Doubled-sided and multi-layered PCBN and PCD abrasive articles
First Claim
1. A polycrystalline compact, comprising:
- a) a metal substrate having a first surface and a second surface, wherein the first and second surfaces are non-contiguous;
b) a first polycrystalline layer attached to the first surface using a first intermediate layer, said first polycrystalline layer including first superabrasive particles bonded together and said first intermediate layer including a consolidated mixture of first intermediate superabrasive particles and a first binder metal; and
c) a second polycrystalline layer attached to the second surface using a second intermediate layer, said second polycrystalline layer including second superabrasive particles bonded together and said second intermediate layer including a consolidated mixture of second intermediate superabrasive particles and a second binder metal.
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Accused Products
Abstract
A doubled-sided PCBN and/or PCD compact can be produced using high pressure high temperature processes allowing for increased effective thickness of abrasive tools, decreased delamination, and increased useful service life. A polycrystalline compact can include a substrate having a first surface and a second surface which are non-contiguous. Additionally, a first polycrystalline layer can be attached to the first surface of the substrate and a second polycrystalline layer attached to the second surface of the substrate. The first and second polycrystalline layers can be attached to the substrate via an intermediate layer containing superabrasive particles. Such double-sided PCBN and PCD compacts allow for increased effective thickness of a tool without suffering from non-homogenous results typical of standard PCD and PCBN compacts, regardless of superabrasive particle size. Each polycrystalline layer can include superabrasive particles of varying particle sizes such that the final tool is tailored for specific abrading characteristics. Such doubled-sided PCBN and PCD compacts can be incorporated into a wide variety of abrasive tools for use in cutting, milling, grinding, polishing, drilling and other similar abrasive applications.
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Citations
32 Claims
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1. A polycrystalline compact, comprising:
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a) a metal substrate having a first surface and a second surface, wherein the first and second surfaces are non-contiguous;
b) a first polycrystalline layer attached to the first surface using a first intermediate layer, said first polycrystalline layer including first superabrasive particles bonded together and said first intermediate layer including a consolidated mixture of first intermediate superabrasive particles and a first binder metal; and
c) a second polycrystalline layer attached to the second surface using a second intermediate layer, said second polycrystalline layer including second superabrasive particles bonded together and said second intermediate layer including a consolidated mixture of second intermediate superabrasive particles and a second binder metal. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A method of forming a polycrystalline compact, comprising steps of:
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a) forming a first superabrasive layer in a reaction assembly, said first superabrasive layer including first superabrasive particles and an optional first binder metal;
b) forming a first intermediate layer adjacent the first superabrasive layer, said first intermediate layer including a mixture of first intermediate superabrasive particles and a first binder metal;
c) forming a metal substrate layer adjacent the first intermediate layer;
d) forming a second intermediate superabrasive layer opposite the first intermediate layer, said second intermediate layer including a mixture of intermediate second superabrasive particles and a second binder metal;
e) forming a second superabrasive layer adjacent the second intermediate layer, said second superabrasive layer including second superabrasive particles and an optional second binder metal; and
f) heating said first and second superabrasive layers such that superabrasive particles of each layer are bonded together to form a multilayer polycrystalline compact. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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Specification