Patent ID: 7575805

Claim:
A polycrystalline diamond abrasive element, comprising: a layer of polycrystalline diamond comprising a binder phase comprising catalyzing material, and a substrate, wherein said layer of the polycrystalline diamond comprises a working surface and is bonded to the substrate along an interface, a region adjacent said working surface which is lean in the catalyzing material, and a region rich in the catalyzing material, wherein said region rich in the catalyzing material comprises said binder phase homogeneously distributed through the rich region, and a fine scale of the binder phase distribution, wherein the binder phase distribution is expressed in terms of an equivalent circle diameter, the standard deviation of the distribution of equivalent circle diameters, expressed as a percentage of the average equivalent circle diameter, is less than 80%, and wherein the layer of the polycrystalline diamond comprises diamond particles having an average particle grain size of less than 20 microns.