US 9,808,911 B2
Polycrystalline abrasive compacts
Antionette Can, Sunward Park (ZA); Anna Emela Mochubele, Benoni (ZA); Geoffrey John Davies, Randburrg (ZA); and Johannes Lodewikus Myburgh, Helderkruin (ZA)
Assigned to ELEMENT SIX ABRASIVES S.A., Luxembourg (LU)
Filed by Antionette Can, Sunward Park (ZA); Anna Emela Mochubele, Benoni (ZA); Geoffrey John Davies, Randburrg (ZA); and Johannes Lodewikus Myburgh, Helderkruin (ZA)
Filed on Mar. 23, 2012, as Appl. No. 13/428,949.
Application 13/428,949 is a division of application No. 11/729,598, filed on Mar. 29, 2007, granted, now 8,419,814, issued on Apr. 16, 2013.
Claims priority of application No. 2006/02580 (ZA), filed on Mar. 29, 2006.
Prior Publication US 2012/0180401 A1, Jul. 19, 2012
Int. Cl. B05D 7/00 (2006.01); B24D 3/14 (2006.01); C03C 14/00 (2006.01); C04B 35/5831 (2006.01); C04B 35/628 (2006.01); C04B 35/645 (2006.01); C22C 26/00 (2006.01); C22C 29/06 (2006.01); C22C 29/12 (2006.01); C22C 29/16 (2006.01); E21B 10/567 (2006.01); B24D 3/02 (2006.01)
CPC B24D 3/14 (2013.01) [B24D 3/02 (2013.01); C03C 14/004 (2013.01); C04B 35/5831 (2013.01); C04B 35/62818 (2013.01); C04B 35/62821 (2013.01); C04B 35/62823 (2013.01); C04B 35/62831 (2013.01); C04B 35/62836 (2013.01); C04B 35/62884 (2013.01); C04B 35/62886 (2013.01); C04B 35/645 (2013.01); C22C 26/00 (2013.01); C22C 29/06 (2013.01); C22C 29/12 (2013.01); C22C 29/16 (2013.01); E21B 10/567 (2013.01); C03C 2214/05 (2013.01); C03C 2214/32 (2013.01); C04B 2235/3225 (2013.01); C04B 2235/3232 (2013.01); C04B 2235/3244 (2013.01); C04B 2235/3251 (2013.01); C04B 2235/386 (2013.01); C04B 2235/441 (2013.01); C04B 2235/465 (2013.01); C04B 2235/5436 (2013.01); C04B 2235/785 (2013.01); C04B 2235/85 (2013.01); C22C 2026/006 (2013.01)] 30 Claims
 
1. A method of manufacturing a polycrystalline ultrahard abrasive material including the steps of
providing a plurality of ultrahard abrasive particles selected from the group consisting of diamond and cubic boron nitride,
manipulating the surface chemistry of the ultrahard abrasive particles to render the surfaces of the particles to be vitreophilic, the vitreophilic surfaces to form chemical bonds with oxides, the vitreophilic surfaces comprising any of oxides and hydroxides of the material of the ultrahard abrasive particles,
colloidal suspension coating the manipulated surfaces of the ultrahard abrasive particles in a suspension with a matrix precursor material via the hydrolysis and polycondensation of alkoxides in the presence of deionised water, thereby to grow coats of hydrated oxide precursor materials onto the surfaces of the vitreophilic suspended particles, the deionised water being added to the suspension over a period of at least one hour,
treating the coated ultrahard abrasive particles to render them suitable for sintering, and
consolidating and sintering the coated ultrahard abrasive particles at a pressure and temperature at which they are crystallographically or thermodynamically stable.