Polycrystalline diamond cutter with integral polycrystalline diamond lined passage

Abstract

Provided are polycrystalline diamond cutters including a substrate, a diamond body, and a passage extending through the cutter along an axis from an opening in a lower side of the substrate to an opening in a first side of a diamond body. The diamond body may have a planar oriented portion and a projecting portion. The planar oriented portion of the diamond body may be attached to the upper side of the substrate and the projecting portion of the diamond body may form at least a portion of an inner wall surface of the first passage.

1 . A polycrystalline diamond cutter, comprising:
 a substrate including an upper side, a lower side opposite the upper side, and at least one edge side connecting the upper side to the lower side;   a diamond body including a planar oriented portion and a projecting portion; and   a first passage extending through the cutter along an axis from a first opening in the lower side of the substrate to a second opening in a first side of the diamond body,   wherein the planar oriented portion of the diamond body is attached to the upper side of the substrate, and   wherein the projecting portion of the diamond body forms at least a portion of an inner wall surface of the first passage.   
     
     
         2 . The polycrystalline diamond cutter of  claim 1 , wherein the projecting portion of the diamond body forms the entire inner wall surface of the first passage 
     
     
         3 . The polycrystalline diamond cutter according to  claim 1 , wherein the planar oriented portion of the diamond body has a first side, a second side opposite the first side, and an outer edge side connecting the first side to the second side, and wherein the outer edge side is aligned with the at least one edge side of the substrate. 
     
     
         4 . The polycrystalline diamond cutter of  claim 3 , wherein the outer edge side transforms into a beveled surface. 
     
     
         5 . The polycrystalline diamond cutter according to  claim 1 , wherein the first side of the planar portion forms a right angle with the inner wall of the first passage. 
     
     
         6 . The polycrystalline diamond cutter according to  claim 1 , wherein the first side of the planar portion forms a non-right angle with the inner wall of the first passage. 
     
     
         7 . The polycrystalline diamond cutter according to claims  claim 1 , wherein the first side of the planar portion transforms into the inner wall of the first passage by a curved surface. 
     
     
         8 . The polycrystalline diamond cutter according to  claim 1 , wherein the first passage has a shape of a right cylinder. 
     
     
         9 . The polycrystalline diamond cutter according to  claim 1 , wherein the first passage has a shape of frustum of a cone. 
     
     
         10 . The polycrystalline diamond cutter according to  claim 1 , wherein the first passage has a shape of a one sheet hyperboloid. 
     
     
         11 . The polycrystalline diamond cutter according to  claim 1 , wherein a thickness of the projecting portion varies as a function of axial position. 
     
     
         12 - 13 . (canceled) 
     
     
         14 . The polycrystalline diamond cutter according to  claim 1 , wherein an axial end of the projecting portion that is distal from the planar portion is aligned with the lower side of the substrate. 
     
     
         15 . The polycrystalline diamond cutter according to  claim 1 , wherein an axial length of the projecting portion is less than an axial length of the inner wall of the first passage. 
     
     
         16 . The polycrystalline diamond cutter according to  claim 1 , wherein the second side of the planar oriented portion is attached to the upper side of the substrate. 
     
     
         17 . The polycrystalline diamond cutter according to  claim 16 , wherein the second side of the planar oriented portion is planar. 
     
     
         18 . The polycrystalline diamond cutter according to  claim 16 , wherein the second side of the planar oriented portion is non-planar. 
     
     
         19 . The polycrystalline diamond cutter according to  claim 16 , wherein the second side of the planar oriented portion has a modulated surface texture. 
     
     
         20 . The polycrystalline diamond cutter according to  claim 1 , wherein the first passage extends axially along an axis coincident with a symmetry axis of the cutter and wherein the diamond body is continuous from the radial outer edge side to an axially most distant end of the projecting portion. 
     
     
         21 . The polycrystalline diamond cutter according to  claim 1 , wherein the first passage extends axially along an axis radially offset from a symmetry axis of the cutter 
     
     
         22 . The polycrystalline diamond cutter according to  claim 21 , wherein the diamond body is continuous from the radial outer edge side to an axially most distant end of the projecting portion. 
     
     
         23 - 42 . (canceled)