Cutting element with core construction

Abstract

A cutting element may include a table at a first longitudinal end in a longitudinal direction of a longitudinal axis, the table having a table outer diameter transverse to the longitudinal direction and the table including an ultrahard material. A cutting element may include a core having a core outer diameter that is less than the table outer diameter, the core being coupled to and configured to receive heat from the table. A cutting element may include an annular sleeve radially outside of the core with a sleeve outer diameter no less than the table outer diameter.

Description

PatentDocket No.: IS22.0421-US-PCTCUTTING ELEMENT WITH CORE CONSTRUCTIONCROSS REFERENCE PARAGRAPH

[0001] This Application claims priority to and the benefit of United States Provisional Patent Application 63 / 702,411 filed October 2, 2024, titled CUTTING ELEMENT WITH CORE CONSTRUCTION, the disclosure of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] Drilling and cutting operations generate heat and mechanical shocks that can rapidly degrade the cutting elements used in drill bits and other cutting devices. Thermal management and shock absorption of the cutting element can improve the operational lifetime of the cutting elements and the device(s) to which the cutting elements are coupled.SUMMARY

[0003] In some aspects, the techniques described herein relate to a cutting element including: a table at a first longitudinal end in a longitudinal direction of a longitudinal axis, the table having a table outer diameter transverse to the longitudinal direction and the table including an ultrahard material; a core having a core outer diameter that is less than the table outer diameter, the core being coupled to and configured to receive heat from the table; and an annular sleeve radially outside of the core with a sleeve outer diameter no less than the table outer diameter.

[0004] In some aspects, the techniques described herein relate to a cutting element including: a table at a first longitudinal end in a longitudinal direction of a longitudinal axis, the table having a table outer diameter transverse to the longitudinal direction and the table being a monolithic PCD compact; a core integrally formed with the monolithic PCD compact of the table and having a core outer diameter that is less than the table outer diameter; a base at a second longitudinal end opposite the first longitudinal end, the base including a substrate material and configured to receive heat from the core; and anPatentDocket No.: IS22.0421-US-PCT annular sleeve radially outside of the core with a sleeve outer diameter no less than the table outer diameter.

[0005] In some aspects, the techniques described herein relate to a cutting element including: a table at a first longitudinal end in a longitudinal direction of a longitudinal axis, the table having a table diameter transverse to the longitudinal direction and the table including an ultrahard material; a core integrally formed with the table and having a core diameter that is less than the table diameter, wherein the core has a core length from the table toward a second longitudinal end opposite the first longitudinal end in the longitudinal direction; and an annular sleeve radially outside of the core with a sleeve outer diameter no less than the table diameter.

[0006] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0007] Additional features and aspects of embodiments of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such embodiments. The features and aspects of such embodiments may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims or may be learned by the practice of such embodiments as set forth hereinafter.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, non-schematic drawings should be considered as being to scale for some embodiments of the present disclosure,PatentDocket No.: IS22.0421-US-PCT but not to scale for other embodiments contemplated herein. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0009] FIG. 1 -1 and FIG. 1-2 are a side cross-sectional view and perspective partial cross-sectional view, respectively, that illustrate a cutting element, according to at least some embodiments of the present disclosure.

[0010] FIG. 2-1 and FIG. 2-2 illustrate a cutting element with a base, according to at least some embodiments of the present disclosure.

[0011] FIG. 3-1 and FIG. 3-2 illustrate a cutting element with an integral table and core, according to at least some embodiments of the present disclosure.

[0012] FIG. 4-1 and FIG. 4-2 illustrate a cutting element with a hybrid core, according to at least some embodiments of the present disclosure.

[0013] FIG. 5 is a perspective partial cross-sectional view of an embodiment of a cutting element 500 with mechanical interlocking features, according to at least some embodiments of the present disclosure.

[0014] FIG. 6-1 and FIG. 6-2 illustrate a cutting element with an integral table and core and separate base, according to at least some embodiments of the present disclosure.

[0015] FIG. 7 illustrates a cutting element with a core and a sleeve in accordance with embodiments.DETAILED DESCRIPTION

[0016] The present disclosure relates generally to improving durability and / or operational lifetime of ultrahard cutting elements. More particularly, the present disclosure relates to ultrahard cutting elements and manufacturing thereof with improved erosion and thermal resistance. In some embodiments, a cutting element includes an ultrahard table at a first longitudinal end of the cutting element coupled to a core. The core has an annular sleeve circumferentially around the core to protect the core. In some embodiments, the cutting element has a base including a substrate material. In somePatentDocket No.: IS22.0421-US-PCT embodiments, at least a portion of the core is integrally formed with the ultrahard table. In some embodiments, at least a portion of the core is integrally formed with the base. In some embodiments, at least a portion of the core is a discrete component from the table and / or base. In some embodiments, at least a portion of the annular sleeve is integrally formed with the ultrahard table. In some embodiments, at least a portion of the annular sleeve is integrally formed with the base.

[0017] In some embodiments, the core has different material properties from the annular sleeve. For example, the core may have a greater thermal conductivity that the annular sleeve to conduct heat away from the table, while the annular sleeve has a higher toughness than the core to protect the cutting element from shock and vibration during drilling or other cutting operations. In some embodiments, the sleeve has a hardness greater than the core. In some examples, the annular sleeve has a different porosity from the core, allowing the cutting element to be brazed or otherwise affixed to a drill bit or other cutting apparatus around the outer surface of the annular sleeve. The annular sleeve around the core, therefore, can allow the cutting element to have beneficial material properties proximate to the contact surface between the cutting element and a pocket or recess into which the cutting element is affixed and proximate to the ultrahard table to distribute heat and / or forces generated during drilling or cutting operations.

[0018] FIG. 1-1 and FIG. 1-2 illustrate an embodiment of a cutting element 100 according to the present disclosure. FIG. 1 -1 is a side cross-sectional view of the embodiment of a cutting element 100. In some embodiments, the cutting element 100 has a table 102 including an ultrahard material. In some embodiments, the ultrahard material is polycrystalline diamond (PCD). In some embodiments, the ultrahard material is a PCD layer on the working surface of the table 102. In some embodiments, the table 102 is a monolithic piece of ultrahard material. For example, the table 102 may be a monolithic polycrystalline diamond compact (PDC).

[0019] The table 102 has a working surface of the cutting element 100 that contacts and abrades, fractures, scrapes, cuts, or otherwise degrades a target material, such as a geological formation, a wellbore casing, or other material cut, reamed, or drilled during wellbore formation and management. In some embodiments, the table 102 is aPatentDocket No.: IS22.0421-US-PCT substantially planar table 102, with a substantially planar upper surface at a first longitudinal end of the cutting element 100. In some examples, a substantially planar table 102 has a beveled, curved, or chamfered corner while remaining substantially planar. In some embodiments, the table 102 has a non-planar working surface, such as an apexed cutting element. In some examples, an apexed cutting element has a leading point (e.g., a substantially conical or bullet-shaped cutting element) or a leading edge (e.g., a ridge or axe-shaped cutting element). In some examples, the table 102 has a non-apexed, non- planar working surface, such as a working surface with a plurality of ridges or plurality of points.

[0020] The cutting element 100 further includes a core 104 with an annular sleeve 106 positioned circumferentially around (e.g., radially outside of) at least a portion of the core 104. The core 104 is coupled to the table 102 and receives heat from the table 102. During drilling or cutting operations, impacts and friction between table 102 and the target material generates heat. The table 102 is in thermal communication with the core 104 to transmit heat to the core 104 away from the table 102.

[0021] In some embodiments, the core 104 has a core length 109 in a longitudinal direction of a longitudinal axis 108 of the cutting element 100 from the table 102 toward a second longitudinal end of the cutting element 100, and the annular sleeve 106 has a sleeve length 111 in the longitudinal direction that is equal to or less than the core length 109.

[0022] Referring now to the exploded view of the embodiment of the cutting element 100 of FIG. 1 -2, in some embodiments, the core 104 is radially within the annular sleeve 106 relative to the longitudinal axis 108 of the cutting element 100. For example, the core 104 has a core outer diameter 110 that is less than or equal to a sleeve inner diameter 112 and the sleeve 106 is radially outside of the core 104. In some embodiments, the core 104 directly contacts the sleeve 106. In some embodiments, the material of the core 104 and the sleeve 106 microstructurally bonds the core 104 and the sleeve 106 to one another. In some embodiments, and additional layer of material is positioned between the core 104 and the sleeve 106. For example, a bonding layer may be located between the core 104 and the sleeve 106 to facilitate a bond between the core 104 and the sleevePatentDocket No.: IS22.0421-US-PCT106. In some examples, the bonding layer is a discrete layer, such as an adhesive, braze, or other material between the core 104 and the sleeve 106. In some examples, the bonding layer is a reaction layer between the material of the core 104 and the sleeve 106 that microstructurally bonds the core 104 and the sleeve 106 to one another.

[0023] In some embodiments, the sleeve 106 has a sleeve outer diameter 114. In some embodiments, the sleeve outer diameter 114 is substantially equal to a table outer diameter 116. In some embodiments, the sleeve outer diameter 114 is no less than a table outer diameter 116. In some embodiments, the core outer diameter 110 is no more than 95% of the sleeve outer diameter 114. In some embodiments, the core outer diameter 110 is no more than 85% of the sleeve outer diameter 114. In some embodiments, the core outer diameter 110 is no more than 75% of the sleeve outer diameter 114. In some embodiments, the core outer diameter 110 is no more than 50% of the sleeve outer diameter 114.

[0024] While embodiments of cutting elements are described herein as substantially cylindrical, other volumetric shapes are possible. For example, while embodiment of cutting elements and components thereof are describes as having diameters, in other embodiments, the descriptions herein of relative diameters may be equally applicable to a transverse cross-sectional dimension of a non-circular cross-sectional shape. In other examples, a sleeve may be a protective sleeve with an inner transverse cross-sectional dimension and an outer transverse cross-sectional dimension, while being non-annular.

[0025] In some embodiments, the core 104 includes a core material with a thermal conductivity greater than that of the sleeve 106. For example, the PCD of the table 102 may have a relatively high thermal conductivity of approximately 2,200 Watts per meter- Kelvin (W / (m*K)) while a sleeve comprising tungsten carbide may have a lower thermal conductivity of approximately 110 W / (m*K). In some embodiments, the core 104 includes diamond, providing a higher thermal conductivity. Conduction of heat generated at the table 102 during operation of the cutting element 100 away from the table 102 can improve an operational lifetime of the cutting element 100. In some embodiments, at least a portion of the core 104 is integrally formed with the table 102. For example, at least a portion of the table 102 may be radially within and longitudinally overlapping a portion ofPatentDocket No.: IS22.0421-US-PCT the sleeve 106. In at least one example, the table 102 and the core 104 are a single monolithic piece of ultrahard material.

[0026] In various embodiments, the cutting element 100 may have a sleeve 106 that may be made from any suitable material. For example, the sleeve 106 may be made from an ultrahard material. In some embodiments, the sleeve 106 may be made from a carbide material, such as tungsten carbide. As should be appreciated, the cutting element 100 and the various components can have different compositions of materials that allow for the improved thermal conductivity characteristics as well as improved strength properties. While not all materials may be discussed, it should be understood that any suitable material may be used.

[0027] FIG. 2-1 and FIG. 2-2 illustrate an embodiment of a cutting element 200 with a base 218 according to the present disclosure. In some embodiments, a cutting element 200 includes a table 202, a core 204, and a sleeve 206, such as described according to at least in relation to FIG. 1-1 and FIG. 1-2. In some embodiments, a cutting element 200 further includes a base 218. The base 218 is, in some embodiments, integrally formed with at least a portion of the core 204. In some embodiments, the base 218 and core 204 are integrally formed in a monolithic piece. In some embodiments, the base 218 is located at a second longitudinal end of the cutting element 200 opposite the table 202 at the first longitudinal end.

[0028] In some embodiments, the cutting element 200 has a table 202 including an ultrahard material. In some embodiments, the ultrahard material is PCD. In some embodiments, the ultrahard material is a PCD layer on the working surface of the table 202. In some embodiments, the table 202 is a monolithic piece of ultrahard material. For example, the table 202 may be a monolithic PDC.

[0029] In some embodiments, the core 204 includes a core material and the base 218 includes a substrate material. In some embodiments, the core material and the substrate material are the same material. In some embodiments, the core 204 and the base 218 have a greater thermal conductivity than the sleeve 206.

[0030] Referring now to FIG. 2-2, the base 218, in some embodiments, has a base outer diameter 220 that is greater than the core outer diameter 210. In somePatentDocket No.: IS22.0421-US-PCT embodiments, the base outer diameter 220 is no less than a sleeve outer diameter 214. In some embodiments, the base outer diameter 220 is no less than a sleeve outer diameter 214. In some embodiments, the base outer diameter 220 is less than the sleeve outer diameter 214, allowing additional material between the base 218 and a pocket into which the cutting element 200 is set. In some embodiments, the sleeve outer diameter 214 is greater than the base outer diameter 220, and a pocket into which the cutting element 200 is set has a complementary geometry to receive the cutting element 200.

[0031] In some embodiments, the core outer diameter 210 is no more than 95% of the base outer diameter 220. In some embodiments, the core outer diameter 210 is no more than 85% of the base outer diameter 220. In some embodiments, the core outer diameter 210 is no more than 75% of the base outer diameter 220. In some embodiments, the core outer diameter 210 is no more than 50% of the base outer diameter 220.

[0032] FIG. 3-1 and FIG. 3-2 illustrate another embodiment of a cutting element 300 according to the present disclosure. In some embodiments, the cutting element 300 includes a table 302 and a core 304 that are integrally formed with one another in a single monolithic piece. For example, the table 302 and the core 304 may be integrally formed from a PCD piece.

[0033] In some embodiments, the cutting element 300 includes a sleeve 306 and a base 318 that are integrally formed with one another in a single monolithic piece. For example, the sleeve 306 and the base 318 may be integrally formed from a single tungsten carbide piece.

[0034] While some embodiments described herein have a core-sleeve interface 322 that is linear and parallel to a longitudinal axis 308, it should be understood that other geometries may be possible. For example, at least a portion of the core-sleeve interface 322 may be curved in the longitudinal direction. A curved core-sleeve interface 322 may allow additional retention of the core 304 relative to the sleeve 306. In some embodiments, at least a portion of the core-sleeve interface 322 may be oriented at a non-parallel angle to the longitudinal direction. For example, the core 304 may taper in the longitudinal direction and the sleeve 306 may be complementarily shaped to mate with the tapered core 304. In at least one example, the core 304 is frustoconical.PatentDocket No.: IS22.0421-US-PCT

[0035] In some embodiments, a sleeve is a discrete component positioned circumferentially around the core, and at least a first portion of the core is integrally formed with the table and at least a second portion of the core is integrally formed with the base. FIG. 4-1 and FIG. 4-2 illustrate an embodiment of a cutting element 400 with a hybrid core 404 according to the present disclosure. In some embodiments, at least a first portion 404-1 of the core 404 is integrally formed with a table 402. In such embodiments, the first portion 404-1 and the table 402 are integrally formed in a monolithic piece. For example, the first portion 404-1 and the table 402 may be a single monolithic PCD piece. In some embodiments, the second portion 404-2 of the core 404 and the base 418 are integrally formed in a monolithic piece. For example, the first portion 404-1 and the table 402 may be a single monolithic piece of a substrate material, such as tungsten carbide.

[0036] In some embodiments, the core 404 includes a first portion 404-1 and a second portion 404-2 in equal volumetric proportions. In some embodiments, the first portion 404- 1 is integrally formed with the table 402 accounts for a larger volumetric proportion of the core 404 than the second portion 404-2 integrally formed with the base 418. In some embodiments, the first portion 404-1 is integrally formed with the table 402 accounts for a smaller volumetric proportion of the core 404 than the second portion 404-2 integrally formed with the base 418.

[0037] As cutting elements according to the present disclosure may experience high forces applied to the cutting element, both internally and externally, the cutting elements may include one or more mechanical interlocking features to limit and / or prevent movement of one component relative to another in at least one direction. For example, FIG. 5 is a perspective partial cross-sectional view of an embodiment of a cutting element 500 with mechanical interlocking features according to the present disclosure. In some embodiments, the core 504 and the sleeve 506 include interlocking features to limit and / or prevent movement of the sleeve 506 relative to the core.

[0038] In some embodiments, an inner surface of the sleeve 506 includes at least one mechanical interlocking feature 524-1 , 524-2 and an outer surface of the core 504 includes a complementary interlocking feature 526-1 , 526-2. In at least one embodiment, the interlock between the mechanical interlocking feature 524-1 , 524-2 and thePatentDocket No.: IS22.0421-US-PCT complementary interlocking feature 526-1 , 526-2 limits and / or prevents the longitudinal movement of the sleeve 506 and the core 504 relative to one another. In at least one embodiment, the interlock between the mechanical interlocking feature 524-1 , 524-2 and the complementary interlocking feature 526-1 , 526-2 limits and / or prevents the rotational and / or lateral movement of the sleeve 506 and the core 504 relative to one another. In at least one embodiment, the interlock between the mechanical interlocking feature 524-1 , 524-2 and the complementary interlocking feature 526-1 , 526-2 limits and / or prevents both longitudinal movement and rotational movement of the sleeve 506 and the core 504 relative to one another. For example, a longitudinal spline(s) and a complementary groove(s) may limit and / or prevent the rotational movement of the sleeve 506 relative to the core 504. For example, a circumferential spline(s) and a complementary groove(s) may limit and / or prevent the longitudinal movement of the sleeve 506 relative to the core 504. For example, a non-circumferential protrusion(s) and a complementary recess(es) may limit and / or prevent both the longitudinal and rotational movement of the sleeve 506 relative to the core 504.

[0039] In some embodiments, the interlocking feature(s) limit and / or prevent movement of a first portion 504-1 and a second portion 504-2 of the core 504 relative to one another. In some embodiments, the interlocking feature(s) limit and / or prevent movement of the table 502 and the base 518 relative to one another. For example, a core 504 including a first portion 504-1 integrally formed with a table 502 and a second portion 504-2 integrally formed with a base 518 may have interlocking features that limit the movement of each relative to the sleeve 506 and, therefore, with one another. In at least one example, a sleeve 506 has a first mechanical interlocking feature 524-1 and a second mechanical interlocking feature 524-2, a first portion 504-1 has a first complementary interlocking feature 526-1 that interlocks with the first mechanical interlocking feature 524- 1 , and a second portion 504-2 has a second complementary interlocking feature 526-2 that interlocks with the second mechanical interlocking feature 524-2.

[0040] FIG. 6-1 and FIG. 6-2 illustrate an embodiment of a cutting element 600 according to the present disclosure. In some embodiments, the cutting element 600 includes a core 604 that is integrally formed with a table 602. The core 604 is in contact with a base 618 that includes a substrate material. A sleeve 606 is positionedPatentDocket No.: IS22.0421-US-PCT circumferentially around the core 604. In some embodiments, the sleeve 606 and the core 604 includes different materials. In some embodiments, the core 604 and the base 618 include different materials. In some embodiments, the sleeve 606 and the base 618 include different materials. In some embodiments, the sleeve 606, the core 604, and the base 618 all include or are made of different materials.

[0041] FIG. 7 is a side cross-sectional view of an embodiment of a cutting element 700. In some embodiments, the table 702 is integrally formed with the core 704. In some embodiments, the table 702 has a longitudinal table length 730, and the core 704 has a longitudinal core length 732 from the table 702 at a first longitudinal end of the cutting element 700 to the second longitudinal end of the cutting element 700. In some embodiments, the table length 730 is greater than a core length 732. In some embodiments, the table length 730 is substantially equal to than a core length 732. In some embodiments, the table length 730 is less than a core length 732. In some embodiments, the sleeve 706 is positioned circumferentially around the core 704.INDUSTRIAL APPLICABILITY

[0042] The present disclosure relates generally to improving durability and / or operational lifetime of ultrahard cutting elements. More particularly, the present disclosure relates to ultrahard cutting elements and manufacturing thereof with improved erosion and thermal resistance. In some embodiments, a cutting element includes an ultrahard table at a first longitudinal end of the cutting element coupled to a core. The core has an annular sleeve circumferentially around the core to protect the core. In some embodiments, the cutting element has a base including a substrate material. In some embodiments, at least a portion of the core is integrally formed with the ultrahard table. In some embodiments, at least a portion of the core is integrally formed with the base. In some embodiments, at least a portion of the core is a discrete component from the table and / or base. In some embodiments, at least a portion of the annular sleeve is integrally formed with the ultrahard table. In some embodiments, at least a portion of the annular sleeve is integrally formed with the base.

[0043] In some embodiments, the core has different material properties from the annular sleeve. For example, the core may have a greater thermal conductivity that thePatentDocket No.: IS22.0421-US-PCT annular sleeve to conduct heat away from the table, while the annular sleeve has a higher toughness than the core to protect the cutting element from shock and vibration during drilling or other cutting operations. In some embodiments, the sleeve has a hardness greater than the core. In some examples, the annular sleeve has a different porosity from the core, allowing the cutting element to be brazed or otherwise affixed to a drill bit or other cutting apparatus around the outer surface of the annular sleeve. The annular sleeve around the core, therefore, can allow the cutting element to have beneficial material properties proximate to the contact surface between the cutting element and a pocket or recess into which the cutting element is affixed and proximate to the ultrahard table to distribute heat and / or forces generated during drilling or cutting operations.

[0044] In some embodiments, the cutting element has a table including an ultrahard material. In some embodiments, the ultrahard material is polycrystalline diamond (PCD). In some embodiments, the ultrahard material is a PCD layer on the working surface of the table. In some embodiments, the table is a monolithic piece of ultrahard material. For example, the table may be a monolithic polycrystalline diamond compact (PDC).

[0045] The table has a working surface of the cutting element that contacts and abrades, fractures, scrapes, cuts, or otherwise degrades a target material, such as a geological formation, a wellbore casing, or other material cut, reamed, or drilled during wellbore formation and management. In some embodiments, the table is a substantially planar table, with a substantially planar upper surface at a first longitudinal end of the cutting element. In some examples, a substantially planar table has a beveled, curved, or chamfered corner while remaining substantially planar. In some embodiments, the table has a non-planar working surface, such as an apexed cutting element. In some examples, an apexed cutting element has a leading point (e.g., a substantially conical or bulletshaped cutting element) or a leading edge (e.g., a ridge or axe-shaped cutting element). In some examples, the table has a non-apexed, non-planar working surface, such as a working surface with a plurality of ridges or plurality of points.

[0046] The cutting element further includes a core with an annular sleeve positioned circumferentially around (e.g., radially outside of) at least a portion of the core. The core is coupled to the table and receives heat from the table. During drilling or cuttingPatentDocket No.: IS22.0421-US-PCT operations, impacts and friction between table and the target material generates heat. The table is in thermal communication with the core to transmit heat to the core away from the table.

[0047] In some embodiments, the core has a core length in a longitudinal direction of a longitudinal axis of the cutting element from the table toward a second longitudinal end of the cutting element, and the annular sleeve has a sleeve length in the longitudinal direction that is equal to or less than the core length.

[0048] In some embodiments, the core is radially within the annular sleeve relative to the longitudinal axis of the cutting element. For example, the core has a core outer diameter that is less than or equal to a sleeve inner diameter and the sleeve is radially outside of the core. In some embodiments, the core directly contacts the sleeve. In some embodiments, the material of the core and the sleeve microstructurally bonds the core and the sleeve to one another. In some embodiments, and additional layer of material is positioned between the core and the sleeve. For example, a bonding layer may be located between the core and the sleeve to facilitate a bond between the core and the sleeve. In some examples, the bonding layer is a discrete layer, such as an adhesive, braze, or other material between the core and the sleeve. In some examples, the bonding layer is a reaction layer between the material of the core and the sleeve that microstructurally bonds the core and the sleeve to one another.

[0049] In some embodiments, the sleeve has a sleeve outer diameter. In some embodiments, the sleeve outer diameter is substantially equal to a table outer diameter. In some embodiments, the sleeve outer diameter is no less than a table outer diameter. In some embodiments, the core outer diameter is no more than 95% of the sleeve outer diameter. In some embodiments, the core outer diameter is no more than 85% of the sleeve outer diameter. In some embodiments, the core outer diameter is no more than 75% of the sleeve outer diameter. In some embodiments, the core outer diameter is no more than 50% of the sleeve outer diameter.

[0050] While embodiments of cutting elements are described herein as substantially cylindrical, other volumetric shapes are possible. For example, while embodiment of cutting elements and components thereof are describes as having diameters, in otherPatentDocket No.: IS22.0421-US-PCT embodiments, the descriptions herein of relative diameters may be equally applicable to a transverse cross-sectional dimension of a non-circular cross-sectional shape. In other examples, a sleeve may be a protective sleeve with an inner transverse cross-sectional dimension and an outer transverse cross-sectional dimension, while being non-annular.

[0051] In some embodiments, the core includes a core material with a thermal conductivity greater than that of the sleeve. For example, the PCD of the table may have a relatively high thermal conductivity of approximately 2,200 Watts per meter-Kelvin (W / (m*K)) while a sleeve comprising tungsten carbide may have a lower thermal conductivity of approximately 110 W / (m*K). In some embodiments, the core includes diamond, providing a higher thermal conductivity. Conduction of heat generated at the table during operation of the cutting element away from the table can improve an operational lifetime of the cutting element. In some embodiments, at least a portion of the core is integrally formed with the table. For example, at least a portion of the table may be radially within and longitudinally overlapping a portion of the sleeve. In at least one example, the table and the core are a single monolithic piece of ultrahard material.

[0052] In some embodiments, a cutting element includes a table, a core, and a sleeve, such as described herein. In some embodiments, a cutting element further includes a base. The base is, in some embodiments, integrally formed with at least a portion of the core. In some embodiments, the base and core are integrally formed in a monolithic piece. In some embodiments, the base is located at a second longitudinal end of the cutting element opposite the table at the first longitudinal end.

[0053] In some embodiments, the cutting element has a table including an ultrahard material. In some embodiments, the ultrahard material is PCD. In some embodiments, the ultrahard material is a PCD layer on the working surface of the table. In some embodiments, the table is a monolithic piece of ultrahard material. For example, the table may be a monolithic PDC.

[0054] In some embodiments, the core includes a core material, and the base includes a substrate material. In some embodiments, the core material and the substrate material are the same material. In some embodiments, the core and the base have a greater thermal conductivity than the sleeve.PatentDocket No.: IS22.0421-US-PCT

[0055] The base, in some embodiments, has a base outer diameter that is greater than the core outer diameter. In some embodiments, the base outer diameter is no less than a sleeve outer diameter. In some embodiments, the base outer diameter is no less than a sleeve outer diameter. In some embodiments, the base outer diameter is less than the sleeve outer diameter, allowing additional material between the base and a pocket into which the cutting element is set. In some embodiments, the sleeve outer diameter is greater than the base outer diameter, and a pocket into which the cutting element is set has a complementary geometry to receive the cutting element.

[0056] In some embodiments, the core outer diameter is no more than 95% of the base outer diameter. In some embodiments, the core outer diameter is no more than 85% of the base outer diameter. In some embodiments, the core outer diameter is no more than 75% of the base outer diameter. In some embodiments, the core outer diameter is no more than 50% of the base outer diameter.

[0057] In some embodiments, the cutting element includes a table and a core that are integrally formed with one another in a single monolithic piece. For example, the table and the core may be integrally formed from a PCD piece.

[0058] In some embodiments, the cutting element includes a sleeve and a base that are integrally formed with one another in a single monolithic piece. For example, the sleeve and the base may be integrally formed from a single tungsten carbide piece.

[0059] While some embodiments described herein have a core-sleeve interface that is linear and parallel to a longitudinal axis, it should be understood that other geometries may be possible. For example, at least a portion of the core-sleeve interface may be curved in the longitudinal direction. A curved core-sleeve interface may allow additional retention of the core relative to the sleeve. In some embodiments, at least a portion of the core-sleeve interface may be oriented at a non-parallel angle to the longitudinal direction. For example, the core may taper in the longitudinal direction and the sleeve may be complementarily shaped to mate with the tapered core. In at least one example, the core is frustoconical.

[0060] In some embodiments, a sleeve is a discrete component positioned circumferentially around the core, and at least a first portion of the core is integrally formedPatentDocket No.: IS22.0421-US-PCT with the table and at least a second portion of the core is integrally formed with the base. In some embodiments, at least a first portion of the core is integrally formed with a table. In such embodiments, the first portion and the table are integrally formed in a monolithic piece. For example, the first portion and the table may be a single monolithic PCD piece. In some embodiments, the second portion of the core and the base are integrally formed in a monolithic piece. For example, the first portion and the table may be a single monolithic piece of a substrate material, such as tungsten carbide.

[0061] In some embodiments, the core includes a first portion and a second portion in equal volumetric proportions. In some embodiments, the first portion is integrally formed with the table accounts for a larger volumetric proportion of the core than the second portion integrally formed with the base. In some embodiments, the first portion is integrally formed with the table accounts for a smaller volumetric proportion of the core than the second portion integrally formed with the base.

[0062] As cutting elements according to the present disclosure may experience high forces applied to the cutting element, both internally and externally, the cutting elements may include one or more mechanical interlocking features to limit and / or prevent movement of one component relative to another in at least one direction. In some embodiments, the core and the sleeve include interlocking features to limit and / or prevent movement of the sleeve relative to the core.

[0063] In some embodiments, an inner surface of the sleeve includes at least one mechanical interlocking feature, and an outer surface of the core includes a complementary interlocking feature. In at least one embodiment, the interlock between the mechanical interlocking feature and the complementary interlocking feature, limits and / or prevents the longitudinal movement of the sleeve and the core relative to one another. In at least one embodiment, the interlock between the mechanical interlocking feature and the complementary interlocking feature limits and / or prevents the rotational and / or lateral movement of the sleeve and the core relative to one another. In at least one embodiment, the interlock between the mechanical interlocking feature and the complementary interlocking feature limits and / or prevents both longitudinal movement and rotational movement of the sleeve and the core relative to one another. For example,PatentDocket No.: IS22.0421-US-PCT a longitudinal spline(s) and a complementary groove(s) may limit and / or prevent the rotational movement of the sleeve relative to the core. For example, a circumferential spline(s) and a complementary groove(s) may limit and / or prevent the longitudinal movement of the sleeve relative to the core. For example, a non-circumferential protrusion(s) and a complementary recess(es) may limit and / or prevent both the longitudinal and rotational movement of the sleeve relative to the core.

[0064] In some embodiments, the interlocking feature(s) limit and / or prevent movement of a first portion and a second portion of the core relative to one another. In some embodiments, the interlocking feature(s) limit and / or prevent movement of the table and the base relative to one another. For example, a core including a first portion integrally formed with a table and a second portion integrally formed with a base may have interlocking features that limit the movement of each relative to the sleeve and, therefore, with one another. In at least one example, a sleeve has a first mechanical interlocking feature and a second mechanical interlocking feature, a first portion has a first complementary interlocking feature that interlocks with the first mechanical interlocking feature, and a second portion has a second complementary interlocking feature that interlocks with the second mechanical interlocking feature.

[0065] In some embodiments, the table is integrally formed with the core. In some embodiments, the table has a longitudinal table length, and the core has a longitudinal core length from the table at a first longitudinal end of the cutting element to the second longitudinal end of the cutting element. In some embodiments, the table length is greater than a core length. In some embodiments, the table length is substantially equal to than a core length. In some embodiments, the table length is less than a core length. In some embodiments, the sleeve is positioned circumferentially around the core.

[0066] The present disclosure relates to cutting elements according to any of the following:

[0067] Clause 1 . A cutting element comprising: a table at a first longitudinal end in a longitudinal direction of a longitudinal axis, the table having a table outer diameter transverse to the longitudinal direction and the table including an ultrahard material; a core having a core outer diameter that is less than the table outer diameter, the core beingPatentDocket No.: IS22.0421-US-PCT coupled to and configured to receive heat from the table; and an annular sleeve radially outside of the core with a sleeve outer diameter no less than the table outer diameter.

[0068] Clause 2. The cutting element of clause 1 , wherein the table includes polycrystalline diamond (PCD).

[0069] Clause 3. The cutting element of clause 1 or 2, wherein at least a portion of the core is integrally formed with the table.

[0070] Clause 4. The cutting element of any preceding clause, further comprising a base at a second longitudinal end opposite the first longitudinal end, the base including a substrate material and configured to receive heat from the core.

[0071] Clause 5. The cutting element of clause 4, wherein at least a portion of the core is integrally formed with the base.

[0072] Clause 6. The cutting element of clause 4, wherein at least a first portion of the core is integrally formed with the table and a second portion of the core is integrally formed with the base.

[0073] Clause 7. The cutting element of clause 4, wherein at least a portion of the core is bonded to the base with a thermal interface material.

[0074] Clause 8. The cutting element of clause 4, wherein the annular sleeve is integrally formed with the base and includes the substrate material.

[0075] Clause 9. The cutting element of clause 4, wherein the annular sleeve has a lower thermal conductivity than the base.

[0076] Clause 10. The cutting element of clause 4, wherein the base has a base outer diameter greater than the core outer diameter.

[0077] Clause 11. The cutting element of any preceding clause, wherein at least a portion of the core is bonded to the table with a thermal interface material.

[0078] Clause 12. The cutting element of any preceding clause, wherein the annular sleeve has a greater hardness than the core.

[0079] Clause 13. The cutting element of any preceding clause, wherein the annular sleeve has a lower thermal conductivity than the core.PatentDocket No.: IS22.0421-US-PCT

[0080] Clause 14. The cutting element of any preceding clause, wherein the annular sleeve includes at least one mechanical interlocking feature on an inner surface thereof, and the core includes at least one complementary interlocking feature on an outer surface thereof configured to complementarily mate with the mechanical interlocking feature.

[0081] Clause 15. The cutting element of clause 14, wherein the mechanical interlocking feature and the complementary interlocking feature are configured to limit movement of the annular sleeve relative to the core in the longitudinal direction.

[0082] Clause 16. The cutting element of clause 14, wherein the mechanical interlocking feature and the complementary interlocking feature are configured to limit movement of the annular sleeve relative to the core in a rotational direction around the longitudinal axis.

[0083] Clause 17. The cutting element of any preceding clause, further comprising a base at a second longitudinal end opposite the first longitudinal end, the base including a substrate material different from a sleeve material of the annular sleeve.

[0084] Clause 18. A cutting element comprising: a table at a first longitudinal end in a longitudinal direction of a longitudinal axis, the table having a table outer diameter transverse to the longitudinal direction and the table being a monolithic PCD compact; a core integrally formed with the monolithic PCD compact of the table and having a core outer diameter that is less than the table outer diameter; a base at a second longitudinal end opposite the first longitudinal end, the base including a substrate material and configured to receive heat from the core; and an annular sleeve radially outside of the core with a sleeve outer diameter no less than the table outer diameter.

[0085] Clause 19. The cutting element of clause 18, wherein the annular sleeve is integrally formed with the base.

[0086] Clause 20. A cutting element comprising: a table at a first longitudinal end in a longitudinal direction of a longitudinal axis, the table having a table diameter transverse to the longitudinal direction and the table including an ultrahard material; a core integrally formed with the table and having a core diameter that is less than the table diameter, wherein the core has a core length from the table to a second longitudinal end oppositePatentDocket No.: IS22.0421-US-PCT the first longitudinal end in the longitudinal direction; and an annular sleeve radially outside of the core with a sleeve outer diameter no less than the table diameter.

[0087] It should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. For example, any element described in relation to an embodiment herein may be combinable with any element of any other embodiment described herein, to the extent such features are not described as being mutually exclusive. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about”, “substantially”, or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1 %, within 0.1 %, or within 0.01 % of a stated value.

[0088] The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that is within standard manufacturing or process tolerances, or which still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1 % of, within less than 0.1 % of, and within less than 0.01 % of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements.

[0089] A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function”PatentDocket No.: IS22.0421-US-PCT clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims. The described embodiments are therefore to be considered as illustrative and not restrictive, and the scope of the disclosure is indicated by the appended claims rather than by the foregoing description.

Claims

PatentDocket No.: IS22.0421-US-PCTCLAIMSWhat is claimed is:1 . A cutting element comprising: a table (102) at a first longitudinal end in a longitudinal direction of a longitudinal axis (108), the table having a table outer diameter (116) transverse to the longitudinal direction and the table including an ultrahard material; a core (104) having a core outer diameter (110) less than the table outer diameter, the core being coupled to and configured to receive heat from the table; and an annular sleeve (106) radially outside of the core with a sleeve outer diameter (114) no less than the table outer diameter.

2. The cutting element of any preceding claim, wherein the table includes polycrystalline diamond (PCD).

3. The cutting element of any preceding claim, wherein at least a portion of the core is integrally formed with the table.

4. The cutting element of any preceding claim, further comprising a base at a second longitudinal end opposite the first longitudinal end, the base including a substrate material and configured to receive heat from the core.

5. The cutting element of claim 4, wherein at least a portion of the core is integrally formed with the base.

6. The cutting element of claim 4, wherein at least a first portion of the core is integrally formed with the table and a second portion of the core is integrally formed with the base.

7. The cutting element of any of claims 4-6, wherein at least a portion of the core is bonded to the base with a thermal interface material.PatentDocket No.: IS22.0421-US-PCT8. The cutting element of any of claims 4-7, wherein the annular sleeve is integrally formed with the base and includes the substrate material.

9. The cutting element of any of claims 4-8, wherein the base has a base outer diameter greater than the core outer diameter.

10. The cutting element of any preceding claim, wherein at least a portion of the core is bonded to the table with a thermal interface material.11 . The cutting element of any preceding claim, wherein the annular sleeve has a greater hardness than the core.

12. The cutting element of any preceding claim, wherein the annular sleeve has a lower thermal conductivity than the core.

13. The cutting element of any preceding claim, wherein the annular sleeve includes at least one mechanical interlocking feature on an inner surface thereof, and the core includes at least one complementary interlocking feature on an outer surface thereof configured to complementarily mate with the mechanical interlocking feature.

14. The cutting element of claim 13, wherein the mechanical interlocking feature and the complementary interlocking feature are configured to limit movement of the annular sleeve relative to the core in the longitudinal direction.

15. The cutting element of claim 13, wherein the mechanical interlocking feature and the complementary interlocking feature are configured to limit movement of the annular sleeve relative to the core in a rotational direction around the longitudinal axis.

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