A polycrystalline diamond composite substrate

Abstract

This application relates to a polycrystalline diamond composite substrate, belonging to the technical field of superhard material composites. It includes a cylinder with one end serving as a bonding surface; a frustum located at one end of the bonding surface, comprising a truncated cone coaxially transitioning onto the cylinder and a frustum coaxially connected to the truncated cone; and a raised structure disposed on the frustum, comprising multiple sets of coaxially arranged raised units, each set of raised units being evenly distributed in a ring around the center of the bonding surface, with grooves formed between adjacent raised units, the grooves being concentric with the bonding surface. This application allows external forces applied to the composite to be more evenly distributed across different parts of the substrate, avoiding localized stress concentration. The raised structure increases the contact area between the substrate and the diamond layer, significantly enhancing the adhesion between them. During drilling, the diamond layer adheres more firmly to the substrate, reducing the risk of premature detachment of the diamond layer due to external forces.

Description

Technical Field

[0001] This application relates to the field of superhard material composite sheet technology, and in particular to a polycrystalline diamond composite sheet matrix. Background Technology

[0002] Polycrystalline diamond composite sheets are ultra-hard composite materials formed by sintering diamond powder and cemented carbide matrix under high temperature and high pressure. They are widely used in many fields such as petroleum, mining, and geological drilling.

[0003] In recent years, shale oil and gas exploration and development has been continuously advancing towards vertical depths exceeding 4000m and horizontal section lengths exceeding 3000m, facing the new normal of "enhanced parameter drilling" and "one-trip drilling." The complex and difficult drilling conditions characterized by high-frequency impact and high abrasiveness pose severe challenges to the adaptability and service life of diamond composite sheets. Due to significant differences in physical properties such as thermal expansion coefficient, hardness, strength, Poisson's ratio, and elastic modulus between diamond and the cemented carbide matrix, the cooling and depressurization process during the later stages of high-temperature and high-pressure synthesis leads to varying degrees of residual stress in different areas of the diamond layer and the cemented carbide matrix. This results in insufficient adhesion between the diamond layer and the cemented carbide matrix, leading to poor impact resistance when used as drilling tools. The diamond layer may prematurely detach or experience abnormal fracture. Furthermore, as the thickness of the diamond layer increases, the supporting capacity of the cemented carbide matrix becomes insufficient, further exacerbating the stress concentration problem. Summary of the Invention

[0004] This application provides a polycrystalline diamond composite substrate, which can solve the problem in related technologies where different areas of the diamond layer and the cemented carbide substrate generate different amounts of residual stress, resulting in poor impact resistance and premature detachment or abnormal fracture of the diamond layer.

[0005] This application provides a polycrystalline diamond composite substrate, comprising: a cylinder with one end configured as a mating surface; a frustum located at one end of the mating surface, the frustum comprising a truncated cone coaxially transitioning onto the cylinder and a frustum coaxially connected to the truncated cone; and a protruding structure disposed on the frustum, the protruding structure comprising multiple sets of coaxially arranged protruding units, each set of protruding units being evenly distributed in a ring around the center of the mating surface, and a groove being formed between adjacent protruding units, the groove being concentrically disposed with the mating surface.

[0006] In some embodiments, the protrusion unit includes: a first type of protrusion disposed at the center of the frustum; a second type of protrusion arranged around the first type of protrusion and forming an annulus concentric with the first type of protrusion; a third type of protrusion arranged around the second type of protrusion and forming an annulus concentric with the second type of protrusion; and the groove formed between the first type of protrusion, the second type of protrusion, and the third type of protrusion.

[0007] In some embodiments, the first type of protrusion includes a frustum protrusion located at the center of the frustum and concentric with the frustum.

[0008] In some embodiments, the second type of protrusion includes: a plurality of curved body protrusions disposed around the first type of protrusion, the plurality of curved body protrusions surrounding to form an annulus concentric with the first type of protrusion.

[0009] In some embodiments, the second type of protrusion is provided around the first type of protrusion at least once.

[0010] In some embodiments, the third type of protrusion includes: a plurality of fan-shaped protrusions arranged around the second type of protrusion, the plurality of fan-shaped protrusions forming a ring concentric with the second type of protrusion.

[0011] In some embodiments, the third type of protrusion is provided around the second type of protrusion at least once.

[0012] In some embodiments, the fan-shaped protrusion has a groove.

[0013] In some embodiments, the spacing between adjacent protrusion units is greater than 0.1 mm.

[0014] In some embodiments, the bonding surface edge of the polycrystalline diamond composite substrate is chamfered.

[0015] The beneficial effects of the technical solutions provided in this application include:

[0016] This application provides a polycrystalline diamond composite substrate. A cylinder serves as the base of the substrate, providing a stable support frame for the entire composite. Columns are coaxially mounted on the cylinder, allowing external forces applied to the composite to be more evenly distributed across different parts of the substrate, avoiding localized stress concentration. The raised structure increases the contact area between the substrate and the diamond layer, significantly enhancing their adhesion. During drilling, the diamond layer adheres more firmly to the substrate, reducing the risk of premature detachment due to external forces and improving the overall quality of the composite. Grooves between adjacent raised units provide channels for releasing residual stress. When residual stress is generated between the diamond layer and the cemented carbide substrate during cooling and depressurization, the grooves can accommodate and alleviate some of the stress, preventing excessive stress concentration at the interface between the diamond layer and the substrate, further improving the service life of the composite. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure provided for an embodiment of this application;

[0019] Figure 2 A frontal view schematic diagram provided for an embodiment of this application;

[0020] Figure 3 A top view schematic diagram provided for an embodiment of this application;

[0021] In the diagram: 1. Cylinder; 2. Column; 20. Frustum; 21. Frustum; 3. Protrusion; 30. Groove; 4. Type I protrusion; 5. Type II protrusion; 6. Type III protrusion; 7. Groove; 8. Chamfer. Detailed Implementation

[0022] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present application.

[0023] This application provides a polycrystalline diamond composite substrate that can solve the problem in related technologies where different areas of the diamond layer and the cemented carbide substrate generate different amounts of residual stress, leading to poor impact resistance and premature detachment or abnormal fracture of the diamond layer.

[0024] See Figures 1 to 3 As shown, this application provides a polycrystalline diamond composite substrate, including a cylinder 1, a frustum 2, and a protrusion structure 3. One end of the cylinder 1 is configured as a mating surface. The frustum 2 is located at one end of the mating surface. The frustum 2 includes a truncated cone 20 coaxially transitioning onto the cylinder 1 and a truncated cone 21 coaxially connected to the truncated cone 20. The protrusion structure 3 is disposed on the truncated cone 21. The protrusion structure 3 includes multiple sets of coaxially arranged protrusion units, and each set of protrusion units is evenly distributed in a ring around the center of the mating surface. The spacing between adjacent protrusion units is greater than 0.1 mm, and a groove 30 is formed between adjacent protrusion units. The groove 30 is concentrically arranged with the mating surface.

[0025] The truncated cones increase the contact area between the cemented carbide matrix and the diamond powder, allowing the diamond layer thickness at the edges to exceed 2.5 mm. Furthermore, the combination of the truncated cone 20 and the truncated cone 21 further enhances the bonding strength between the cemented carbide diamond matrix and the diamond powder, providing a larger bonding area and reducing localized stress concentration. Therefore, a larger bonding area means more contact space between the two, which helps improve adhesion and allows the diamond layer to bond more firmly to the matrix, reducing the risk of detachment due to impacts during use. Specifically, when subjected to external forces, the truncated cone 21 can disperse stress, preventing excessive stress concentration in any one area, thereby reducing the possibility of excessive stress leading to fracture at the diamond layer-matrix interface, improving the overall impact resistance of the composite material, and extending the drill bit's service life.

[0026] Furthermore, multiple sets of raised units create a mechanical interlocking effect. The spacing between the raised units is greater than 0.1mm, which effectively disperses stress, allowing it to be distributed over a wider range, reducing stress concentration, and improving the impact resistance of the composite sheet. When the diamond layer is bonded to the matrix, the raised units can embed into the diamond layer, increasing the connection strength between the two and further enhancing the adhesion between the diamond layer and the cemented carbide matrix, effectively preventing the diamond layer from sliding or falling off during use. In addition, it can improve the stress distribution of the composite sheet, reducing tooth chipping and interface decapping. Specifically, when the polycrystalline diamond composite sheet is subjected to impact during drilling rotation, it reduces the possibility of the diamond composite layer peeling and edge breakage, and increases the shear resistance of the shear surface, thereby improving the quality of the diamond composite sheet and significantly extending the service life of the polycrystalline high-strength diamond composite sheet matrix.

[0027] In addition, the presence of the groove 30 provides a certain space for stress release. When the composite sheet is subjected to external forces, the groove 30 can accommodate and disperse some of the stress, avoid excessive stress concentration near the bonding surface, reduce the risk of cracks or fractures at the bonding point between the diamond layer and the matrix, and improve the impact resistance and service life of the composite sheet.

[0028] In this application, the protruding unit includes: a first type of protrusion 4, a second type of protrusion 5, and a third type of protrusion 6. The first type of protrusion 4 is located at the center of the frustum 21, specifically including a frustum protrusion. This frustum protrusion is located at the center of the frustum 21 and is concentric with the frustum 21. The diameter of the frustum protrusion is preferably 2.1 mm, and the height is preferably 0.5 mm. The frustum protrusion increases the contact area between the cemented carbide substrate and the central region of the diamond layer, improving the adhesion between them. When subjected to impact forces, the central region is one of the stress concentration points; the frustum protrusion can better transfer and disperse stress, reducing the risk of diamond layer detachment or fracture in the central region.

[0029] The second type of protrusion 5 is arranged around the first type of protrusion 4, forming a concentric ring with the first type of protrusion 4. Specifically, it includes multiple curved protrusions surrounding the first type of protrusion 4, forming a concentric ring with the first type of protrusion 4. The second type of protrusion 5 surrounds the first type of protrusion 4 at least once. The curved protrusions are preferably semi-ellipsoidal or semi-fusiform in shape, with radial side lengths at both ends preferably 0.5mm-4mm and axial side lengths at the center preferably 0.1mm-2mm. The curved protrusions allow for more uniform stress distribution near the interface between the substrate and the diamond layer. The curved shape of the protrusions can, to some extent, change the direction of stress transmission, preventing excessive stress concentration in local areas, thereby improving the impact resistance of the composite sheet and reducing damage caused by stress concentration. Furthermore, when the curved protrusions are combined with the diamond layer, their curved shape can be better embedded in the diamond layer, forming a more complex mechanical interlocking structure. This interlocking effect further enhances the bonding strength between the matrix and the diamond layer, effectively preventing the diamond layer from sliding or falling off during use, especially under high-frequency impact and high-abrasive conditions, it can maintain a stable bonding state.

[0030] The third type of protrusion 6 is arranged around the second type of protrusion 5, forming a concentric ring with the second type of protrusion 5. Specifically, it includes multiple fan-shaped protrusions surrounding the second type of protrusion 5, forming a concentric ring with the second type of protrusion 5. The third type of protrusion 6 is arranged in at least one ring around the second type of protrusion 5, and each fan-shaped protrusion has a groove 7, preferably a U-shaped groove or a V-shaped groove. The multiple fan-shaped protrusions arranged around the second type of protrusion 5 and forming a concentric ring further expands the support range of the matrix for the diamond layer. During drilling, the edge area of ​​the diamond layer often bears greater stress. The presence of the fan-shaped protrusions provides additional support for these areas, preventing the diamond layer from falling off or breaking at the edge, and improving the overall strength and durability of the composite sheet. The U-shaped or V-shaped grooves further enhance the mechanical interlock between the fan-shaped protrusions and the diamond layer. When the diamond layer is bonded to the substrate, the diamond material fills these grooves 7, forming a wedge-like structure that makes the bond between the two tighter, greatly improving the bonding strength and effectively preventing the diamond layer from falling off the fan-shaped protrusions during use, thus improving the reliability and durability of the composite sheet under high-temperature conditions.

[0031] Finally, the groove 30 is formed between the first type of protrusion 4, the second type of protrusion 5, and the third type of protrusion 6, providing space for stress release and buffering. When the composite sheet is subjected to impact force, the groove 30 can accommodate and disperse some of the stress, avoiding excessive stress concentration between the protrusions and reducing the risk of protrusion damage or cracking at the junction of the diamond layer and the cemented carbide matrix due to excessive stress.

[0032] In this application, during the bonding process between the diamond layer and the substrate, the edge of the bonding surface is a region where stress easily concentrates. Therefore, a chamfer 8 is provided at the edge of the bonding surface of the polycrystalline diamond composite substrate. After providing the chamfer 8, the sharp part of the edge is removed, forming a smooth transition, which can effectively disperse stress and reduce stress concentration at the edge. This helps to improve the bonding strength between the diamond layer and the substrate and reduce the risk of bonding surface cracking or diamond layer detachment caused by stress concentration.

[0033] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0034] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0035] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A polycrystalline diamond composite sheet matrix, characterized in that, It includes: A cylinder (1), one end of which is set as a mating surface; A pedestal (2) located at one end of the mating surface, the pedestal (2) comprising a frustum (20) coaxially transitioning onto the cylinder (1) and a frustum (21) coaxially connected to the frustum (20). A protruding structure (3) is disposed on the frustum (21). The protruding structure (3) includes multiple sets of coaxially arranged protruding units. Each set of protruding units is evenly distributed in a ring around the center of the mating surface. A groove (30) is formed between adjacent protruding units. The groove (30) is concentrically disposed with the mating surface. The protruding unit includes: - A first type of protrusion (4) is disposed at the center of the frustum (21). The first type of protrusion (4) includes: a frustum protrusion, which is located at the center of the frustum (21) and is concentric with the frustum (21); - A second type of protrusion (5) is arranged around the first type of protrusion (4) and forms a ring concentric with the first type of protrusion (4). The second type of protrusion (5) includes: a plurality of curved protrusions arranged around the first type of protrusion (4), and the plurality of curved protrusions form a ring concentric with the first type of protrusion (4). - A third type of protrusion (6) is arranged around the second type of protrusion (5) and forms a ring concentric with the second type of protrusion (5). The third type of protrusion (6) includes: a plurality of fan-shaped protrusions arranged around the second type of protrusion (5), and the plurality of fan-shaped protrusions form a ring concentric with the second type of protrusion (5). The groove (30) is formed between the first type of protrusion (4), the second type of protrusion (5) and the third type of protrusion (6).

2. The polycrystalline diamond composite substrate as described in claim 1, characterized in that: The second type of protrusion is provided with at least one ring around the first type of protrusion (4).

3. The polycrystalline diamond composite substrate as described in claim 1, characterized in that: The third type of protrusion (6) is provided with at least one ring around the second type of protrusion (5).

4. The polycrystalline diamond composite substrate as described in claim 1, characterized in that: The fan-shaped protrusion is provided with a groove (7).

5. The polycrystalline diamond composite substrate as described in claim 1, characterized in that: The spacing between adjacent protrusions is greater than 0.1 mm.

6. The polycrystalline diamond composite substrate as described in claim 1, characterized in that: The bonding surface edge of the polycrystalline diamond composite substrate is chamfered (8).

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