Patent ID: 9435159
Filing Date: 2016-09-06
CPC Classification: B22F,C04B,C22C,E21B

Claim Text:
1. A method of forming a polycrystalline diamond element, the method comprising: forming a polycrystalline diamond compact from diamond particles at a temperature and a pressure sufficient to form diamond-to-diamond bonds in the presence of a catalyst comprising one of a Group VIII element or an alloy thereof; substantially removing the catalyst from the polycrystalline diamond compact; and introducing only a single material comprising a catalytic binder material differing at least in part from a material of the catalyst and comprising one of a Group VIII element different from the Group VIII element or an alloy thereof or an alloy of the different Group VIII element into interstitial voids between diamond particles of the polycrystalline diamond compact having the catalyst substantially removed therefrom at a temperature and a pressure sufficient to maintain stability of diamond-to-diamond bonds in the polycrystalline diamond compact to substantially fill at least a portion of the polycrystalline diamond compact with the binder material.