Cutting element for drill bits

Claim 2

A cutting element, comprising: (a) a metal carbide stud having an outer hemispherical end portion; (b) a plurality of ridges formed on said outer end portion, wherein each of said ridges has a substantially planar top surface extending outwardly from the outer end portion of said metal carbide stud; and (c) a layer of polycrystalline material disposed over the ridges and the outer end portion of said metal carbide stud, said polycrystalline material comprising abrasive particles selected from diamond, cubic boron nitride, wurtzite boron nitride, and mixtures thereof, bonded together in a unitary relationship.

Claim 3

The cutting element of claim 1 wherein said metal carbide stud is cylindrical.

Claim 4

The cutting element of claim 2 wherein said outer end portion of said metal carbide stud has a reduced diameter hemispherical projection.

Claim 5

The cutting element of claim 3 wherein said plurality of ridges are concentric.

Claim 6

The cutting element of claim 3 wherein said plurality of ridges collectively define a spiraling ridge.

Claim 7

The cutting element of claim 3 wherein said plurality of ridges define a checkerboard pattern.

Claim 8

The cutting element of claim 3 wherein said metal carbide includes tungsten carbide particles.

Claim 9

The cutting element of claim 1 wherein said plural ridges extend from said outer end portion of said stud to define an area between said ridges, said area being a portion of said hemispherical end portion so that said riges and end portion define a bonded interface with said layer disposed over said ridges and said interface secures said layer to said stud.

Claim 10

A cutting element, comprising: (a) a cylindrical metal carbide stud having an outer hemispherical end portion, said metal carbide stud including tungsten carbide particles; (b) a plurality of ridges formed in said outer end portion, wherein each of said ridges has a substantially planar top surface extending outwardly from the outer end portion of said metal carbide stud; and (c) a layer of polycrystalline diamond disposed over the ridges and the outer end portion of said metal carbide stud, bonded together in a unitary relationship.

Claim 11

A cutting element, comprising: (a) a cylindrical metal carbide stud having an outer hemispherical end portion, said metal carbide stud including tungsten carbide particles; (b) a plurality of ridges formed in said outer end portion, wherein each of said ridges has a substantially planar top surface extending outwardly from the outer end portion of said metal carbide stud; and (c) a layer of polycrystalline diamond disposed over the ridges and the outer end portion of said metal carbide stud, bonded together in a unitary relationship.

Claim 12

The cutting element of claim 9 wherein said plurality of ridges are stepped.

Claim 13

The cutting element of claim 9 wherein said layer of polycrystalline material has a uniform thickness over the ridges of said outer end portion.

Claim 14

The cutting element of claim 9 wherein said outer end portion of said metal carbide stud has a reduced diameter hemispherical projection.

Claim 15

The cutting element of claim 12 wherein said plurality of ridges are concentric.

Claim 16

The cutting element of claim 12 wherein said plurality of ridges collectively define a spiraling ridge.

Claim 17

A cutting element, comprising: (a) a cylindrical metal carbide stud having an outer hemispherical end portion, said metal carbide including tungsten carbide particles; (b) a plurality of ridges formed in said outer end portion, wherein each of said ridges has a substantially planar top surface extending outwardly from said outer end portion of said metal carbide stud; and (c) a layer of polycrystalline material disposed over the outer end portion of said metal carbide stud, wherein said polycrystalline material is bonded together in a unitary relationship, wherein said layer of polycrystalline material is applied between said ridges to a thickness equal to or exceeding the height of said ridges, and wherein the top surface of said ridges is at least partially exposed.

Claim 18

A cutting element, comprising: (a) a cylindrical metal carbide stud having an outer hemispherical end portion, said metal carbide including tungsten carbide particles; (b) a plurality of ridges formed in said outer end portion, wherein each of said ridges has a substantially planar top surface extending outwardly from said outer end portion of said metal carbide stud; and (c) a layer of polycrystalline material disposed over the outer end portion of said metal carbide stud, wherein said polycrystalline material is bonded together in a unitary relationship, wherein said layer of polycrystalline material is applied between said ridges to a thickness equal to or exceeding the height of said ridges, and wherein the top surface of said ridges is at least partially exposed.

Claim 19

The cutting element of claim 15 wherein said plurality of ridges are concentric.

Claim 20

The cutting element of claim 15 wherein said plurality of ridges collectively define a single spiraling ridge.

Claim 21

The cutting element of claim 15 wherein said plurality of ridges are stepped.

Claim 22

The cutting element of claim 15 wherein said stud is positioned and secured in a drill bit body.

Claim 23

The cutting element of claim 19 wherein said drill bit body anchors a set of said studs to define a drill bit body for drilling.

Claim 24

The cutting element of claim 15 wherein said plural ridges extend from said outer end portion of said stud to define an area between said ridges, said area being a portion of said hemispherical end portion so that said riges and end portion define a bonded interface with said layer disposed over said ridges and said interface secures said layer to said stud.