US4780274A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Manufacture of rotary drill bits
Assignee: Camco Drilling Group Ltd
•
Filing: 1986-10-24
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Granted: 1988-10-25
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Expires: 2006-10-24
Abstract
Abstract A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof comprises the steps of forming a hollow mould for moulding at least a portion of the bit body, packing the mould with powdered matrix material, and infiltrating the material with a metal alloy in a furnace to form a matrix. Before packing the mould with powdered matrix material, there are postioned in spaced locations on the interior surface of the mould a plurality of cutting element, each of which is formed of a material, such as a polycrystalline diamond material, which is thermally stable at the temperature necessary to form the matrix. Also positioned in the mould, adjacent the rearward side of each cutting element, is a support material such that, at least after formation of the matrix, the support material has a higher modulus of elasticity than the matrix.
Inventors
- 👤 John D. Barr
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 21:43
CPC Classifications
B; B22; B22F; B22F7/00; B22F7/06; B22F7/08; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12014; Y10T428/12028; Y10T428/12146
Claims Analysis
Total Claims: 39
Claim 1
Independent Claim
184 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. positioning in spaced locations on the interior surface of the mould a plurality of cutting elements; c. then locating a support material adjacent the rearward side of each cutting element so positioned; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. the support material, at least after formation of the solid infiltrated matrix, having a higher modulus of elasticity than that of the solid infiltrated matrix.
Claim 2
Independent Claim
184 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. positioning in spaced locations on the interior surface of the mould a plurality of cutting elements; c. then locating a support material adjacent the rearward side of each cutting element so positioned; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. the support material, at least after formation of the solid infiltrated matrix, having a higher modulus of elasticity than that of the solid infiltrated matrix.
Claim 3
Dependent Claim
40 words
A method according to claim 1, wherein the support material comprises a single preformed solid insert, the insert being so shaped as to be held in the finished bit body by the formation of solid infiltrated matrix around the insert.
Claim 4
Dependent Claim
27 words
A method according to claim 1, wherein the support material comprises a plurality of solid inserts, the solid infiltrated matrix being formed between and around the inserts.
Claim 5
Dependent Claim
57 words
A method according to claim 1, wherein the support material is applied to the mould in the form of a material which is converted to a hard material of higher modulus of elasticity than the solid infiltrated matrix forming the rest of the bit body as a result of the process for forming the solid infiltrated matrix.
Claim 6
Dependent Claim
23 words
A method according to claim 4, wherein the support material is applied to the mould in the form of a powdered matrix-forming material.
Claim 7
Dependent Claim
31 words
A method according to claim 5, wherein the powdered matrix-forming material is applied to the mould as a compound comprising the powdered material mixed with a liquid to form a paste.
Claim 8
Dependent Claim
12 words
A method according to claim 6, wherein the liquid is a hydrocarbon.
Claim 9
Dependent Claim
25 words
A method according to claim 1, including the step of providing a holding structure to hold each cutting element in position on the bit body.
Claim 10
Dependent Claim
84 words
A method according to claim 8, including forming a recess in the surface of the mould extending across part of the frontward surface of each cutting element, when said element is in position in the mould, which recess receives powdered material when the mould is packed and thus, when the solid infiltrated matrix is formed, provides a holding portion integral with the solid infiltrated matrix body and engaging the front face of the cutting element to hold it in position on the bit body.
Claim 11
Dependent Claim
64 words
A method according to claim 8, including providing a preformed element which is initially located in the mould in engagement with the frontward side of each cutting element in such manner that, after packing of the mould and formation of the solid infiltrated matrix, the element is held by the matrix and, in turn, holds the cutting element in position on the bit body.
Claim 12
Independent Claim
189 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. positioning in spaced locations on the interior surface of the mould a plurality of masses of support material; c. then locating a respective cutting element adjacent the forward side of each mass of support material so positioned; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. the support material, at least after formation of the solid infiltrated matrix, having a higher modulus of elasticity than that of the solid infiltrated matrix.
Claim 13
Independent Claim
189 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. positioning in spaced locations on the interior surface of the mould a plurality of masses of support material; c. then locating a respective cutting element adjacent the forward side of each mass of support material so positioned; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. the support material, at least after formation of the solid infiltrated matrix, having a higher modulus of elasticity than that of the solid infiltrated matrix.
Claim 14
Dependent Claim
43 words
A method according to claim 11, wherein each such mass of support material comprises a single preformed solid insert, the insert being so shaped as to be held in the finished bit body by the formation of solid infiltrated matrix around the insert.
Claim 15
Dependent Claim
30 words
A method according to claim 12, wherein each such mass of support material comprises a plurality of solid inserts, the solid infiltrated matrix being formed between and around the inserts.
Claim 16
Dependent Claim
57 words
A method according to claim 12, wherein the support material is applied to the mould in the form of a material which is converted to a hard material of higher modulus of elasticity than the solid infiltrated matrix forming the rest of the bit body as a result of the process for forming the solid infiltrated matrix.
Claim 17
Dependent Claim
23 words
A method according to claim 14, wherein the support material is applied to the mould in the form of a powdered matrix-forming material.
Claim 18
Dependent Claim
31 words
A method according to claim 15, wherein the powdered matrix-forming material is applied to the mould as a compound comprising the powdered material mixed with a liquid to form a paste.
Claim 19
Dependent Claim
12 words
A method according to claim 16, wherein the liquid is a hydrocarbon.
Claim 20
Dependent Claim
25 words
A method according to claim 12, including the step of providing a holding structure to hold each cutting element in position on the bit body.
Claim 21
Dependent Claim
84 words
A method according to claim 18, including forming a recess in the surface of the mould extending across part of the frontward surface of each cutting element, when said element is in position in the mould, which recess receives powdered material when the mould is packed and thus, when the solid infiltrated matrix is formed, provides a holding portion integral with the solid infiltrated matrix body and engaging the front face of the cutting element to hold it in position on the bit body.
Claim 22
Dependent Claim
64 words
A method according to claim 18, including providing a preformed element which is initially located in the mould in engagement with the frontward side of each cutting element in such manner that, after packing of the mould and formation of the solid infiltrated matrix, the element is held by the matrix and, in turn, holds the cutting element is position on the bit body.
Claim 23
Independent Claim
206 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. locating a plurality of masses of support material adjacent respective cutting elements; c. positioning in spaced locations on the interior surface of the mould a plurality of such paired support materials and cutting elements, each mass of support material being located adjacent the rearward side of its respective cutting element and positioned simultaneously therewith; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. the support material, at least after formation of the solid infiltrated matrix, having a higher modulus of elasticity than that of the solid infiltrated matrix.
Claim 24
Independent Claim
206 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. locating a plurality of masses of support material adjacent respective cutting elements; c. positioning in spaced locations on the interior surface of the mould a plurality of such paired support materials and cutting elements, each mass of support material being located adjacent the rearward side of its respective cutting element and positioned simultaneously therewith; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. the support material, at least after formation of the solid infiltrated matrix, having a higher modulus of elasticity than that of the solid infiltrated matrix.
Claim 25
Dependent Claim
25 words
A method according to claim 21, including the step of providing a holding structure to hold each cutting element in position on the bit body.
Claim 26
Dependent Claim
84 words
A method according to claim 22, including forming a recess in the surface of the mould extending across part of the frontward surface of each cutting element, when said element is in position in the mould, which recess receives powdered material when the mould is packed and thus, when the solid infiltrated matrix is formed, provides a holding portion integral with the solid infiltrated matrix body and engaging the front face of the cutting element to hold it in position on the bit body.
Claim 27
Dependent Claim
64 words
A method according to claim 22, including providing a preformed element which is initially located in the mould in engagement with the frontward side of each cutting element in such manner that, after packing of the mould and formation of the solid infiltrated matrix, the element is held by the matrix and, in turn, holds the cutting element in position on the bit body.
Claim 28
Independent Claim
204 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. positioning in spaced locations on the interior surface of the mould a plurality of cutting elements; c. then locating an insert adjacent the rearward side of each cutting element so positioned; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. each insert being such that, at least after formation of the solid infiltrated matrix, material adjacent the rear surface of the cutting element has a higher modulus of elasticity in the vicinity of the cutting edge of the element than it does away from the vicinity.
Claim 29
Independent Claim
204 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. positioning in spaced locations on the interior surface of the mould a plurality of cutting elements; c. then locating an insert adjacent the rearward side of each cutting element so positioned; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. each insert being such that, at least after formation of the solid infiltrated matrix, material adjacent the rear surface of the cutting element has a higher modulus of elasticity in the vicinity of the cutting edge of the element than it does away from the vicinity.
Claim 30
Dependent Claim
46 words
A method according to claim 25, wherein the insert is of higher modulus of elasticity than the solid infiltrated matrix forming the rest of the bit body, and is located on the rearward side of the cutting element in the vicinity of the cutting edge thereof.
Claim 31
Dependent Claim
48 words
A method according to claim 25, wherein the insert is of a lower modulus of elasticity than the solid infiltrated matrix forming the rest of the bit body, and is located on the rearward side of the cutting element away from the vicinity of the cutting edge thereof.
Claim 32
Independent Claim
216 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. positioning in spaced locations on the interior surface of the mould a plurality of masses of support material, each comprising at least one insert; c. then locating a respective cutting element adjacent the forward side of each mass of support material so positioned; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. each insert being such that, at least after formation of the solid infiltrated matrix, material adjacent the rear surface of the cutting element has a higher modulus of elasticity in the vicinity of the cutting edge of the element than it does away from the vicinity.
Claim 33
Independent Claim
216 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. positioning in spaced locations on the interior surface of the mould a plurality of masses of support material, each comprising at least one insert; c. then locating a respective cutting element adjacent the forward side of each mass of support material so positioned; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. each insert being such that, at least after formation of the solid infiltrated matrix, material adjacent the rear surface of the cutting element has a higher modulus of elasticity in the vicinity of the cutting edge of the element than it does away from the vicinity.
Claim 34
Dependent Claim
46 words
A method according to claim 28, wherein the insert is of higher modulus of elasticity than the solid infiltrated matrix forming the rest of the bit body, and is located on the rearward side of the cutting element in the vicinity of the cutting edge thereof.
Claim 35
Dependent Claim
48 words
A method according to claim 28, wherein the insert is of a lower modulus of elasticity than the solid infiltrated matrix forming the rest of the bit body, and is located on the rearward side of the cutting element away from the vicinity of the cutting edge thereof.
Claim 36
Independent Claim
233 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. locating a plurality of masses of support material, each comprising at least one insert, adjacent respective cutting elements; c. positioning in spaced locations on the interior surface of the mould a plurality of such paired support materials and cutting elements, each mass of support material being located adjacent the rearward side of its respective cutting element and positioned simultaneously therewith; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. each insert being such that, at least after formation of the solid infiltrated matrix, material adjacent the rear surface of the cutting element has a higher modulus of elasticity in the vicinity of the cutting edge of the element than it does away from the vicinity.
Claim 37
Independent Claim
233 words
A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof, the method comprising the steps of: a. forming a hollow mould for moulding at least a portion of the bit body; b. locating a plurality of masses of support material, each comprising at least one insert, adjacent respective cutting elements; c. positioning in spaced locations on the interior surface of the mould a plurality of such paired support materials and cutting elements, each mass of support material being located adjacent the rearward side of its respective cutting element and positioned simultaneously therewith; d. packing the mould with powdered matrix material; e. providing a metal alloy in contact with the powdered matrix material in the mould; f. heating the packed mould in a furnace to an infiltration temperature at which the metal alloy fuses and infiltrates the powdered matrix material; and g. cooling the mould to solidify the infiltrated matrix; h. each cutting element being formed of a material which is thermally stable at said infiltration temperature; and i. each insert being such that, at least after formation of the solid infiltrated matrix, material adjacent the rear surface of the cutting element has a higher modulus of elasticity in the vicinity of the cutting edge of the element than it does away from the vicinity.
Claim 38
Dependent Claim
46 words
A method according to claim 31, wherein the insert is of higher modulus of elasticity than the solid infiltrated matrix forming the rest of the bit body, and is located on the rearward side of the cutting element in the vicinity of the cutting edge thereof.
Claim 39
Dependent Claim
48 words
A method according to claim 31, wherein the insert is of a lower modulus of elasticity than the solid infiltrated matrix forming the rest of the bit body, and is located on the rearward side of the cutting element away from the vicinity of the cutting edge thereof.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-10-25 | 1992-04-25 | 1992-10-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-10-25 | 1996-04-25 | 1996-10-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-10-25 | 2000-04-25 | 2000-10-25 | $7700.00 | Window Closed / Lapsed |