US5238074A — Mosaic diamond drag bit cutter having a nonunifor…

Claim 1

Independent Claim 118 words

A cutter in a rotating drag bit comprising: a cutting face; a first group of cutting elements each having at least one end surface and being subject to wear at a first rate, said end surfaces being exposed on said cutting face; a second group of cutting elements each having at least one end surface and being subject to wear at a second rate different from said first rate, said second group end surfaces also being exposed on said cutting face; and a cutting slug formed of matrix material and having said first and second groups of cutting elements disposed therein, said cutting face being defined by a plurality of said end surfaces exposed on said cutting face.

Claim 2

Dependent Claim 118 words

A cutter in a rotating drag bit comprising: a cutting face; a first group of cutting elements each having at least one end surface and being subject to wear at a first rate, said end surfaces being exposed on said cutting face; a second group of cutting elements each having at least one end surface and being subject to wear at a second rate different from said first rate, said second group end surfaces also being exposed on said cutting face; and a cutting slug formed of matrix material and having said first and second groups of cutting elements disposed therein, said cutting face being defined by a plurality of said end surfaces exposed on said cutting face.

Claim 3

Dependent Claim 41 words

The cutter of claim 1 wherein said elements in said first group are arranged in a first row and wherein said the elements in said second group area arranged in a second row and wherein said rows are adjacent one another.

Claim 4

Dependent Claim 54 words

The cutter of claim 2 wherein said first and second groups of polycrystalline diamond have substantially the same wear ratio and wherein said first group and said second group have different thicknesses thereby wearing the elements in said second group at a different rate than those in said first group responsive to bit rotation.

Claim 5

Dependent Claim 52 words

The cutter of claim 2 wherein said first and second groups of polycrystalline diamond have substantially the same thicknesses and wherein said first and second groups have different wear ratios thereby wearing the elements in said second group at a different rate than those in said first group responsive to bit rotation.

Claim 6

Dependent Claim 45 words

The cutter of claim 1 wherein said elements in said first group are arranged in a first layer and said elements in said second group are arranged in a second layer adjacent said first layer, said first layer element end surfaces comprising said cutting surface.

Claim 7

Dependent Claim 54 words

The cutter of claim 5 wherein said first and second groups of polycrystalline diamond have substantially the same wear ratio and wherein said first group and said second group have different thicknesses thereby wearing the elements in said second group at a different rate than those in said first group responsive to bit rotation.

Claim 8

Dependent Claim 52 words

The cutter of claim 5 wherein said first and second groups of polycrystalline diamond have substantially the same thicknesses and wherein said first and second groups have different wear ratios thereby wearing the elements in said second group at a different rate than those in said first group responsive to bit rotation.

Claim 9

Dependent Claim 12 words

The cutter of claim 1 wherein said cutting face is substantially planar.

Claim 10

Dependent Claim 16 words

The cutter of claim 1 wherein said exposed end surfaces each have a substantially square boundary.

Claim 11

Dependent Claim 16 words

The cutter of claim 1 wherein said exposed end surfaces each have a substantially triangular boundary.

Claim 12

Dependent Claim 16 words

The cutter of claim 1 wherein said exposed end surfaces each have a substantially irregular boundary.

Claim 13

Dependent Claim 18 words

The cutter of claim 1 wherein the cutting elements in said first and second groups are randomly distributed.

Claim 14

Dependent Claim 126 words

A diamond cutter in a rotating drag bit comprising: a plurality of thermally stable, prefabricated polycrystalline diamond synthetic elements each having at least one end surface; a cutting slug formed of matrix material, said plurality of elements disposed within said cutting slug and said matrix material filling between said plurality of elements; a cutting face formed on said cutting slug and defined by a plurality of said end surfaces exposed on said cutting face; and a cutting edge formed on one side of said cutting face and including side surfaces presented by said polycrystalline diamond elements, said cutting edge including elements which wear at different rates thereby forming a cutting edge having a profile dependent upon the wear rate of the elements comprising said cutting edge.

Claim 15

Dependent Claim 126 words

A diamond cutter in a rotating drag bit comprising: a plurality of thermally stable, prefabricated polycrystalline diamond synthetic elements each having at least one end surface; a cutting slug formed of matrix material, said plurality of elements disposed within said cutting slug and said matrix material filling between said plurality of elements; a cutting face formed on said cutting slug and defined by a plurality of said end surfaces exposed on said cutting face; and a cutting edge formed on one side of said cutting face and including side surfaces presented by said polycrystalline diamond elements, said cutting edge including elements which wear at different rates thereby forming a cutting edge having a profile dependent upon the wear rate of the elements comprising said cutting edge.

Claim 16

Dependent Claim 69 words

The diamond cutter of claim 13 wherein said elements are selected from a first group having a first wear rate and from a second group having a second wear rate, said elements selected from said first group being arranged in a first row and said elements selected from said second group being arranged in a second row and wherein said rows are oriented substantially normal to said cutting edge.

Claim 17

Dependent Claim 55 words

The diamond cutter of claim 14 wherein said first and second groups of polycrystalline diamond have substantially the same wear ratio and wherein said first group and said second group have different thicknesses thereby wearing the elements in said second group at a different rate than those in said first group responsive to bit rotation.

Claim 18

Dependent Claim 53 words

The diamond cutter of claim 14 wherein said first and second groups of polycrystalline diamond have substantially the same thicknesses and wherein said first and second groups have different wear ratios thereby wearing the elements in said second group at a different rate than those in said first group responsive to bit rotation.

Claim 19

Dependent Claim 71 words

The diamond cutter of claim 13 wherein said elements are selected from a first group having a first wear rate and from a second group having a second wear rate, said elements selected from said first group being arranged in a first layer and said elements selected from said second group being arranged in a second layer adjacent said first layer, said first layer element end surfaces comprising said cutting face.

Claim 20

Dependent Claim 55 words

The diamond cutter of claim 17 wherein said first and second groups of polycrystalline diamond have substantially the same wear ratio and wherein said first group and said second group have different thicknesses thereby wearing the elements in said second group at a different rate than those in said first group responsive to bit rotation.

Claim 21

Dependent Claim 53 words

The diamond cutter of claim 17 wherein said first and second groups of polycrystalline diamond have substantially the same thicknesses and wherein said first and second groups have different wear ratios thereby wearing the elements in said second group at a different rate than those in said first group responsive to bit rotation.

Claim 22

Dependent Claim 13 words

The diamond cutter of claim 13 wherein said cutting face is substantially planar.

Claim 23

Dependent Claim 17 words

The diamond cutter of claim 13 wherein said exposed end surfaces each have a substantially square boundary.

Claim 24

Dependent Claim 17 words

The diamond cutter of claim 13 wherein said exposed end surfaces each have a substantially triangular boundary.

Claim 25

Dependent Claim 17 words

The diamond cutter of claim 13 wherein said exposed end surfaces each have a substantially irregular boundary.

Claim 26

Dependent Claim 19 words

The diamond cutter of claim 13 wherein the cutting elements in said first and second groups are randomly distributed.

Claim 27

Dependent Claim 73 words

A rotating drag bit comprising: a plurality of cutters, including at least two cutters of the type made from cutting elements embedded in a matrix material and presenting a plurality of end surfaces which define a cutting face; a first one of such cutters having elements which wear at a first rate; and a second one of such cutters having cutting elements which wear at a second rate different from said first rate.

Claim 28

Dependent Claim 73 words

A rotating drag bit comprising: a plurality of cutters, including at least two cutters of the type made from cutting elements embedded in a matrix material and presenting a plurality of end surfaces which define a cutting face; a first one of such cutters having elements which wear at a first rate; and a second one of such cutters having cutting elements which wear at a second rate different from said first rate.

Claim 29

Dependent Claim 50 words

The drag bit of claim 25 wherein said cutters are arranged in blades and wherein the cutters in one of said blades are of the type which wear at said first rate and the cutters in another of said blades are of the type which wear at said second rate.

Claim 30

Dependent Claim 31 words

The drag bit of claim 26 wherein said drag bit comprises four blades arranged at 90° intervals and wherein the cutters in adjacent blades have cutters which wear at different rates.

Claim 31

Dependent Claim 65 words

The drag bit of claim 25 wherein the cutting elements on said first and second cutters have substantially the same wear ratio and wherein the cutting elements on said first cutter have a different thickness from the cutting elements on said second cutter thereby wearing the elements in said second cutter at a different rate than those in said first cutter responsive to bit rotation.

Claim 32

Dependent Claim 65 words

The drag bit of claim 25 wherein the cutting elements on said first and second cutters have substantially the same thickness and wherein the cutting elements on said first cutter have a different wear ratio from the cutting elements on said second cutter thereby wearing the elements in said second cutter at a different rate than those in said first cutter responsive to bit rotation.

Claim 33

Independent Claim 66 words

A method of precussive drilling comprising the steps of: bonding a first layer of cutting elements to a precussive drill bit; bonding a second layer of such elements to said first layer; operating the precussive drill bit; orienting the bit to effect repeated striking of the cutting elements against an earth formation in a manner which compresses the cutting elements each time it strikes the formation.

Claim 34

Independent Claim 66 words

A method of precussive drilling comprising the steps of: bonding a first layer of cutting elements to a precussive drill bit; bonding a second layer of such elements to said first layer; operating the precussive drill bit; orienting the bit to effect repeated striking of the cutting elements against an earth formation in a manner which compresses the cutting elements each time it strikes the formation.

Claim 35

Dependent Claim 57 words

The method of claim 30 wherein the step of orienting the bit to effect repeated striking of the cutting element against an earth formation in a manner which compresses the cutting element each time it strikes the formation comprises the step of orienting the bit to strike the second layer of such elements against the earth formation.

Claim 36

Dependent Claim 33 words

The method of claim 30 wherein the step of bonding a second layer of such elements to said first layer comprises the step of offsetting said second layer relative to said first layer.

Claim 37

Dependent Claim 13 words

The method of claim 30 wherein said cutting elements comprise polycrystalline cutting elements.

Claim 38

Dependent Claim 56 words

A precussive drill bit comprising: a bit body having a working surface profile of a type suitable for precussive drilling wherein a working surface on said bit body repeatedly strikes an earth formation; and a layer of polycrystalline diamond bonded to said bit body and having a surface which defines substantially all of said working surface.

Claim 39

Dependent Claim 56 words

A precussive drill bit comprising: a bit body having a working surface profile of a type suitable for precussive drilling wherein a working surface on said bit body repeatedly strikes an earth formation; and a layer of polycrystalline diamond bonded to said bit body and having a surface which defines substantially all of said working surface.

Claim 40

Dependent Claim 23 words

The drill bit of claim 34 wherein said layer of polycrystalline diamond comprises a plurality of cutting elements bonded to said bit body.

Claim 41

Dependent Claim 36 words

The drill bit of claim 35 wherein said drill bit further comprises a second layer of polycrystalline diamond cutting elements bonded to said first layer and wherein said working surface is defined on said second layer.

Claim 42

Dependent Claim 25 words

The drill bit of claim 36 wherein the cutting elements in said second layer are offset relative to the cutting elements in said first layer.

Claim 43

Dependent Claim 16 words

The drill bit of claim 35 wherein some of said cutting elements have different wear ratios.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1996-08-23	1997-02-22	1997-08-24	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2000-08-23	2001-02-22	2001-08-24	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2004-08-23	2005-02-22	2005-08-24	$7700.00	Window Closed / Lapsed

Mosaic diamond drag bit cutter having a nonuniform wear pattern

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