Patent ID: 11794290

Abstract:
The method for forming cutters includes applying a protective layer on an O-ring so as to form a protected O-ring. The protected O-ring is placed around a cutter body having a substrate section and diamond section with a metallic binder. The method includes inserting the cutter body into the pod cavity and leaching the metallic binder through an end portion of the diamond section for at least one day at 60 degrees Celsius or higher so as to form a polycrystalline diamond compact cutter from the cutter body. The protected O-ring seals the substrate section during the step of leaching. The step of leaching forms an exposed O-ring from the protected O-ring with a hardness reduction and a modulus reduction that identifies a time window for maintaining a sealing force to protect the substrate, while achieving the target profile of the diamond table for a high quality and reliable cutter.