US 11,865,672 B1
Polycrystalline diamond compacts, methods of fabricating the same, and methods of using the same
Daniel Call Mortensen, Eagle Mountain, UT (US); Lindsay Sue Patton, Provo, UT (US); Trevor Allen Olsen, Spanish Fork, UT (US); Casey Wade Swan, Spanish Fork, UT (US); Shawn Casey Scott, Payson, UT (US); Matthew Kimball Baker, Provo, UT (US); Anne-Grethe Slotnaes, South Jordan, UT (US); Kenneth E. Bertagnolli, Riverton, UT (US); Jiang Qian, Cedar Hills, UT (US); Jason Lott, Payson, UT (US); and Joshua Adam Hawks, Saratoga Springs, UT (US)
Assigned to US Synthetic Corporation, Orem, UT (US)
Filed by US SYNTHETIC CORPORATION, Orem, UT (US)
Filed on Jul. 22, 2019, as Appl. No. 16/518,049.
Application 16/518,049 is a division of application No. 15/402,525, filed on Jan. 10, 2017, granted, now 10,399,206.
Claims priority of provisional application 62/279,271, filed on Jan. 15, 2016.
Int. Cl. C22C 1/04 (2023.01); B24D 3/00 (2006.01); E21B 10/62 (2006.01); B24D 3/10 (2006.01); E21B 10/567 (2006.01); E21B 10/55 (2006.01); E21B 10/633 (2006.01); C22C 1/05 (2023.01); C22C 1/051 (2023.01)
CPC B24D 3/007 (2013.01) [B24D 3/10 (2013.01); C22C 1/04 (2013.01); C22C 1/05 (2013.01); C22C 1/051 (2013.01); E21B 10/55 (2013.01); E21B 10/5673 (2013.01); E21B 10/62 (2013.01); E21B 10/633 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of fabricating a polycrystalline diamond compact, the method comprising:
leaching at least a portion of at least one interstitial constituent from a polycrystalline diamond table to a leach depth measured inwardly from an upper surface and to a lateral leach depth measured inwardly from at least one lateral surface of the polycrystalline diamond table to form a leached region, the leach depth being less than a depth of the polycrystalline diamond table to produce an unleached region;
after leaching the polycrystalline diamond table, forming a plurality of recessed features that extend from the upper surface of the polycrystalline diamond table to a depth less than the leach depth of the leached region such that the plurality of recessed features are entirely contained within the leached region and do not extend into the unleached region of the polycrystalline diamond table; and
forming at least a portion of one recessed feature of the plurality of recessed features proximate to an anticipated leach boundary-wear intersection location;
wherein forming the plurality of recessed features forms a plurality of cells on the upper surface that are at least partially defined by the plurality of recessed features.