Patent
US 10,538,432METHODS OF FORMING GRAPHENE-COATED DIAMOND PARTICLES AND POLYCRYSTALLINE COMPACTS
Soma Chakraborty, Anthony A. DiGiovanni, Gaurav Agrawal, Danny E. Scott et al.
US
Copyright © 2026 Matter42. All rights reserved.
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1. The coated diamond particle 120 or 121 may then be immersed in a solution containing an oppositely charged species. Multiple graphene layers 108 and/or …
FIG. 2, the carbon shell 104 may be omitted. The surface of the core 102 may be chemically modified by attaching a reactive group to the core 102, such as an …
FIG. 3 is a simplified cross-section of an embodiment of a coated diamond particle 120 comprising at least one additional layer 110. Coated diamond particle 120 …
FIG. 4. Coated diamond particle 120 or 121 may further comprise an outer layer 112 having one or more graphene layers 108 and one or more additional layers …
FIG. 5. DETAILED DESCRIPTION [0020] The illustrations presented herein are not actual views of any particular particles, polycrystalline compact, …
FIG. 6 is an enlarged, schematic view illustrating how a microstructure of the hard polycrystalline material 132 of the polycrystalline compact 130 may appear …
FIG. 7 illustrates a fixed-cutter type earth-boring rotary drill bit 150 that includes a plurality of polycrystalline compacts 130 as previously described …
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A method of forming a polycrystalline compact, comprising: forming at least two graphene layers separated by at least one additional layer of material on each of a first plurality of diamond particles; and catalyzing the formation of inter-granular bonds between adjacent particles of the first plurality of diamond particles. Currently amended
The method of claim 1, further comprising interspersing the first plurality of diamond particles with a second plurality of diamond particles. Original
The method of claim 1, further comprising: providing a first volume comprising the first plurality of diamond particles; providing a second volume comprising a second plurality of diamond particles having at least one graphene layer, wherein the second plurality of diamond particles has a different average diameter from an average diameter of the first plurality of diamond particles; and catalyzing the formation of inter-granular bonds between adjacent particles of the second plurality of diamond particles. Previously presented
The method of claim 1, further comprising suspending the first plurality of diamond particles in a fluid. Original
The method of claim 1, wherein the first plurality of diamond particles comprises diamond nanoparticles, the method further comprising mixing the diamond nanoparticles with nondiamond nanoparticles. Currently amended
The method of claim 1, wherein forming the at least two graphene la y ers on each of a first plurality of diamond particles comprises coating diamond nanoparticles with the at least two graphene layers. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises at least one process selected from the group consisting of wet chemistry processes, physical deposition processes, and chemical deposition processes. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises coating the diamond particles in a fluidized-bed reactor. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises coating the diamond particles with at least one material selected from the group consisting of Group VIII A metals, carbonates, ceramics, and refractory metals. Currently amended
The method of claim 1, wherein the first plurality of diamond particles further comprise loose diamond particles. Previously presented
Canceled
A method of forming a polycrystalline compact, comprising: forming a first plurality of coated diamond particles, wherein each coated diamond particle comprises at least two graphene la y ers separated by at least one additional layer comprising a material selected from the group consisting of cobalt, iron, nickel, niobium, tantalum, molybdenum, tungsten, rhenium, titanium, vanadium, chromium, silicon, carbonates, carbides, and oxides; and subjecting the first plurality of coated diamond particles to a high-temperature high-pressure process. Currently amended
The method of claim 17, wherein each coated diamond particle comprises at least two additional layers separated by at least one graphene layer of the at least two graphene layers. Currently amended
The method of claim 17, subjecting the first plurality of coated diamond particles to an HT H P process comprises subjecting the coated diamond particles to a pressure greater than about 5.0 GPa and a temperature greater than about 1,000 0 C. Previously presented
the method of claim 17, wherein the first plurality of diamond particles further comprise loose diamond particles. Previously presented
Canceled
Layer stacks claimed or described, ordered top of device to substrate.
polycrystalline compact
Materials described outside the worked examples.
diamond particles
C
additional layer material
graphene
catalyst material
cobalt
Co
iron
Fe
nickel
Ni
magnesium carbonate
MgCO₃
ceramics
refractory metals
nondiamond nanoparticles
Group VIII A metals
carbonates
niobium
Nb
tantalum
Ta
molybdenum
Mo
tungsten
W
rhenium
Re
titanium
Ti
vanadium
V
chromium
Cr
silicon
Si
carbides
oxides
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
durability, but poor wettability may cause uncoated crystals to settle. Functionalized graphene coatings may increase wettability of diamond crystals in polishing liquids, promoting more uniform polishing. [0035] Wettability may also be beneficial in polymers a
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Temperature | ≥ 800 °C | — |
Duration | ≥ 30 minutes | — |
Temperature | ≥ 1 °C | — |
Temperature | ≥ 1500 °C | — |
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1. The coated diamond particle 120 or 121 may then be immersed in a solution containing an oppositely charged species. Multiple graphene layers 108 and/or …
FIG. 2, the carbon shell 104 may be omitted. The surface of the core 102 may be chemically modified by attaching a reactive group to the core 102, such as an …
FIG. 3 is a simplified cross-section of an embodiment of a coated diamond particle 120 comprising at least one additional layer 110. Coated diamond particle 120 …
FIG. 4. Coated diamond particle 120 or 121 may further comprise an outer layer 112 having one or more graphene layers 108 and one or more additional layers …
FIG. 5. DETAILED DESCRIPTION [0020] The illustrations presented herein are not actual views of any particular particles, polycrystalline compact, …
FIG. 6 is an enlarged, schematic view illustrating how a microstructure of the hard polycrystalline material 132 of the polycrystalline compact 130 may appear …
FIG. 7 illustrates a fixed-cutter type earth-boring rotary drill bit 150 that includes a plurality of polycrystalline compacts 130 as previously described …
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A method of forming a polycrystalline compact, comprising: forming at least two graphene layers separated by at least one additional layer of material on each of a first plurality of diamond particles; and catalyzing the formation of inter-granular bonds between adjacent particles of the first plurality of diamond particles. Currently amended
The method of claim 1, further comprising interspersing the first plurality of diamond particles with a second plurality of diamond particles. Original
The method of claim 1, further comprising: providing a first volume comprising the first plurality of diamond particles; providing a second volume comprising a second plurality of diamond particles having at least one graphene layer, wherein the second plurality of diamond particles has a different average diameter from an average diameter of the first plurality of diamond particles; and catalyzing the formation of inter-granular bonds between adjacent particles of the second plurality of diamond particles. Previously presented
The method of claim 1, further comprising suspending the first plurality of diamond particles in a fluid. Original
The method of claim 1, wherein the first plurality of diamond particles comprises diamond nanoparticles, the method further comprising mixing the diamond nanoparticles with nondiamond nanoparticles. Currently amended
The method of claim 1, wherein forming the at least two graphene la y ers on each of a first plurality of diamond particles comprises coating diamond nanoparticles with the at least two graphene layers. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises at least one process selected from the group consisting of wet chemistry processes, physical deposition processes, and chemical deposition processes. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises coating the diamond particles in a fluidized-bed reactor. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises coating the diamond particles with at least one material selected from the group consisting of Group VIII A metals, carbonates, ceramics, and refractory metals. Currently amended
The method of claim 1, wherein the first plurality of diamond particles further comprise loose diamond particles. Previously presented
Canceled
A method of forming a polycrystalline compact, comprising: forming a first plurality of coated diamond particles, wherein each coated diamond particle comprises at least two graphene la y ers separated by at least one additional layer comprising a material selected from the group consisting of cobalt, iron, nickel, niobium, tantalum, molybdenum, tungsten, rhenium, titanium, vanadium, chromium, silicon, carbonates, carbides, and oxides; and subjecting the first plurality of coated diamond particles to a high-temperature high-pressure process. Currently amended
The method of claim 17, wherein each coated diamond particle comprises at least two additional layers separated by at least one graphene layer of the at least two graphene layers. Currently amended
The method of claim 17, subjecting the first plurality of coated diamond particles to an HT H P process comprises subjecting the coated diamond particles to a pressure greater than about 5.0 GPa and a temperature greater than about 1,000 0 C. Previously presented
the method of claim 17, wherein the first plurality of diamond particles further comprise loose diamond particles. Previously presented
Canceled
Layer stacks claimed or described, ordered top of device to substrate.
polycrystalline compact
Materials described outside the worked examples.
diamond particles
C
additional layer material
graphene
catalyst material
cobalt
Co
iron
Fe
nickel
Ni
magnesium carbonate
MgCO₃
ceramics
refractory metals
nondiamond nanoparticles
Group VIII A metals
carbonates
niobium
Nb
tantalum
Ta
molybdenum
Mo
tungsten
W
rhenium
Re
titanium
Ti
vanadium
V
chromium
Cr
silicon
Si
carbides
oxides
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
durability, but poor wettability may cause uncoated crystals to settle. Functionalized graphene coatings may increase wettability of diamond crystals in polishing liquids, promoting more uniform polishing. [0035] Wettability may also be beneficial in polymers a
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Temperature | ≥ 800 °C | — |
Duration | ≥ 30 minutes | — |
Temperature | ≥ 1 °C | — |
Temperature | ≥ 1500 °C | — |
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1. The coated diamond particle 120 or 121 may then be immersed in a solution containing an oppositely charged species. Multiple graphene layers 108 and/or …
FIG. 2, the carbon shell 104 may be omitted. The surface of the core 102 may be chemically modified by attaching a reactive group to the core 102, such as an …
FIG. 3 is a simplified cross-section of an embodiment of a coated diamond particle 120 comprising at least one additional layer 110. Coated diamond particle 120 …
FIG. 4. Coated diamond particle 120 or 121 may further comprise an outer layer 112 having one or more graphene layers 108 and one or more additional layers …
FIG. 5. DETAILED DESCRIPTION [0020] The illustrations presented herein are not actual views of any particular particles, polycrystalline compact, …
FIG. 6 is an enlarged, schematic view illustrating how a microstructure of the hard polycrystalline material 132 of the polycrystalline compact 130 may appear …
FIG. 7 illustrates a fixed-cutter type earth-boring rotary drill bit 150 that includes a plurality of polycrystalline compacts 130 as previously described …
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A method of forming a polycrystalline compact, comprising: forming at least two graphene layers separated by at least one additional layer of material on each of a first plurality of diamond particles; and catalyzing the formation of inter-granular bonds between adjacent particles of the first plurality of diamond particles. Currently amended
The method of claim 1, further comprising interspersing the first plurality of diamond particles with a second plurality of diamond particles. Original
The method of claim 1, further comprising: providing a first volume comprising the first plurality of diamond particles; providing a second volume comprising a second plurality of diamond particles having at least one graphene layer, wherein the second plurality of diamond particles has a different average diameter from an average diameter of the first plurality of diamond particles; and catalyzing the formation of inter-granular bonds between adjacent particles of the second plurality of diamond particles. Previously presented
The method of claim 1, further comprising suspending the first plurality of diamond particles in a fluid. Original
The method of claim 1, wherein the first plurality of diamond particles comprises diamond nanoparticles, the method further comprising mixing the diamond nanoparticles with nondiamond nanoparticles. Currently amended
The method of claim 1, wherein forming the at least two graphene la y ers on each of a first plurality of diamond particles comprises coating diamond nanoparticles with the at least two graphene layers. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises at least one process selected from the group consisting of wet chemistry processes, physical deposition processes, and chemical deposition processes. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises coating the diamond particles in a fluidized-bed reactor. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises coating the diamond particles with at least one material selected from the group consisting of Group VIII A metals, carbonates, ceramics, and refractory metals. Currently amended
The method of claim 1, wherein the first plurality of diamond particles further comprise loose diamond particles. Previously presented
Canceled
A method of forming a polycrystalline compact, comprising: forming a first plurality of coated diamond particles, wherein each coated diamond particle comprises at least two graphene la y ers separated by at least one additional layer comprising a material selected from the group consisting of cobalt, iron, nickel, niobium, tantalum, molybdenum, tungsten, rhenium, titanium, vanadium, chromium, silicon, carbonates, carbides, and oxides; and subjecting the first plurality of coated diamond particles to a high-temperature high-pressure process. Currently amended
The method of claim 17, wherein each coated diamond particle comprises at least two additional layers separated by at least one graphene layer of the at least two graphene layers. Currently amended
The method of claim 17, subjecting the first plurality of coated diamond particles to an HT H P process comprises subjecting the coated diamond particles to a pressure greater than about 5.0 GPa and a temperature greater than about 1,000 0 C. Previously presented
the method of claim 17, wherein the first plurality of diamond particles further comprise loose diamond particles. Previously presented
Canceled
Layer stacks claimed or described, ordered top of device to substrate.
polycrystalline compact
Materials described outside the worked examples.
diamond particles
C
additional layer material
graphene
catalyst material
cobalt
Co
iron
Fe
nickel
Ni
magnesium carbonate
MgCO₃
ceramics
refractory metals
nondiamond nanoparticles
Group VIII A metals
carbonates
niobium
Nb
tantalum
Ta
molybdenum
Mo
tungsten
W
rhenium
Re
titanium
Ti
vanadium
V
chromium
Cr
silicon
Si
carbides
oxides
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
durability, but poor wettability may cause uncoated crystals to settle. Functionalized graphene coatings may increase wettability of diamond crystals in polishing liquids, promoting more uniform polishing. [0035] Wettability may also be beneficial in polymers a
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Temperature | ≥ 800 °C | — |
Duration | ≥ 30 minutes | — |
Temperature | ≥ 1 °C | — |
Temperature | ≥ 1500 °C | — |
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1. The coated diamond particle 120 or 121 may then be immersed in a solution containing an oppositely charged species. Multiple graphene layers 108 and/or …
FIG. 2, the carbon shell 104 may be omitted. The surface of the core 102 may be chemically modified by attaching a reactive group to the core 102, such as an …
FIG. 3 is a simplified cross-section of an embodiment of a coated diamond particle 120 comprising at least one additional layer 110. Coated diamond particle 120 …
FIG. 4. Coated diamond particle 120 or 121 may further comprise an outer layer 112 having one or more graphene layers 108 and one or more additional layers …
FIG. 5. DETAILED DESCRIPTION [0020] The illustrations presented herein are not actual views of any particular particles, polycrystalline compact, …
FIG. 6 is an enlarged, schematic view illustrating how a microstructure of the hard polycrystalline material 132 of the polycrystalline compact 130 may appear …
FIG. 7 illustrates a fixed-cutter type earth-boring rotary drill bit 150 that includes a plurality of polycrystalline compacts 130 as previously described …
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A method of forming a polycrystalline compact, comprising: forming at least two graphene layers separated by at least one additional layer of material on each of a first plurality of diamond particles; and catalyzing the formation of inter-granular bonds between adjacent particles of the first plurality of diamond particles. Currently amended
The method of claim 1, further comprising interspersing the first plurality of diamond particles with a second plurality of diamond particles. Original
The method of claim 1, further comprising: providing a first volume comprising the first plurality of diamond particles; providing a second volume comprising a second plurality of diamond particles having at least one graphene layer, wherein the second plurality of diamond particles has a different average diameter from an average diameter of the first plurality of diamond particles; and catalyzing the formation of inter-granular bonds between adjacent particles of the second plurality of diamond particles. Previously presented
The method of claim 1, further comprising suspending the first plurality of diamond particles in a fluid. Original
The method of claim 1, wherein the first plurality of diamond particles comprises diamond nanoparticles, the method further comprising mixing the diamond nanoparticles with nondiamond nanoparticles. Currently amended
The method of claim 1, wherein forming the at least two graphene la y ers on each of a first plurality of diamond particles comprises coating diamond nanoparticles with the at least two graphene layers. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises at least one process selected from the group consisting of wet chemistry processes, physical deposition processes, and chemical deposition processes. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises coating the diamond particles in a fluidized-bed reactor. Currently amended
The method of claim 1, wherein forming the at least one additional layer on each of the first plurality of diamond particles comprises coating the diamond particles with at least one material selected from the group consisting of Group VIII A metals, carbonates, ceramics, and refractory metals. Currently amended
The method of claim 1, wherein the first plurality of diamond particles further comprise loose diamond particles. Previously presented
Canceled
A method of forming a polycrystalline compact, comprising: forming a first plurality of coated diamond particles, wherein each coated diamond particle comprises at least two graphene la y ers separated by at least one additional layer comprising a material selected from the group consisting of cobalt, iron, nickel, niobium, tantalum, molybdenum, tungsten, rhenium, titanium, vanadium, chromium, silicon, carbonates, carbides, and oxides; and subjecting the first plurality of coated diamond particles to a high-temperature high-pressure process. Currently amended
The method of claim 17, wherein each coated diamond particle comprises at least two additional layers separated by at least one graphene layer of the at least two graphene layers. Currently amended
The method of claim 17, subjecting the first plurality of coated diamond particles to an HT H P process comprises subjecting the coated diamond particles to a pressure greater than about 5.0 GPa and a temperature greater than about 1,000 0 C. Previously presented
the method of claim 17, wherein the first plurality of diamond particles further comprise loose diamond particles. Previously presented
Canceled
Layer stacks claimed or described, ordered top of device to substrate.
polycrystalline compact
Materials described outside the worked examples.
diamond particles
C
additional layer material
graphene
catalyst material
cobalt
Co
iron
Fe
nickel
Ni
magnesium carbonate
MgCO₃
ceramics
refractory metals
nondiamond nanoparticles
Group VIII A metals
carbonates
niobium
Nb
tantalum
Ta
molybdenum
Mo
tungsten
W
rhenium
Re
titanium
Ti
vanadium
V
chromium
Cr
silicon
Si
carbides
oxides
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
durability, but poor wettability may cause uncoated crystals to settle. Functionalized graphene coatings may increase wettability of diamond crystals in polishing liquids, promoting more uniform polishing. [0035] Wettability may also be beneficial in polymers a
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Temperature | ≥ 800 °C | — |
Duration | ≥ 30 minutes | — |
Temperature | ≥ 1 °C | — |
Temperature | ≥ 1500 °C | — |