Patent ID: 8858663

Claim:
A method of forming a cutting element for an earth-boring tool using catalyst material to catalyze formation of polycrystalline diamond material, comprising: providing a first powder comprising diamond crystals adjacent a surface of a cutting element substrate; providing a generally planar barrier structure adjacent the first powder on a side thereof opposite the cutting element substrate, the barrier structure comprising at least one of a disc, a film, and a foil of barrier material; providing a second powder comprising diamond crystals adjacent the barrier structure on a side thereof opposite the first powder; subjecting the cutting element substrate, the first powder, the barrier structure, and the second powder to high temperature and high pressure conditions and forming a continuous multi-layer diamond table including a first layer including polycrystalline diamond material adjacent the cutting element substrate, a barrier layer including polycrystalline diamond material adjacent the first layer on a side thereof opposite the cutting element substrate, and a second layer including polycrystalline diamond material adjacent the barrier layer on a side thereof opposite the first layer, the barrier material disposed in interstitial spaces between grains of polycrystalline diamond material within the barrier layer; and hindering migration of catalyst material across a plane of the generally planar barrier structure while subjecting the cutting element substrate, the first powder, the barrier structure, and the second powder to the high temperature and high pressure conditions.