Innovative cutting element and cutting structure using same

Abstract

A cutting tool is disclosed that includes a tool body, a plurality of cutting element support structures extending from the tool body, at least one slot formed in at least one of the cutting element support structures, a cutting element having a diamond shearing element with a plurality of surfaces, and at least one mechanical retention mechanism adjacent to the cutting element. Each cutting element support structure has a leading face, a top side, and a trailing face, and the slot has two side surfaces, each side surface terminating at the leading face and top side of the cutting element support structure. Each surface of the cutting element has two dimensional values, wherein the cutting element is positioned in the at least one slot such that a plane in which the shortest dimensional value lies intersects the slot side surfaces.

What is claimed is: 
     
         1 . A cutting element, comprising:
 two side surfaces;   four circumferential surfaces;   three dimensional values, wherein each dimensional value is defined by the longest length measured between two opposite surfaces, and wherein the three dimensional values comprise:
 a short dimensional value formed between the two side surfaces; and 
 two long dimensional values, wherein each long dimensional value is formed between two opposite circumferential surfaces; and 
   four edges formed by the intersection of the two side surface and four circumferential surfaces;   wherein at least one of the four edges comprises a thermally stable polycrystalline diamond layer extending the entire length of the shortest dimensional value and at least a partial length of each of the two long dimensional values.   
     
     
         2 . The cutting element of  claim 1 , wherein the thermally stable polycrystalline diamond layer has a thickness of at least 0.3 inches. 
     
     
         3 . The cutting element of  claim 1 , wherein the entire cutting element comprises polycrystalline diamond. 
     
     
         4 . The cutting element of  claim 1 , wherein the cutting element comprises at least one hole extending partially into the cutting element from one of the two side surfaces. 
     
     
         5 . The cutting element of  claim 1 , wherein the cutting element comprises at least one hole extending through the short dimensional value of the cutting element from one of the two side surfaces to the opposite surface. 
     
     
         6 . The cutting tool of  claim 1 , wherein at least one of a depression and a protrusion is formed on at least one of the side surfaces and the circumferential surfaces of the cutting element.