Binary Alloy Sealants for Polycrystalline Diamond Compact Formation

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Solution Overview

Problem

Conventional polycrystalline diamond compact (PDC) formation methods face challenges such as contamination, degradation, and graphitization due to the use of conventional braze materials, which also impede the degassing process and result in warping issues during the high-pressure/high-temperature (HPHT) process.

Innovation Solution

The use of binary alloy sealants comprising Group 8 and Group 11 elements, such as copper-nickel alloys, which facilitate degassing and hermetic sealing, while minimizing contamination and warping by controlling the melting temperature and preventing graphitization, and forming a substrate with a concave bottom surface to counteract warping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional braze materials are used during HPHT processing, then the sealing function is provided, but contamination, degradation, and graphitization occur while impeding the degassing process

Engineering Contradiction:

Improvesealing functionVSAvoidcontamination and graphitization

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameters of the sealant from conventional braze materials to binary alloys of Group 8 and Group 11 elements, specifically controlling the melting temperature to be below the HPHT processing temperature. This parameter change allows the sealant to remain solid during processing, preventing contamination and graphitization while maintaining sealing functionality.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a consumable sealant made of binary alloy that is designed to be replaced rather than reused. The sealant performs its sealing function during the HPHT process and is then discarded, eliminating the need for complex removal processes and avoiding contamination from conventional braze materials in subsequent operations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If conventional sealants are used, then sealing is achieved, but the degassing process is impeded resulting in gas entrapment and warping

Engineering Contradiction:

Improvesealing functionVSAvoiddegassing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent changes the melting temperature parameter of the sealant to be below the HPHT processing temperature. This ensures the sealant remains solid during the degassing phase, allowing gases to escape freely from the diamond particles without being blocked by melted sealant material, thus improving degassing efficiency while maintaining sealing.

Inventive Principle:

Principle #35Parameter changes

3Strength

If HPHT processing is applied to form PDCs, then diamond particles bond to form polycrystalline structure, but warping occurs due to gas entrapment and contamination

Engineering Contradiction:

Improvediamond grain bondingVSAvoidwarping

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent changes the material composition and melting temperature parameters of the sealant to prevent gas entrapment during HPHT processing. By using a binary alloy sealant with melting point below processing temperature, the sealant remains solid and allows complete degassing, preventing warping while still enabling strong diamond grain bonding through the HPHT process.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The binary alloy sealants enhance the formation of high-quality PDCs by ensuring effective degassing and hermetic sealing, reducing contamination and warping, and providing a stable substrate for post-HPHT shaping processes.

Implementation Method 1

heating the assembly to a degassing temperature effective to at least partially remove absorbed gases from the diamond material

Methodology Applied

Scientific EffectDegassing:

Implementation Method 2

melting the sealant such that the sealant seals the chamber from an exterior

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

The substrates and volume of diamond particles are then processed under HPHT conditions in the presence of a catalyst material that causes the diamond particles to bond to one another to form a matrix of bonded diamond grains

Methodology Applied

Scientific EffectHigh-pressure/high-temperature bonding:

Implementation Method 4

processed under HPHT conditions in the presence of a catalyst material that causes the diamond particles to bond to one another

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS20240383104A1Assemblies and methods of forming polycrystalline diamond using such assemblies

Publication Date: 2024.11.21 US SYNTHETIC CORP

AI summary

Embodiments disclosed herein are directed to assemblies for forming polycrystalline diamond compacts and methods for forming the polycrystalline diamond compacts with the assemblies. An example assembly includes a substrate and a diamond material positioned adjacent to an interfacial surface of the substrate. The assembly also includes an enclosure defining a chamber. The substrate and the diamond material are disposed in the chamber. In an embodiment, the assembly includes a sealant and the sealant includes at least one of cobalt or a copper-nickel alloy. In an embodiment, the substrate includes a concave bottom surface that is opposite the interfacial surface.