectively fixed to a surface plate without bubbles, and have excellent resistance to water and a polishing solution and shear strength applied in a polishing process. In addition, the pressure-sensitive adhesive tape may be easily removed from a carrier or surface plate for a polishing pad without residues after polishing.
    Type: Application
    Filed: June 23, 2014
    Publication date: October 9, 2014
    Inventors: Se Woo YANG, Suk Ky CHANG, Min Soo PARK
  • Publication number: 20140302757
    Abstract: A rotary dresser includes a cored bar, an electroformed layer, and superabrasive grains fixed to an outer circumferential surface of the electroformed layer, and a plurality of island regions in which a plurality of superabrasive grains is gathered is provided at certain intervals. Since a plurality of the island regions in which a plurality of the superabrasive grains is gathered is provided at certain intervals, the same degree of dressing accuracy can be obtained as in a case in which expensive large superabrasive grains are fixed at a low density using cheap and small superabrasive grains, it is possible to decrease the contact area of a single superabrasive grain, and favorable cutting quality can be obtained.
    Type: Application
    Filed: October 24, 2012
    Publication date: October 9, 2014
    Inventors: Kunihito Inamori, Manabu Sato
  • Publication number: 20140290145
    Abstract: A coating on mono- or poly-crystalline diamond or diamond-containing material includes a first adhesive layer formed directly on the diamond or diamond-containing material, the first layer including tungsten and tungsten carbide alloyed with fluorine in an amount of 0.001 to 0.12 wt % calculated on the total weight of the first layer. The coating further includes a second protective layer formed on the first layer, the second layer including at least tungsten alloyed with fluorine in an amount of 0.001 to 0.12 wt % calculated on the total weight of the second layer. The adhesive layer provides excellent bond strength to diamond, while the protective layer provides good protection against oxidation and molten metals used for attaching the coated diamonds to tools.
    Type: Application
    Filed: April 17, 2013
    Publication date: October 2, 2014
    Applicant: Hardide plc
    Inventors: Yuri ZHUK, Yuri LAKHOTKIN
  • Publication number: 20140291037
    Abstract: Diamond bonded constructions comprise a body comprising a plurality of bonded together diamond grains with interstitial regions disposed between the grains that are substantially free of the catalyst material used to initially sinter the body. A metallic substrate is attached to the body, and a braze joint is interposed between the body and the substrate. The body is metallized to include a metallic material disposed along a substrate attachment surface in contact with the braze joint, wherein the metallic material is different from the braze joint material. The metallic material may exist within a region of the body extending fully or partially into the body, and/or may exist as a layer extending away from the substrate attachment surface. The body includes a working surface characterized by empty interstitial regions or by interstitial regions filled with an infiltrant material, wherein the infiltrant material is different from the metallizing material.
    Type: Application
    Filed: June 11, 2014
    Publication date: October 2, 2014
    Inventors: Peter Cariveau, Georgiy Voronin, J. Daniel Belnap
  • Patent number: 8840696
    Abstract: A method of forming an abrasive article includes depositing a mixture into an opening of a substrate, contacting an exposed surface of the mixture in the opening to a texturing form to form a textured preform, and removing the mixture from the opening and forming an abrasive particle having a textured surface.
    Type: Grant
    Filed: January 10, 2013
    Date of Patent: September 23, 2014
    Assignee: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Michael D. Kavanaugh, Doruk O. Yener, Jennifer H. Czerepinski
  • Patent number: 8840695
    Abstract: A method of forming a mixture including a ceramic material into a sheet, sectioning at least a portion of the sheet using a mechanical object and forming at least one shaped abrasive particle from the sheet, such that the at least one shaped abrasive particle can have a two-dimensional shape as viewed in a plane defined by a length and a width of the shaped abrasive particle selected from the group consisting of polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, and a combination thereof.
    Type: Grant
    Filed: December 31, 2012
    Date of Patent: September 23, 2014
    Assignee: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Paul P. Braun, Doruk O. Yener, Jennifer H. Czerepinski, Ralph Bauer, Krishnamoorthy Subramanian, Robin Bright, Anuj Seth, Gregory G. Lafond
  • Publication number: 20140259496
    Abstract: A cleaning pad is provided. The cleaning pad includes a cover layer, a core, and an attachment layer. The core is located between the cover layer and the attachment layer. A porous abrasive substance is applied to the attachment layer.
    Type: Application
    Filed: March 15, 2013
    Publication date: September 18, 2014
    Inventor: Joseph D. Wahlquist
  • Publication number: 20140251698
    Abstract: Polycrystalline compacts include a hard polycrystalline material comprising first and second regions. The first region comprises a first plurality of grains of hard material having a first average grain size, and a second plurality of grains of hard material having a second average grain size smaller than the first average grain size. The first region comprises catalyst material disposed in interstitial spaces between inter-bonded grains of hard material. Such interstitial spaces between grains of the hard material in the second region are at least substantially free of catalyst material. In some embodiments, the first region comprises a plurality of nanograins of the hard material. Cutting elements and earth-boring tools include such polycrystalline compacts.
    Type: Application
    Filed: May 20, 2014
    Publication date: September 11, 2014
    Applicant: Baker Hughes Incorporated
    Inventors: Danny E. Scott, Anthony A. DiGiovanni
  • Publication number: 20140256232
    Abstract: A multilayer chemical mechanical polishing pad is provided, having: a polishing layer having a polishing surface, a counterbore opening, a polishing layer interfacial region parallel to the polishing surface; a porous subpad layer having a bottom surface and a porous subpad layer interfacial region parallel to the bottom surface; and, a broad spectrum, endpoint detection window block comprising, comprises an olefin copolymer; wherein the window block exhibits a uniform chemical composition across its thickness; wherein the polishing layer interfacial region and the porous subpad layer interfacial region form a coextensive region; wherein the multilayer chemical mechanical polishing pad has a through opening that extends from the polishing surface to the bottom surface of the porous subpad layer; wherein the counterbore opening opens on the polishing surface, enlarges the through opening and forms a ledge; and, wherein the window block is disposed within the counterbore opening.
    Type: Application
    Filed: March 7, 2013
    Publication date: September 11, 2014
    Applicants: Dow Global Technologies LLC, Rohm and Haas Electronic Materials CMP Holdings Inc.
    Inventors: Angus Repper, Mary A. Leugers, David B. James, Marty W. DeGroot
  • Publication number: 20140246254
    Abstract: A method of forming a casing bit includes positioning a cutting element adjacent an outer surface of a casing bit body. The cutting element has a superhard material and a bonding material that is used to bond the cutting element to a body of the casing bit. The bonding material may be a weldable or brazable metal alloy, and a welding process or a brazing process, respectively, may be used to bond the cutting elements to body of the casing bit. Casing bits fabricated using such methods may exhibit reduced bond strength between the cutting elements and the casing bit body.
    Type: Application
    Filed: March 1, 2013
    Publication date: September 4, 2014
    Applicant: BAKER HUGHES INCORPORATED
    Inventors: Wesley Dean Fuller, Suresh G. Patel