U.S. patent application number 13/826119 was filed with the patent office on 2013-12-05 for cutter assembly with at least one island and a method of manufacturing a cutter assembly.
The applicant listed for this patent is Diamond Innovations, Inc.. Invention is credited to Yuanbo Lin, John W. Lucek, Bruce Jake Reierson, Joseph Michael Rhodes.
Application Number | 20130318884 13/826119 |
Document ID | / |
Family ID | 49668554 |
Filed Date | 2013-12-05 |
United States Patent
Application |
20130318884 |
Kind Code |
A1 |
Lin; Yuanbo ; et
al. |
December 5, 2013 |
CUTTER ASSEMBLY WITH AT LEAST ONE ISLAND AND A METHOD OF
MANUFACTURING A CUTTER ASSEMBLY
Abstract
A cutter assembly and a method of making the cutter assembly are
disclosed. A method of fabricating a cutting element having at
least one island structure in at least one pocket of a substrate
may comprise steps of building a substrate green body with at least
one pocket; building at least one island green body; assembling the
at least one island green body and the substrate green body with at
least one pocket in the substrate green body to form a green body
assembly; and subjecting the green body assembly to a final
fabrication process to form the said cutting element.
Inventors: |
Lin; Yuanbo; (Houston,
TX) ; Reierson; Bruce Jake; (Delaware, OH) ;
Rhodes; Joseph Michael; (Heath, OH) ; Lucek; John
W.; (Powell, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Diamond Innovations, Inc. |
Worthington |
OH |
US |
|
|
Family ID: |
49668554 |
Appl. No.: |
13/826119 |
Filed: |
March 14, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13339483 |
Dec 29, 2011 |
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13826119 |
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13339474 |
Dec 29, 2011 |
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13339483 |
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13339838 |
Dec 29, 2011 |
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13339474 |
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13339854 |
Dec 29, 2011 |
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13339838 |
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Current U.S.
Class: |
51/309 ;
51/307 |
Current CPC
Class: |
B24D 3/06 20130101; B24D
18/0009 20130101; B24D 99/005 20130101 |
Class at
Publication: |
51/309 ;
51/307 |
International
Class: |
B24D 3/06 20060101
B24D003/06 |
Claims
1. A method of fabricating a cutting element having at least one
island structure in at least one pocket of a substrate, comprising:
building a substrate green body with at least one pocket; building
at least one island green body; assembling the at least one island
green body and the substrate green body with at least one pocket in
the substrate green body to form a green body assembly; and
subjecting the green body assembly to a final fabrication process
to form the cutting element.
2. The method according to claim 1, further comprising a binding
agent in forming the substrate green body with at least one pocket
in it and the at least one island green body.
3. The method according to claim 1, wherein the island is at least
one of WC, polycrystalline diamond, single crystalline diamond,
polycrystalline cubic boron nitride, single crystalline boron
nitride, cermet, ceramics, thermally stable diamond, and diamond
composite.
4. The method according to claim 1, wherein the substrate green
body comprises at least one of WC, polycrystalline diamond, single
crystalline diamond, polycrystalline cubic boron nitride, single
crystalline boron nitride, cermet, ceramics, thermally stable
diamond, and diamond composite.
5. The method according to claim 1, wherein the substrate green
body with at least one pocket is pre-formed with methods of
pre-compaction, die-pressing, extrusion, slurry casting.
6. The method according to claim 1, wherein the at least one pocket
in the substrate green body is pre-formed with methods of milling,
drilling, turning, grinding, coring.
7. The method according to claim 1, wherein the at least one island
green body is pre-formed with methods of pre-compaction,
die-pressing, extrusion, slurry casting.
8. The method according to claim 1, wherein the at least one island
green body is pre-formed with methods of milling, drilling,
turning, grinding, coring.
9. The method according to claim 1, wherein the final fabrication
process is HPHT process.
10. The method according to claim 1, wherein sintering additive or
aid is added to facilitate the HPHT process.
11. The method according to claim 10, wherein the sintering
additive or aid comprises Group VIII metals, cobalt, iron, nickel
or metalloid silicon.
12. The method according to claim 9, wherein the HTHP process is
under temperature between 900.degree. C. to 2300.degree. C.
13. The method according to claim 9, wherein the HTHP process is
under pressure range between 3 GPa to 20 GPa.
14. The method according to claim 9, wherein the HTHP process is
under pressure range between 0.01 GPA to 20 GPa.
15. A method of fabricating a cutting element having at least one
island structure in at least one pocket of a substrate, comprising:
assembling at least one island green body and a substrate green
body with at least one pocket in the substrate green body to form a
green body assembly; and subjecting the green body assembly to a
high temperature high pressure sintering process to form the
cutting element.
16. The method according to claim 15, further comprising a binding
agent in forming the substrate green body with at least one pocket
in it and the at least one island green body.
17. The method according to claim 15, wherein the island is at
least one of WC, polycrystalline diamond, single crystalline
diamond, polycrystalline cubic boron nitride, single crystalline
boron nitride, cermet, ceramics, thermally stable diamond, and
diamond composite.
18. The method according to claim 15, wherein the at least one
pocket in the substrate green body is pre-formed with methods of
milling, drilling, turning, grinding, coring.
19. The method according to claim 15, wherein the at least one
island green body is pre-formed with methods of pre-compaction,
die-pressing, extrusion, slurry casting.
20. The method according to claim 15, wherein sintering additive or
aid is added to facilitate the HPHT process.
21. The method according to claim 15, wherein the sintering
additive or aid comprises Group VIII metals, cobalt, iron, nickel
or metalloid silicon.
Description
FIELD
[0001] The present disclosure relates to a cutter assembly with at
least one island.
[0002] More particularly, the present disclosure relates a cutter
assembly that can include a substrate and at least one island
disposed in the substrate.
BACKGROUND
[0003] In the discussion of the background that follows, reference
is made to certain structures and/or methods. However, the
following references should not be construed as an admission that
these structures and/or methods constitute prior art. Applicants
expressly reserve the right to demonstrate that such structures
and/or methods do not qualify as prior art.
[0004] Cutters can be subject to abrasion which can shorten the
working life of the cutter. Thus, there is a need in the art for a
cutter assembly that can provide higher abrasion resistance or
longer cutter life.
SUMMARY
[0005] Exemplary embodiments provide a cutter assembly and a method
of manufacturing a cutter assembly. The cutter assembly includes a
substrate and at least one island. The substrate includes a surface
circumscribed by a peripheral edge, a flank surface extending from
the peripheral edge, and at least one pocket with an opening on the
surface and spaced apart from the peripheral edge. The at least one
pocket extends from the opening towards an interior of the
substrate. The at least one island is in the at least one pocket,
and the at least one island includes a cutting surface that is
exposed by the opening of the at least one pocket.
[0006] In another construction, the cutter assembly includes a
substrate and at least one island. The substrate includes a surface
circumscribed by a peripheral edge, a flank surface extending from
the peripheral edge, and at least one pocket with an opening on the
surface and the flank surface. The at least one pocket extends from
the opening towards an interior of the substrate, and the at least
one island is in the at least one pocket so that the at least one
island protrudes beyond the flank surface. The at least one island
includes a cutting surface that is exposed by the opening of the at
least one pocket.
[0007] In another construction, the cutter assembly includes a
substrate and at least one island. The substrate includes a surface
circumscribed by a peripheral edge, a flank surface extending from
the peripheral edge, and at least one pocket disposed in the
substrate away from the surface and the flank surface. The at least
one island is disposed in the at least one pocket, and the at least
one island includes a cutting surface.
[0008] The method of manufacturing a cutter assembly includes:
providing at least one island; treating the at least one island;
providing a substrate; forming a surface circumscribed by a
peripheral edge on the substrate; forming at least one pocket with
an opening disposed on the surface and spaced apart from the
peripheral edge, the at least one pocket extending from the opening
towards an interior of the substrate and having a shape that
engages with the at least one island; disposing the at least one
island in the at least one pocket; and coupling the at least island
to the at least one pocket.
[0009] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory and are intended to provide further explanation of
the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWING
[0010] The following detailed description can be read in connection
with the accompanying drawings in which like numerals designate
like elements and in which:
[0011] FIG. 1 is a perspective view of a cutter assembly with at
least one island in accordance with an embodiment.
[0012] FIG. 2a is a side view of the cutter assembly with at least
one island shown in FIG. 1 according to one embodiment.
[0013] FIG. 2b is a side view of the cutter assembly with at least
one island shown in FIG. 1 according to another embodiment.
[0014] FIG. 3a is a sectional side view of the cutter assembly with
at least one island shown in FIG. 1 according to one
embodiment.
[0015] FIG. 3b is a sectional side view of the cutter assembly with
at least one island shown in FIG. 1 according to another
embodiment.
[0016] FIG. 4 is a top view of the cutter assembly with at least
one island shown in FIG. 1.
[0017] FIG. 5 is a perspective view of a cutter assembly with at
least one island of an alternate construction.
[0018] FIG. 6 is a side view of the cutter assembly with at least
one island of an alternate construction shown in FIG. 5.
[0019] FIG. 7 is a sectional side view of the cutter assembly with
at least one island of an alternate construction shown in FIG.
5.
[0020] FIG. 8 is a perspective view of a cutter assembly with at
least one island of an alternate construction.
[0021] FIG. 9 is a side view of the cutter assembly with at least
one island of an alternate construction shown in FIG. 8.
[0022] FIG. 10 is a sectional side view of the cutter assembly with
at least one island of an alternate construction shown in FIG.
8.
[0023] FIG. 11 is a perspective view of a cutter assembly with at
least one island of an alternate construction.
[0024] FIG. 12 is a side view of the cutter assembly with at least
one island of an alternate construction shown in FIG. 11.
[0025] FIG. 13 is a sectional side view of the cutter assembly with
at least one island of an alternate construction shown in FIG.
11.
[0026] FIG. 14 is a top view of a cutter assembly with at least one
island of an alternate construction.
[0027] FIG. 15 is a top view of a cutter assembly with at least one
island of an alternate construction.
[0028] FIG. 16 is a top view of a cutter assembly with at least one
island of an alternate construction.
[0029] FIG. 17 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction,
[0030] FIG. 18 is a side view of the cutter assembly with at least
one island shown in FIG. 17.
[0031] FIG. 19 is a sectional side view of the cutter assembly with
at least one island shown in FIG. 17.
[0032] FIG. 20 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0033] FIG. 21 is a side view of the cutter assembly with at least
one island shown in FIG. 20.
[0034] FIG. 22 is a sectional side view of the cutter assembly with
at least one island shown in FIG. 20.
[0035] FIG. 23 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0036] FIG. 24 is a side view of the cutter assembly with at least
one island shown in FIG. 23.
[0037] FIG. 25 is a sectional side view of the cutter assembly with
at least one island shown in FIG. 23.
[0038] FIG. 26 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0039] FIG. 27 is a side view of the cutter assembly with at least
one island shown in FIG. 26.
[0040] FIG. 28 is an exploded, sectional side view of the cutter
assembly with at least one island shown in FIG. 26.
[0041] FIG. 29 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0042] FIG. 30 is a side view of the cutter assembly with at least
one island shown in FIG. 29.
[0043] FIG. 31 is an exploded, sectional side view of the cutter
assembly with at least one island shown in FIG. 29.
[0044] FIG. 32 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0045] FIG. 33 is a side view of the cutter assembly with at least
one island shown in FIG. 32.
[0046] FIG. 34 is an exploded, sectional side view of the cutter
assembly with at least one island shown in FIG. 32.
[0047] FIG. 35 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0048] FIG. 36 is a side view of the cutter assembly with at least
one island shown in FIG. 35.
[0049] FIG. 37 is an exploded, sectional side view of the cutter
assembly with at least one island shown in FIG. 35.
[0050] FIG. 38 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0051] FIG. 39 is a side view of the cutter assembly with at least
one island shown in FIG. 38.
[0052] FIG. 40 is an exploded, sectional side view of the cutter
assembly with at least one island shown in FIG. 38.
[0053] FIG. 41 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0054] FIG. 42 is a side view of the cutter assembly with at least
one island shown in FIG. 41.
[0055] FIG. 43 is an exploded, sectional side view of the cutter
assembly with at least one island shown in FIG. 41.
[0056] FIG. 44 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0057] FIG. 45 is a side view of the cutter assembly with at least
one island shown in FIG. 44.
[0058] FIG. 46 is an exploded, sectional side view of the cutter
assembly with at least one island shown in FIG. 44.
[0059] FIG. 47 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0060] FIG. 48 is a side view of the cutter assembly with at least
one island shown in FIG. 47.
[0061] FIG. 49 is an exploded, sectional side view of the cutter
assembly with at least one island shown in FIG. 47.
[0062] FIG. 50 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0063] FIG. 51 is a side view of the cutter assembly with at least
one island shown in FIG. 50.
[0064] FIG. 52 is an exploded, sectional side view of the cutter
assembly with at least one island shown in FIG. 50.
[0065] FIG. 53 is a perspective view of a cutter assembly with at
least one island in accordance with an alternate construction.
[0066] FIG. 54 is a side view of the cutter assembly with at least
one island shown in FIG. 53.
[0067] FIG. 55 is an exploded, sectional side view of the cutter
assembly with at least one island shown in FIG. 53.
[0068] FIG. 56 is a flowchart of a method of manufacturing a cutter
with at least one island in accordance with an embodiment.
[0069] FIG. 5 is a flowchart of a method of manufacturing a cutter
with at least one island in accordance with an alternate
construction.
DETAILED DESCRIPTION
[0070] Referring to FIGS. 1-56, embodiments can provide a cutter
assembly 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100,
1200, 1300, 1400, 1500, 1600, 1700, 1800, and 1900 with higher
abrasion resistance, longer life, better toughness, and/or thermal
stability. Embodiments can utilize, for example, fully leached
polycrystalline diamond, which can have significantly better
thermal stability up to approximately 1,000.degree. C. When fully
leached polycrystalline diamond is used and coupled with, for
example, a cobalt-tungsten carbide, embodiments can also provide
higher strength at the interface between fully leached
polycrystalline diamond and cobalt-tungsten carbide. Embodiments
can also provide a method of manufacturing a cutter assembly 100 .
. . 1900, that includes, for example, a fully leached
polycrystalline diamond, which is coupled to, for example,
cobalt-tungsten carbide securely and economically.
[0071] The cutter assembly 100 . . . 1900 can comprise a substrate
102, 202, 302, 402, 502, 602, 702, 802, 902, 1002, 1102, 1202,
1302, 1402, 1502, 1602, 1702, 1802, and 1902 at least one island
150a, 150b, 250, 350, 450, 550, 650, 750, 850, 950, 1050, 1150,
1250, 1350, 1450, 1550, 1650, 1750, 1850, and 1950 disposed in the
substrate 102 . . . 1902.
[0072] The at least one island 150a . . . 1950 can be disposed in
the substrate 102 . . . 1902. The substrate 102 . . . 1902 can have
a surface 104, 204, 304, 404, 504, 604, 704, 804, 904, 1004, 1104,
1204, 1304, 1404, 1504, 1604, 1704, 1804, and 1904. The surface 104
. . . 1904 can receive one or more of the islands 150a . . . 1950.
In other constructions of the cutter assembly 100 . . . 1900, the
substrate 102 . . . 1902 can have a plurality of surfaces 104 . . .
1904, and each one of the plurality of surfaces 104 . . . 1904 can
receive one or more of the islands 150a . . . 1950.
[0073] The at least one island 150a . . . 1950 can be disposed in
the substrate 102 . . . 1902 such that the at least one island 150a
. . . 1950 is spaced apart from another island 150a . . . 1950.
[0074] The substrate 102 . . . 1902 can be made from tungsten
carbide cobalt (W--Co), a diamond-silicon carbide composite
material, binderless carbide, or some other suitable materials. One
example of a diamond-silicon carbide composite material is
commercially available as Versimax. Binderless can refer to
tungsten carbide composites with less amount of metal binder phase
than a metal-WC composite cermet material, such as Co--WC composite
cermet material, Ni--WC composite cermet material, Fe--WC composite
cermet material, and the like. Examples of binderless carbide can
include a cermet of tungsten carbide binded with a molybdenum metal
and a low metal content of about 1 wt % to about 2 wt %. Binderless
carbide can also include a type of tungsten carbide sintered with
low metal content, such as about 1 wt % to about 2 wt %, and a
binding phase that is mainly eta-phase
(Co.sub.3W.sub.3O.sub.6).
[0075] The at least one island 150a . . . 1950 can be made from
polycrystalline diamond (PCD), diamond, cubic boron nitride (CBN),
polycrystalline cubic boron nitride (PCBN), or a diamond-silicon
carbide composite material. One example of a diamond-silicon
carbide composite material is commercially available as
Versimax.
[0076] The at least one island 150a . . . 1950 can be a thermally
stable material. However, in other constructions of the cutter
assembly 100 . . . 1900, the at least one island 150a . . . 1950
can be made from a material that is thermally stable.
[0077] If the at least one island 150a . . . 1950 is made from PCD,
the at least one island 150a . . . 1950 made from PCD can be fully
leached, partially leached, or unleached. In a construction of the
cutter assembly 100 that includes fully leached PCD, the cutter
assembly 100 . . . 1900 can provide thermal stability.
[0078] The at least one island 150a . . . 1950 can be coated. The
coating material can comprise a metal, a metal alloy, a compound of
the metal and/or combination of series thereof. The metal may
comprise tungsten, titanium, niobium, zirconium, tantalum,
vanadium, chromium, or molybdenum. The coating can be applied upon
at least a portion of the at least one island 150a . . . 1950 via a
coating method that can comprise physical vapor deposition,
chemical vapor deposition, sputtering, evaporation, electroless
plating, electroplating, and/or combinations or series thereof. The
coating layer can have a thickness of about 0.1 .mu.m to about 100
.mu.m.
[0079] The at least one island 150a . . . 1950 can have a casing.
In some constructions of the cutter assembly 100 . . . 1900, the at
least one island 150a . . . 1950 can be press fit into the casing.
The casing can be a metal casing. The metal casing can provide a
medium between the at least one island 160a . . . 1950 and the
substrate 102 . . . 1902 and can help to manage the deformation and
stress condition between the at least one island 150a . . . 1950
and the substrate 102 . . . 1902. The casing layer can have a
thickness of about 0.1 .mu.m to about 100 .mu.m. In another
embodiment the at least one island 150 . . . 1950 can be directly
fitted into the substrate 102 . . . 1902, and thus, no casing may
be needed.
[0080] The at least one island 150a . . . 1950 can be coupled to
the substrate 102 . . . 1902. The at least one island 150a . . .
1950 can be coupled to the substrate 102 . . . 1902 by, for
example, gluing, brazing, bonding, welding, clamping, mechanical
locking, or some other suitable coupling. An embodiment can include
a method for brazing an island. The method for brazing the island
can comprise: brazing a coated island to a substrate, wherein the
island material can comprise a cemented carbide, a polycrystalline
cubic boron nitride (cBN) superabrasive, a ceramic, a metal, a
metal ahoy, and/or combinations thereof; a substrate; an optional
coating layer, wherein the coating layer may be in direct contact
with the island or the substrate, and the coating layer may be
continuous or discontinuous. The brazing step can comprise: heating
at least one of the braze metal, the coating layer, and the
substrate, to a temperature above a liquidus temperature sufficient
to melt the braze metal; and bringing the melted braze metal into
contact with both the island and the substrate and optionally the
coating to form a braze metal layer. The braze metal layer can
comprise silver, copper, magnesium, nickel, zinc, palladium,
chromium, boron, titanium, tin, silicon, or an alloy or composite
thereof. The substrate can comprise a second island, and the second
island materials can comprise a cemented carbide, a polycrystalline
cubic boron nitride (cBN) superabrasive, a ceramic, a metal, a
metal alloy, and/or combinations thereof. In an embodiment of the
method, the first and second island material may each independently
comprise a single crystal diamond, a chemical vapor deposition
diamond, a silicon carbide bonded diamond composite, a
cobalt-polycrystalline diamond composite, a thermally-stable
diamond composite, and/or combinations thereof. In an embodiment of
the method, the coating metal may comprise tungsten, titanium,
niobium, zirconium, tantalum, vanadium, chromium, molybdenum and/or
combinations thereof. In an embodiment of the method, the coating
metal may comprise at least one refractory metal and, optionally,
at least one non-refractory metal. In an embodiment of the method,
the refractory metal carbide may comprise at least one metal of the
refractory metal or the refractory metal alloy. In an embodiment of
the method, the refractory metal layer may have a thickness of
about 0.1 .mu.m to about 100 .mu.m. In an embodiment of the method,
the brazing step may comprise applying a heat source to heat at
least the braze metal to the temperature of from about 500.degree.
C. to about 1000.degree. C. In an embodiment of the method, the
heat source may be at least one of a torch, a furnace, a microwave
device, an arc welder, a laser, or an induction coil. In an
embodiment of the method, the heat source may be an induction coil;
and the temperature is maintained from about 700.degree. C. to
about 900.degree. C. for a time period of at least about 5 seconds.
In an embodiment of the method, the brazing step may be performed
under ambient air pressure and in air. In another embodiment of the
method, the brazaing step may be performed under flowing or
stagnant inert protection gas or gas mixtures.
[0081] The substrate 102 . . . 1902 can have any suitable shape.
For example, in FIGS. 1-13, 17-34, and 38-52, the substrate 102 . .
. 402, 802 . . . 1302, and 1502 . . . 1802 can have a generally
cylindrical shape. In other constructions of the cutter assembly
100 . . . 1900, the substrate 102 . . . 1902 can have a shape that
is not generally cylindrical. For example, FIGS. 35-37 and 53-55
show a substrate 1402 and 1902 that includes a concavity.
[0082] The at least one island 150a . . . 1950 can have any
suitable shape. As shown in FIGS. 1 to 13, 23-28, and 38-55, the at
least one island 150, 250, 350, 450, 1050, 1150, 1550, 1650, 1750,
1850, and 1950 can have a generally cylindrical shape. As shown in
FIGS. 14-19, the at least one island 550, 650, 750, and 850 can
have a cross-sectional shape that is not substantially circular. As
shown in FIGS. 29-37, the at least one island 1250, 1350, and 1450
can be have a ring shape or be a plurality of rings.
[0083] Turning to FIGS. 1-4, the cutter assembly 100 can have a
substrate 102 with a generally cylindrical shape. The substrate 102
can have a surface 104. The surface 104 can be an end surface. The
substrate 102 can also have a flank surface 106. The surface 104
can be substantially perpendicular to the flank surface 106. The
flank surface 106 can meet the surface 104 so that a common
boundary between the surface 104 and the flank surface 106 defines
a peripheral edge 108 of the surface 104. The surface 104 can be a
substantially planar surface. The flank surface 106 can provide the
substrate 102 with a generally circular cross-sectional shape. In
other embodiments, the substrate 102 can have a cross-sectional
shape that can be triangular, can be similar to a polygon, and/or
can have any regular or irregular shape besides circular.
[0084] The substrate 102 can include a pocket 110. The pocket 110
can have an opening 112. The opening 112 can be disposed on the
surface 104 of the substrate 102. The pocket 110 can extend from
the opening 112 on the surface 104 to an interior of the substrate
102. The pocket 110 can have a shape that can receive at least a
portion of the at least one island 150.
[0085] Referring to FIGS. 2a and 3a, the at least one island 150a
can have a generally cylindrical shape. The at least one island
150a can have an end surface 152, a flank surface 154, and an
opposite end surface 156. The end surface 152 can be a planar
surface that can be substantially perpendicular to the flank
surface 154. The opposite end surface 156 can also be a planar
surface that is substantially perpendicular to the flank surface
154. The at least one island 150a can be disposed in the pocket 110
of the substrate 102. The at least one island 150a can be disposed
in the pocket 110 of the substrate 102 so that the end surface 152
of the at least one island 150a is substantially co-planar with
surface 104 of the substrate 102, the flank surface 154 extends
into the interior of the substrate 102, and the opposite end
surface 156 is disposed within the interior of the substrate 102.
The end surface 152 can be a cutting surface, or the end surface
152 and the flank surface 154 together can form a cutting
surface.
[0086] Referring to FIGS. 2b and 3b, the at least one island 150b
can have a generally cylindrical shape. The at least one island
150b can have an end surface 152, a flank surface 154, and an
opposite end surface 156. However, unlike the at least one island
150a, the at least one island 150b can also include an edge 158.
The edge 158 can be rounded or a chamfer. The edge 150 can relieve
stress. The end surface 152 can be a planar surface that can be
substantially perpendicular to the flank surface 154. The opposite
end surface 156 can also be a planar surface that is substantially
perpendicular to the flank surface 154. The at least one island
150b can be disposed in the pocket 110 of the substrate 102. The at
least one island 150b can be disposed in the pocket 110 of the
substrate 102 so that the end surface 152 of the at least one
island 150a is substantially co-planar with surface 104 of the
substrate 102, the flank surface 154 extends into the interior of
the substrate 102, and the opposite end surface 156 is disposed
within the interior of the substrate 102. Because the at least one
island 150b can include the edge 158, the pocket 110 can include a
complementary shape that can receive the edge 158. The end surface
152 can be a cutting surface, or the end surface 152 and the flank
surface 154 together can form a cutting surface.
[0087] In the construction shown in FIGS. 1-4, there are three
islands 150 spaced equally apart from each other and equidistant
from a center of the surface 104. However, in other constructions,
there may be more or less than the three islands 150 shown. Also,
the exact position of each of the island 150 with respect to each
other or the center of the surface 104 can be different from that
shown in FIGS. 1-4. Also, the exact size of the islands 150 can be
different. The exact number and size of islands 150 and the exact
position for each of the islands 150 can depend on, for example,
the application of the cutter assembly 100.
[0088] Turning to FIGS. 5-7, the cutter assembly 200 can have a
substrate 202 with a generally cylindrical shape. The substrate 202
can have a surface 204. The surface 204 can be an end surface. The
substrate 202 can also have a flank surface 206. The surface 204
can be substantially perpendicular to the flank surface 206. The
flank surface 206 can meet the surface 204 so that a common
boundary between the surface 204 and the flank surface 206 defines
a peripheral edge 208 of the surface 204. The surface 204 can be a
substantially planar surface. The flank surface 206 can provide the
substrate 202 with a generally circular cross-sectional shape. In
other embodiments, the substrate 202 can have a cross-sectional
shape that can be triangular, can be similar to a polygon, and/or
can have any regular or irregular shape besides circular.
[0089] The substrate 202 can include a pocket 210. The pocket 210
can have an opening 212. The opening 212 can be disposed on the
surface 204 of the substrate 202. The pocket 210 can extend from
the opening 212 on the surface 204 to an interior of the substrate
202. The pocket 210 can have a shape that can receive at least a
portion of the at least one island 250.
[0090] The at least one island 250 can have a generally cylindrical
shape. The at least one island 250 can have an end surface 252, a
flank surface 254, and an opposite end surface 256. Unlike the at
least one island 150 shown in FIGS. 1-4, the end surface 252 can
include a dome shape. The opposite end surface 256 can be a planar
surface that can be substantially perpendicular to the flank
surface 254. The at least one island 250 can be disposed in the
pocket 210 of the substrate 202. The at least one island 250 can be
disposed in the pocket 210 of the substrate 202 so that the end
surface 252 of the at least one island 250 protrudes away from the
surface 204 of the substrate 202 and away from the interior of the
substrate 202, the flank surface 254 extends into the interior of
the substrate 202, and the opposite end surface 256 is disposed
within the interior of the substrate 202. The end surface 252 can
be a cutting surface, or the end surface 252 and the flank surface
254 together can form a cutting surface.
[0091] In the construction shown in FIGS. 5-7, there are three
islands 250 spaced equally apart from each other and equidistant
from a center of the surface 204. However, in other constructions,
there may be more or less than the three islands 250 shown. Also,
the exact position of each of the island 250 with respect to each
other or the center of the surface 204 can be different from that
shown in FIGS. 5-7. Also, the exact size of the islands 250 can be
different. The exact number and size of islands 250 and the exact
position for each of the islands 250 can depend on, for example,
the application of the cutter assembly 200.
[0092] Turning to FIGS. 8-10, the cutter assembly 300 can have a
substrate 302 with a generally cylindrical shape. The substrate 302
can have a surface 304. The surface 304 can be an end surface. The
substrate 302 can also have a flank surface 306. The surface 304
can be substantially perpendicular to the flank surface 306. The
flank surface 306 can meet the surface 304 so that a common
boundary between the surface 304 and the flank surface 306 defines
a peripheral edge 308 of the surface 304. The surface 304 can be a
substantially planar surface. The flank surface 306 can provide the
substrate 302 with a generally circular cross-sectional shape. In
other embodiments, the substrate 302 can have a cross-sectional
shape that can be triangular, can be similar to a polygon, and/or
can have any regular or irregular shape besides circular.
[0093] The substrate 302 can include a pocket 310. The pocket 310
can have an opening 312. The opening 312 can be disposed on the
surface 304 of the substrate 302. The pocket 310 can extend from
the opening 312 on the surface 304 to an interior of the substrate
302. The pocket 310 can have a shape that can receive at least a
portion of the at least one island 350.
[0094] The at least one island 350 can have a generally cylindrical
shape. The at least one island 350 can have an end surface 352, a
flank surface 354, and an opposite end surface 356. Unlike the at
least one island 150 shown in FIGS. 1-4, the end surface 352 can
include be a planar surface that is at an angle with respect to the
flank surface 354 and not generally perpendicular to the flank
surface 354. The end surface 352 can be angled such that its planar
surface slopes downward toward a center of the surface 304. The
opposite end surface 356 can be a planar surface that can be
substantially perpendicular to the flank surface 354. The at least
one island 350 can be disposed in the pocket 310 of the substrate
302. The at least one island 350 can be disposed in the pocket 310
of the substrate 302 so that the end surface 352 of the at least
one island 350 protrudes away from the surface 304 of the substrate
302 and away from the interior of the substrate 302, the flank
surface 354 extends into the interior of the substrate 302, and the
opposite end surface 356 is disposed within the interior of the
substrate 302. The end surface 352 can be a cutting surface, or the
end surface 352 and the flank surface 354 together can form a
cutting surface.
[0095] In the construction shown in FIGS. 8-10, there are three
islands 350 spaced equally apart from each other and equidistant
from a center of the surface 304. However, in other constructions,
there may be more or less than the three islands 350 shown. Also,
the exact position of each of the island 350 with respect to each
other or the center of the surface 304 can be different from that
shown in FIGS. 8-10. Also, the exact size of the islands 350 can be
different. The exact number and size of islands 350 and the exact
position for each of the islands 350 can depend on, for example,
the application of the cutter assembly 300.
[0096] Turning to FIGS. 11-13, the cutter assembly 400 can have a
substrate 402 with a generally cylindrical shape. The substrate 402
can have a surface 404. The surface 404 can be an end surface. The
substrate 402 can also have a flank surface 406. The surface 404
can be substantially perpendicular to the flank surface 406. The
flank surface 406 can meet the surface 404 so that a common
boundary between the surface 404 and the flank surface 406 defines
a peripheral edge 408 of the surface 404. The surface 404 can be a
substantially planar surface. The flank surface 406 can provide the
substrate 402 with a generally circular cross-sectional shape. In
other embodiments, the substrate 402 can have a cross-sectional
shape that can be triangular, can be similar to a polygon, and/or
can have any regular or irregular shape besides circular.
[0097] The substrate 402 can include a pocket 410. The pocket 410
can have an opening 412. The opening 412 can be disposed on the
surface 404 of the substrate 402. The pocket 410 can extend from
the opening 412 on the surface 404 to an interior of the substrate
402. The pocket 410 can have a shape that can receive at least a
portion of the at least one island 450.
[0098] The at least one island 450 can have a generally cylindrical
shape. The at least one island 450 can have an end surface 452, a
flank surface 454, and an opposite end surface 456. Unlike the at
least one island 150 shown in FIGS. 1-4, the end surface 452 can
include a concavity that curves toward the opposite surface 456.
The opposite end surface 456 can be a planar surface that can be
substantially perpendicular to the flank surface 454. The at least
one island 450 can be disposed in the pocket 410 of the substrate
402. The at least one island 450 can be disposed in the pocket 410
of the substrate 402 so that the end surface 452 of the at least
one island 450 protrudes away from the surface 404 of the substrate
402 and towards the interior of the substrate 402, the flank
surface 454 extends into the interior of the substrate 402, and the
opposite end surface 456 is disposed within the interior of the
substrate 402. The end surface 452 can be a cutting surface, or the
end surface 452 and the flank surface 454 together can form a
cutting surface.
[0099] In the construction shown in FIGS. 11-13, there are three
islands 450 spaced equally apart from each other and equidistant
from a center of the surface 404. However, in other constructions,
there may be more or less than the three islands 450 shown. Also,
the exact position of each of the island 450 with respect to each
other or the center of the surface 404 can be different from that
shown in FIGS. 11-13. Also, the exact size of the islands 450 can
be different. The exact number and size of islands 450 and the
exact position for each of the islands 450 can depend on, for
example, the application of the cutter assembly 400.
[0100] Turning to FIG. 14, the cutter assembly 500 can have a
substrate 502 with a generally cylindrical shape. The substrate 502
can have a surface 504. The surface 504 can be an end surface. The
substrate 502 can also have a flank surface 506. The surface 504
can be substantially perpendicular to the flank surface 506. The
flank surface 506 can meet the surface 504 so that a common
boundary between the surface 504 and the flank surface 506 defines
a peripheral edge 508 of the surface 504. The surface 504 can be a
substantially planar surface. The flank surface 506 can provide the
substrate 502 with a generally circular cross-sectional shape. In
other embodiments, the substrate 502 can have a cross-sectional
shape that can be triangular, can be similar to a polygon, and/or
can have any regular or irregular shape besides circular.
[0101] The substrate 502 can include a pocket 510. The pocket 510
can have an opening 512. The opening 512 can be disposed on the
surface 504 of the substrate 502. The pocket 510 can extend from
the opening 512 on the surface 504 to an interior of the substrate
502. The pocket 510 can have a shape that can receive at least a
portion of the at least one island 550.
[0102] The at least one island 550 can have a generally cylindrical
shape. The at least one island 550 can have an end surface 552, a
flank surface, and an opposite end surface. Unlike the at least one
island 150 shown in FIGS. 1-4, the at least one island 550 can have
a cross-sectional shape that can be generally semi-circular. The at
least one island 550 can be disposed in the pocket 510 of the
substrate 502. The at least one island 550 can be disposed in the
pocket 510 of the substrate 502 so that the end surface 552 can be
generally co-planar with the surface 504 of the substrate 502, the
flank surface extends into the interior of the substrate 502, and
the opposite end surface is disposed within the interior of the
substrate 502. The end surface 552 can alternatively have a
convexity such that the end surface 552 can protrude from the
surface 504 of the substrate 502. In a further alternative, the end
surface 552 can have a concavity such that the end surface 552 can
sag from the surface 504 toward an interior of the substrate 502.
The end surface 552 can be a cutting surface, or the end surface
552 and the flank surface together can form a cutting surface.
[0103] In the construction shown in FIG. 14, there are three
islands 550 spaced equally apart from each other and equidistant
from a center of the surface 504. However, in other constructions,
there may be more or less than the three islands 550 shown. Also,
the exact position of each of the island 550 with respect to each
other or the center of the surface 504 can be different from that
shown in FIG. 14. Also, the exact size of the islands 550 can be
different. The exact number and size of islands 550 and the exact
position for each of the islands 550 can depend on, for example,
the application of the cutter assembly 500.
[0104] Turning to FIG. 15, the cutter assembly 600 can have a
substrate 602 with a generally cylindrical shape. The substrate 602
can have a surface 604. The surface 604 can be an end surface. The
substrate 602 can also have a flank surface 606. The surface 604
can be substantially perpendicular to the flank surface 606. The
flank surface 606 can meet the surface 604 so that a common
boundary between the surface 604 and the flank surface 606 defines
a peripheral edge 608 of the surface 604. The surface 604 can be a
substantially planar surface. The flank surface 606 can provide the
substrate 602 with a generally circular cross-sectional shape, In
other embodiments, the substrate 602 can have a cross-sectional
shape that can be triangular, can be similar to a polygon, and/or
can have any regular or irregular shape besides circular.
[0105] The substrate 602 can include a pocket 610. The pocket 610
can have an opening 612. The opening 612 can be disposed on the
surface 604 of the substrate 602. The pocket 610 can extend from
the opening 612 on the surface 604 to an interior of the substrate
602. The pocket 610 can have a shape that can receive at least a
portion of the at least one island 650.
[0106] The at least one island 650 can have a generally cylindrical
shape. The at least one island 650 can have an end surface 652, a
flank surface, and an opposite end surface. Unlike the at least one
island 150 shown in FIGS. 1-4, the at least one island 650 can have
a cross-sectional shape that can be generally ovalular. The at
least one island 650 can be disposed in the pocket 610 of the
substrate 602. The at least one island 650 can be disposed in the
pocket 610 of the substrate 602 so that the end surface 652 can be
generally co-planar with the surface 604 of the substrate 602, the
flank surface extends into the interior of the substrate 602, and
the opposite end surface is disposed within the interior of the
substrate 602. The end surface 652 can alternatively have a
convexity such that the end surface 652 can protrude from the
surface 604 of the substrate 602. In a further alternative, the end
surface 652 can have a concavity such that the end surface 652 can
sag from the surface 604 toward an interior of the substrate 602.
The end surface 652 can be a cutting surface, or the end surface
652 and the flank surface together can form a cutting surface.
[0107] In the construction shown in FIG. 15, there are three
islands 650 spaced equally apart from each other and equidistant
from a center of the surface 604. However, in other constructions,
there may be more or less than the three islands 650 shown. Also,
the exact position of each of the island 650 with respect to each
other or the center of the surface 604 can be different from that
shown in FIG. 15. Also, the exact size of the islands 650 can be
different. The exact number and size of islands 650 and the exact
position for each of the islands 650 can depend on, for example,
the application of the cutter assembly 600.
[0108] Turning to FIG. 16 the cutter assembly 700 can have a
substrate 702 with a generally cylindrical shape. The substrate 702
can have a surface 704. The surface 704 can be an end surface. The
substrate 702 can also have a flank surface 706. The surface 704
can be substantially perpendicular to the flank surface 706. The
flank surface 706 can meet the surface 704 so that a common
boundary between the surface 704 and the flank surface 706 defines
a peripheral edge 708 of the surface 704. The surface 704 can be a
substantially planar surface. The flank surface 706 can provide the
substrate 702 with a generally circular cross-sectional shape. In
other embodiments, the substrate 702 can have a cross-sectional
shape that can be triangular, can be similar to a polygon, and/or
can have any regular or irregular shape besides circular.
[0109] The substrate 702 can include a pocket 710. The pocket 710
can have an opening 712. The opening 712 can be disposed on the
surface 704 of the substrate 702. The pocket 710 can extend from
the opening 712 on the surface 704 to an interior of the substrate
702. The pocket 710 can have a shape that can receive at least a
portion of the at least one island 750.
[0110] The at least one island 750 can have a generally cylindrical
shape. The at least one island 750 can have an end surface 752, a
flank surface, and an opposite end surface. Unlike the at least one
island 150 shown in FIGS. 1-4, the at least one island 750 can have
a cross-sectional shape that can be generally triangular. In other
embodiments, the at least one island 750 can have a cross-sectional
shape that can be similar to a polygon, and/or can have any regular
or irregular shape. The at least one island 750 can be disposed in
the pocket 710 of the substrate 702. The at least one island 750
can be disposed in the pocket 710 of the substrate 702 so that the
end surface 752 can be generally co-planar with the surface 704 of
the substrate 702, the flank surface extends into the interior of
the substrate 702, and the opposite end surface is disposed within
the interior of the substrate 702. The end surface 752 can
alternatively have a convexity such that the end surface 752 can
protrude from the surface 704 of the substrate 702. In a further
alternative, the end surface 752 can have a concavity such that the
end surface 752 can sag from the surface 704 toward an interior of
the substrate 702. The end surface 752 can be a cutting surface, or
the end surface 752 and the flank surface together can form a
cutting surface.
[0111] In the construction shown in FIG. 16, there are three
islands 750 spaced equally apart from each other and equidistant
from a center of the surface 704. However, in other constructions,
there may be more or less than the three islands 750 shown. Also,
the exact position of each of the island 750 with respect to each
other or the center of the surface 704 can be different from that
shown in FIG. 16. Also, the exact size of the islands 750 can be
different. The exact number and size of islands 750 and the exact
position for each of the islands 750 can depend on, for example,
the application of the cutter assembly 700.
[0112] Turning to FIGS. 17-19, the cutter assembly 800 can have a
substrate 802 with a generally cylindrical shape. The substrate 802
can have a surface 804. The surface 804 can be an end surface. The
substrate 802 can also have a flank surface 806. The flank surface
806 can meet the surface 804 so that a common boundary between the
surface 804 and the flank surface 806 defines a peripheral edge 808
of the surface 804. The flank surface 806 can provide the substrate
802 with a generally circular cross-sectional shape. In other
embodiments, the substrate 802 can have a cross-sectional shape
that can be triangular, can be similar to a polygon, and/or can
have any regular or irregular shape besides circular.
[0113] The substrate 802 can include a pocket 810. The pocket 810
can have an opening 812. The opening 812 can be disposed on the
surface 804 of the substrate 802. The pocket 810 can extend from
the opening 812 on the surface 804 to an interior of the substrate
802. The pocket 810 can have a shape that can receive at least a
portion of the at least one island 850.
[0114] The at least one island 850 can have a generally cylindrical
shape. The at least one island 850 can have an end surface 852, a
flank surface 854, and an opposite end surface 856. Unlike the
cutter assembly 100 shown in FIGS. 1-4, the surface 804 of the
substrate 802 and the end surface 852 can together form a shape
protruding away from the center of the substrate 802. Because the
end surface 852 can slope downwards, the end surface 852 can meet
the opposite end surface 856, and thus, the flank surface 854 may
not extend the entire periphery of the end surface 852. The
opposite end surface 856 can be a planar surface that is
substantially perpendicular to the flank surface 854. The at least
one island 850 can be disposed in the pocket 810 of the substrate
802. The at least one island 850 can be disposed in the pocket 810
of the substrate 802 so that the end surface 852 of the at least
one island 850 is substantially co-planar with surface 804 of the
substrate 802, the flank surface 854 extends into the interior of
the substrate 802, and the opposite end surface 856 is disposed
within the interior of the substrate 802. The end surface 852 can
alternatively have a convexity such that the end surface 852 can
protrude from the surface 804 of the substrate 802. In a further
alternative, the end surface 852 can have a concavity such that the
end surface 852 can sag from the surface 804 toward an interior of
the substrate 802. The end surface 852 can be a cutting surface, or
the end surface 852 and the flank surface 854 together can form a
cutting surface.
[0115] In the construction shown in FIGS. 17-19, there are three
islands 850 spaced equally apart from each other and equidistant
from a center of the surface 804. However, in other constructions,
there may be more or less than the three islands 850 shown. Also,
the exact position of each of the island 850 with respect to each
other or the center of the surface 804 can be different from that
shown in FIGS. 17-19. Also, the exact size of the islands 850 can
be different. The exact number and size of islands 850 and the
exact position for each of the islands 850 can depend on, for
example, the application of the cutter assembly 800.
[0116] Turning to FIGS. 20-22, the cutter assembly 900 can have a
substrate 902 with a generally cylindrical shape. The substrate 902
can have a surface 904. The surface 904 can be an end surface. The
substrate 902 can also have a flank surface 906. The flank surface
906 can meet the surface 904 so that a common boundary between the
surface 904 and the flank surface 906 defines a peripheral edge 908
of the surface 904. The flank surface 906 can provide the substrate
902 with a generally circular cross-sectional shape. In other
embodiments, the substrate 902 can have a cross-sectional shape
that can be triangular, can be similar to a polygon, and/or can
have any regular or irregular shape besides circular.
[0117] The substrate 902 can include a pocket 910. The pocket 910
can have an opening 912. The opening 912 can be disposed on the
surface 904 of the substrate 902. The pocket 910 can extend from
the opening 912 on the surface 904 to an interior of the substrate
902. The pocket 910 can have a shape that can receive at least a
portion of the at least one island 950.
[0118] The at least one island 950 can have a generally cylindrical
shape. The at least one island 950 can have an end surface 952, a
flank surface 954, and an opposite end surface 956. Unlike the
cutter assembly 100 shown in FIGS. 1-4, the surface 904 of the
substrate 902 and the end surface 952 can together form a shape
protruding away from the center of the substrate 902. Also, the
surface 904 and the end surface 952 protrude less from the center
of the substrate 902 than the cutter assembly 800 shown in FIGS.
17-19. Because the end surface 952 can slope downwards, the end
surface 952 can meet the opposite end surface 956, and thus, the
flank surface 954 may not extend the entire periphery of the end
surface 952. The opposite end surface 956 can be a planar surface
that is substantially perpendicular to the flank surface 954. The
at least one island 950 can be disposed in the pocket 910 of the
substrate 902. The at least one island 950 can be disposed in the
pocket 910 of the substrate 902 so that the end surface 952 of the
at least one island 950 is substantially co-planar with surface 904
of the substrate 902, the flank surface 954 extends into the
interior of the substrate 902, and the opposite end surface 956 is
disposed within the interior of the substrate 902. The end surface
952 can alternatively have a convexity such that the end surface
952 can protrude from the surface 904 of the substrate 902. In a
further alternative, the end surface 952 can have a concavity such
that the end surface 952 can sag from the surface 904 toward an
interior of the substrate 902. The end surface 952 can be a cutting
surface, or the end surface 952 and the flank surface 954 together
can form a cutting surface.
[0119] In the construction shown in FIGS. 20-22, there are three
islands 950 spaced equally apart from each other and equidistant
from a center of the surface 904. However, in other constructions,
there may be more or less than the three islands 950 shown. Also,
the exact position of each of the island 950 with respect to each
other or the center of the surface 904 can be different from that
shown in FIGS. 20-22. Also, the exact size of the islands 950 can
be different. The exact number and size of islands 950 and the
exact position for each of the islands 950 can depend on, for
example, the application of the cutter assembly 900.
[0120] Turning to FIGS. 23-25, the cutter assembly 1000 can have a
substrate 1002 with a generally cylindrical shape. The substrate
1002 can have a surface 1004. The surface 1004 can be an end
surface. The substrate 1002 can also have a flank surface 1006. The
flank surface 1006 can meet the surface 1004 so that a common
boundary between the surface 1004 and the flank surface 1006
defines a peripheral edge 1008 of the surface 1004. The flank
surface 1006 can provide the substrate 1002 with a generally
circular cross-sectional shape. In other embodiments, the substrate
1002 can have a cross-sectional shape that can be triangular, can
be similar to a polygon, and/or can have any regular or irregular
shape besides circular.
[0121] The substrate 1002 can include a pocket 1010. The pocket
1010 can have an opening 1012. The opening 1012 can be disposed on
the surface 1004 of the substrate 1002. The pocket 1010 can extend
from the opening 1012 on the surface 1004 to an interior of the
substrate 1002. The pocket 1010 can have a shape that can receive
at least a portion of the at least one island 1050.
[0122] The at least one island 1050 can have a generally
cylindrical shape. The at least one island 1050 can have an end
surface 1052, a flank surface 1054, and an opposite end surface
1056. Unlike the cutter assembly 100 shown in FIGS. 1-4, the
surface 1004 of the substrate 1002 and the end surface 1052 can
together form a shape protruding towards the center of the
substrate 1002. Because the end surface 1052 can slope downwards,
the end surface 1052 can meet the opposite end surface 1056, and
thus, the flank surface 1054 may not extend the entire periphery of
the end surface 1052. The opposite end surface 1056 can be a planar
surface that is substantially perpendicular to the flank surface
1054. The at least one island 1050 can be disposed in the pocket
1010 of the substrate 1002. The at least one island 1050 can be
disposed in the pocket 1010 of the substrate 1002 so that the end
surface 1052 of the at least one island 1050 is substantially
co-planar with surface 1004 of the substrate 1002, the flank
surface 1054 extends into the interior of the substrate 1002, and
the opposite end surface 1056 is disposed within the interior of
the substrate 1002. The end surface 1052 can alternatively have a
convexity such that the end surface 1052 can protrude from the
surface 1004 of the substrate 1002. In a further alternative, the
end surface 1052 can have a concavity such that the end surface
1052 can sag from the surface 1004 toward an interior of the
substrate 1002. The end surface 1052 can be a cutting surface, or
the end surface 1052 and the flank surface 1054 together can form a
cutting surface.
[0123] In the construction shown in FIGS. 23-25, there are three
islands 1050 spaced equally apart from each other and equidistant
from a center of the surface 1004. However, in other constructions,
there may be more or less than the three islands 1050 shown. Also,
the exact position of each of the island 1050 with respect to each
other or the center of the surface 1004 can be different from that
shown in FIGS. 23-25. Also, the exact size of the islands 1050 can
be different. The exact number and size of islands 1050 and the
exact position for each of the islands 1050 can depend on, for
example, the application of the cutter assembly 1000.
[0124] Turning to FIGS. 26-28, the cutter assembly 1100 can have a
substrate 1102 with a generally cylindrical shape. The substrate
1102 can have a surface 1104. The surface 1104 can be an end
surface. The surface 1104 can be a substantially planar surface.
The substrate 1102 can also have a flank surface 1106. The surface
1104 can be substantially perpendicular to the flank surface 1106.
The flank surface 1106 can meet the surface 1104 so that a common
boundary between the surface 1104 and the flank surface 1106
defines a peripheral edge 1108 of the surface 1104. The flank
surface 1106 can provide the substrate 1102 with a generally
circular cross-sectional shape. In other embodiments, the substrate
1102 can have a cross-sectional shape that can be triangular, can
be similar to a polygon, and/or can have any regular or irregular
shape besides circular.
[0125] The substrate 1102 can include a pocket 1110. The pocket
1110 can have an opening 1112. The opening 1112 can be disposed on
the surface 1104 of the substrate 1102. The pocket 1110 can extend
from the opening 1112 on the surface 1104 to an opposite opening
1114 on an opposite end surface 1116 of the substrate 1102. The
pocket 1110 can have a shape that can receive at least a portion of
the at least one island 1150.
[0126] The at least one island 1150 can have a generally truncated
conical shape. The at least one island 1150 can have an end surface
1152, a flank surface 1154, and an opposite end surface 1156.
Unlike the cutter assembly 100 shown in FIGS. 1-4, the end surface
1152 can be larger than opposite end surface 1156 so that the flank
surface 1154 is disposed at an angle with respect to the end
surface 1152. The at least one island 1150 can be disposed in the
pocket 1110 of the substrate 1102. The at least one island 1150 can
be disposed in the pocket 1110 of the substrate 1102 so that the
end surface 1152 of the at least one island 1150 is substantially
co-planar with surface 1104 of the substrate 1102, the flank
surface 1154 extends to the opposite end surface 1116 of the
interior of the substrate 1102, and the opposite end surface 1156
is substantially coplanar with opposite end surface 1116. The end
surface 1152 can alternatively have a convexity such that the end
surface 1152 can protrude from the surface 1104 of the substrate
1102. In a further alternative, the end surface 1152 can have a
concavity such that the end surface 1152 can sag from the surface
1104 toward an interior of the substrate 1102. The end surface 1152
can be a cutting surface, or the end surface 1152 and the flank
surface 1154 together can form a cutting surface.
[0127] In the construction shown in FIGS. 26-28, there are three
islands 1150 spaced equally apart from each other and equidistant
from a center of the surface 1104. However, in other constructions,
there may be more or less than the three islands 1150 shown. Also,
the exact position of each of the island 1150 with respect to each
other or the center of the surface 1104 can be different from that
shown in FIGS. 26-28. Also, the exact size of the islands 1150 can
be different. The exact number and size of islands 1150 and the
exact position for each of the islands 1150 can depend on, for
example, the application of the cutter assembly 1100.
[0128] Turning to FIGS. 29-31, the cutter assembly 1200 can have a
substrate 1202 with a generally cylindrical shape. The substrate
1202 can have a surface 1204. The surface 1204 can be an end
surface. The surface 1204 can be a substantially planar surface.
The substrate 1202 can also have a flank surface 1206. The surface
1204 can be substantially perpendicular to the flank surface 1206.
The flank surface 1206 can provide the substrate 1202 with a
generally circular cross-sectional shape. In other embodiments, the
substrate 1202 can have a cross-sectional shape that can be
triangular, can be similar to a polygon, and/or can have any
regular or irregular shape besides circular. However, the surface
1204 and the flank surface 1206 may not meet. Instead, the
substrate 1202 can include a pocket 1210 so that the flank surface
1206 can extend to one side of an opening 1212 for a pocket 1210,
and the surface 1204 can form another side of the opening 1212 for
the pocket 1210. The pocket 1210 can extend from the opening 1212
towards an interior of the substrate 1202. The pocket 1210 can have
a shape that can receive at least a portion of the at least one
island 1250.
[0129] The at least one island 1250 can have a generally ring-like
shape. The at least one island 1250 can have an end surface 1252, a
flank surface 1254, and an opposite end surface 1256. The flank
surface 1254 can be substantially perpendicular to the end surface
1252, the opposite end surface 1256, or both. Unlike the cutter
assembly 100 shown in FIGS. 1-4, the at least one island can
include a second flank surface 1258. The second flank surface 1258
can be substantially perpendicular to the end surface 1252, the
opposite end surface 1256, or both. The at least one island 1250
can be disposed in the pocket 1210 of the substrate 1202. The at
least one island 1250 can be disposed in the pocket 1210 of the
substrate 1202 so that the end surface 1252 of the at least one
island 1250 can be substantially co-planar with surface 1204 of the
substrate 1202, the flank surface 1254 can extend between the flank
surface 1206 of the substrate 1202 and the surface 1250, the
opposite end surface 1256 can be disposed in the pocket 1210, and
the second flank surface 1256 can be disposed in the pocket 1210.
The end surface 1252 can alternatively have a convexity such that
the end surface 1252 can protrude from the surface 1204 of the
substrate 1202. In a further alternative, the end surface 1252 can
have a concavity such that the end surface 1252 can sag from the
surface 1204 toward an interior of the substrate 1202. The end
surface 1252 can be a cutting surface, or the end surface 1252 and
the flank surface 1254 together can form a cutting surface.
[0130] In the construction shown in FIGS. 29-31, there is one
island 1250 disposed equidistant from a center of the surface 1204.
However, in other constructions, there may be more or less than the
one island 1250 shown. Also, the exact position of the island 1250
with respect to the center of the surface 1204 can be different
from that shown in FIGS. 29-31. Also, the exact size of the islands
1250 can be different. The exact number and size of islands 1250
and the exact position for each of the islands 1250 can depend on,
for example, the application of the cutter assembly 1200.
[0131] Turning to FIGS. 32-34, the cutter assembly 1300 can have a
substrate 1302 with a generally cylindrical shape. The substrate
1302 can have a surface 1304. The surface 1304 can be an end
surface. The surface 1304 can be a substantially planar surface.
The substrate 1302 can also have a flank surface 1306. The surface
1304 can be substantially perpendicular to the flank surface 1306.
The flank surface 1306 can meet the surface 1304 so that a common
boundary between the surface 1304 and the flank surface 1306
defines a peripheral edge 1308 of the surface 1304. The flank
surface 1306 can provide the substrate 1302 with a generally
circular cross-sectional shape. In other embodiments, the substrate
1302 can have a cross-sectional shape that can be triangular, can
be similar to a polygon, and/or can have any regular or irregular
shape besides circular.
[0132] The substrate 1302 can include one or more pockets 1310. The
one or more pockets 1310 can each have an opening 1312. The
openings 1312 can be disposed on the surface 1304 of the substrate
1302. The openings 1312 can be disposed such that one of the
openings 1312 is surrounded by another of the openings 1312. The
one or more pockets 1310 can extend from the openings 1312 on the
surface 1304 to an interior of the substrate 1302. The one or more
pockets 1310 can have a shape that can receive at least a portion
of the at least one island 1350.
[0133] The at least one island 1350 can have a generally ring-like
shape. The at least one island 1350 can have an end surface 1352, a
flank surface 1354, and an opposite end surface 1356. The flank
surface 1354 can be substantially perpendicular to the end surface
1352, the opposite end surface 1356, or both. Unlike the cutter
assembly 100 shown in FIGS. 1-4, the at least one island can
include a second flank surface 1358. The second flank surface 1358
can be substantially perpendicular to the end surface 1352, the
opposite end surface 1356, or both. The at least one island 1350
can be disposed in the one or more pockets 1310 of the substrate
1302. The at least one island 1350 can be disposed in the one or
more pockets 1310 of the substrate 1302 so that the end surface
1352 of the at least one island 1350 can be substantially co-planar
with surface 1304 of the substrate 1302, the flank surface 1354 and
the second flank surface 1358 can extend into an interior of the
substrate 1302, and the opposite end surface 1356 can be disposed
in the one or more pockets 1310. The end surface 1352 can
alternatively have a convexity such that the end surface 1352 can
protrude from the surface 1304 of the substrate 1302. In a further
alternative, the end surface 1352 can have a concavity such that
the end surface 1352 can sag from the surface 1304 toward an
interior of the substrate 1302. The end surface 1352 can be a
cutting surface, or the end surface 1352 and the flank surface 1354
together can form a cutting surface.
[0134] In the construction shown in FIGS. 32-34, there are two
islands 1350 disposed concentrically with respect to a center of
the surface 1304. However, in other constructions, there may be
more or less than the two islands 1350 shown. Also, the exact
position of the islands 1350 with respect to the center of the
surface 1304 can be different from that shown in FIGS. 32-34. Also,
the exact size of the islands 1350 can be different. The exact
number and size of islands 1350 and the exact position for each of
the islands 1350 can depend on, for example, the application of the
cutter assembly 1300.
[0135] Turning to FIGS. 35-37, the cutter assembly 1400 can have a
substrate 1402 with a generally cylindrical shape. The substrate
1402 can have a surface 1404. The surface 1404 can be an end
surface. The surface 1404 can be a substantially planar surface.
The substrate 1402 can also have a flank surface 1406. The flank
surface 1406 can include a concavity that curves towards an
interior of the substrate 1402 or bulges away from the substrate
1402. The flank surface 1406 can provide the substrate 1402 with a
generally circular cross-sectional shape. In other embodiments, the
substrate 1402 can have a cross-sectional shape that can be
triangular, can be similar to a polygon, and/or can have any
regular or irregular shape besides circular. However, the surface
1404 and the flank surface 1406 may not meet. Instead, the
substrate 1402 can include a pocket 1410 so that the flank surface
1406 can extend to one side of an opening 1412 for a pocket 1410,
and the surface 1404 can form another side of the opening 1412 for
the pocket 1410. The pocket 1410 can extend from the opening 1412
towards an interior of the substrate 1402. The pocket 1410 can have
a shape that can receive at least a portion of the at least one
island 1450.
[0136] The at least one island 1450 can have a generally ring-like
shape. The at least one island 1450 can have an end surface 1452, a
flank surface 1454, and an opposite end surface 1456. The flank
surface 1454 can be substantially perpendicular to the end surface
1452, the opposite end surface 1456, or both. Unlike the cutter
assembly 100 shown in FIGS. 1-4, the at least one island can
include a second flank surface 1458. The second flank surface 1458
can be substantially perpendicular to the end surface 1452, the
opposite end surface 1456, or both. The at least one island 1450
can be disposed in the pocket 1410 of the substrate 1402. The at
least one island 1450 can be disposed in the pocket 1410 of the
substrate 1402 so that the end surface 1452 of the at least one
island 1450 can be substantially co-planar with surface 1404 of the
substrate 1402, the flank surface 1454 can extend between the flank
surface 1406 of the substrate 1402 and the surface 1450, the
opposite end surface 1456 can be disposed in the pocket 1410, and
the second flank surface 1456 can be disposed in the pocket 1410.
The end surface 1452 can alternatively have a convexity such that
the end surface 1452 can protrude from the surface 1404 of the
substrate 1402. In a further alternative, the end surface 1452 can
have a concavity such that the end surface 1452 can sag from the
surface 1404 toward an interior of the substrate 1402. The end
surface 1452 can be a cutting surface, or the end surface 1452 and
the flank surface 1454 together can form a cuffing surface.
[0137] In the construction shown in FIGS. 35-37, there is one
island 1450 disposed equidistant from a center of the surface 1404.
However, in other constructions, there may be more or less than the
one island 1450 shown. Also, the exact position of the island 1450
with respect to the center of the surface 1404 can be different
from that shown in FIGS. 35-37. Also, the exact size of the islands
1450 can be different. The exact number and size of islands 1450
and the exact position for each of the islands 1450 can depend on,
for example, the application of the cutter assembly 1400.
[0138] Turning to FIGS. 38-40, the cutter assembly 1500 can have a
substrate 1502 with a generally cylindrical shape. The substrate
1502 can have a surface 1504. The surface 1504 can be an end
surface. The substrate 1502 can also have a flank surface 1506. The
surface 1504 can be substantially perpendicular to the flank
surface 1506. The flank surface 1506 can meet the surface 1504 so
that a common boundary between the surface 1504 and the flank
surface 1506 defines a peripheral edge 1508 of the surface 1504.
The surface 1504 can be a substantially planar surface. The flank
surface 1506 can provide the substrate 1502 with a generally
circular cross-sectional shape. In other embodiments, the substrate
1502 can have a cross-sectional shape that can be triangular, can
be similar to a polygon, and/or can have any regular or irregular
shape besides circular.
[0139] The substrate 1502 can include a pocket 1510. The pocket
1510 can have an opening 1512. The opening 1512 can be disposed on
the surface 1504, the edge 1508, and the flank surface 1506 of the
substrate 1502. The pocket 1510 can extend from the opening 1512 on
the surface 1504, the edge 1508, and the flank surface 1506 to an
interior of the substrate 1502. The pocket 1510 can have a shape
that can receive at least a portion of the at least one island
1550.
[0140] The at least one island 1550 can have a generally
cylindrical shape. The at least one island 1550 can have an end
surface 1552, a flank surface 1554, and an opposite end surface
1556. The end surface 1552 can be a planar surface that can be
substantially perpendicular to the flank surface 1554. The opposite
end surface 1556 can also be a planar surface that is substantially
perpendicular to the flank surface 1554. The at least one island
1550 can be disposed in the pocket 1510 of the substrate 1502. The
at least one island 1550 can be disposed in the pocket 1510 of the
substrate 1502 so that the end surface 1552 of the at least one
island 1550 is substantially co-planar with surface 1504 of the
substrate 1502, the flank surface 1554 extends into the interior of
the substrate 1502 and protrudes beyond the flank surface 1506 of
the substrate 1502, and the opposite end surface 1556 is at least
partially disposed within the interior of the substrate 1502. The
end surface 1552 can alternatively have a convexity such that the
end surface 1552 can protrude from the surface 1504 of the
substrate 1502. In a further alternative, the end surface 1552 can
have a concavity such that the end surface 1552 can sag from the
surface 1504 toward an interior of the substrate 1502. The end
surface 1552 can be a cutting surface, or the end surface 1552 and
the flank surface 1554 together can form a cutting surface.
[0141] In the construction shown in FIGS. 38-40, there are three
islands 1550 spaced equally apart from each other and equidistant
from a center of the surface 1504. However, in other constructions,
there may be more or Tess than the two islands 1550 shown. Also,
the exact position of the islands 1550 with respect to each other
or the center of the surface 1504 can be different from that shown
in FIGS. 38-40. Also, the exact size of the islands 1550 can be
different. The exact number and size of islands 1550 and the exact
position for each of the islands 1550 can depend on, for example,
the application of the cutter assembly 1500.
[0142] For example, turning to FIGS. 41-43, there are four islands
1550 spaced equally apart from each other and equidistant from a
center of the surface 1504.
[0143] Turning to FIGS. 44-46, the cutter assembly 1600 can have a
substrate 1602 with a generally cylindrical shape. The substrate
1602 can have a surface 1604. The surface 1604 can be an end
surface. The substrate 1602 can also have a flank surface 1606. The
surface 1604 can be substantially perpendicular to the flank
surface 1606. The flank surface 1606 can meet the surface 1604 so
that a common boundary between the surface 1604 and the flank
surface 1606 defines a peripheral edge 1608 of the surface 1604.
The surface 1604 can be a substantially planar surface. The flank
surface 1606 can provide the substrate 1602 with a generally
circular cross-sectional shape. In other embodiments, the substrate
1602 can have a cross-sectional shape that can be triangular, can
be similar to a polygon, and/or can have any regular or irregular
shape besides circular.
[0144] The substrate 1602 can include a pocket 1610 and portion
1614 that can extend the pocket 1610 beyond the flank surface 1606
of the substrate 1602. The portion 1614 can be shaped to receive a
portion of the at least one island 1650. As best seen in FIG. 46,
the portion 1614 can also be shaped to include a curve between the
portion 1614 and the flank surface 1606 of the substrate 1602, and
the portion 1614 can further include another curve where the
portion 1614 receives the at least one island 1650. The pocket 1610
can have an opening 1612. The opening 1612 can be disposed on the
surface 1604, the edge 1608, the flank surface 1606, and the
portion 1614 of the substrate 1602. The pocket 1610 can extend from
the opening 1612 on the surface 1604, the edge 1608, and the flank
surface 1606 to an interior of the substrate 1602. The pocket 1610
can have a shape that can receive at least a portion of the at
least one island 1650.
[0145] The at least one island 1650 can have a generally
cylindrical shape. The at least one island 1650 can have an end
surface 1652, a flank surface 1654, and an opposite end surface
1656. The end surface 1652 can be a planar surface that can be
substantially perpendicular to the flank surface 1654. The opposite
end surface 1656 can also be a planar surface that is substantially
perpendicular to the flank surface 1654. The at least one island
1650 can be disposed in the pocket 1610 of the substrate 1602. The
at least one island 1650 can be disposed in the pocket 1610 of the
substrate 1602 so that the end surface 1652 of the at least one
island 1650 is substantially co-planar with surface 1604 of the
substrate 1602. The at least one island 1650 can also be disposed
in the pocket 1610 of the substrate 1602 so that the flank surface
1654 extends into the interior of the substrate 1602 and protrudes
beyond the flank surface 1606 of the substrate 1602. The at least
one island 1650 can be further disposed in the pocket 1610 of the
substrate 1602 so that the opposite end surface 1656 is at least
partially disposed within the interior of the substrate 1602 and
partially disposed on the portion 1614. The end surface 1652 can
alternatively have a convexity such that the end surface 1652 can
protrude from the surface 1604 of the substrate 1602. In a further
alternative, the end surface 1652 can have a concavity such that
the end surface 1652 can sag from the surface 1604 toward an
interior of the substrate 1602. The end surface 1652 can be a
cutting surface, or the end surface 1652 and the flank surface 1654
together can form a cutting surface.
[0146] In the construction shown in FIGS. 44-46, there are three
islands 1650 spaced equally apart from each other and equidistant
from a center of the surface 1604. However, in other constructions,
there may be more or less than the two islands 1650 shown. Also,
the exact position of the islands 1650 with respect to each other
or the center of the surface 1604 can be different from that shown
in FIGS. 44-46. Also, the exact size of the islands 1650 can be
different. The exact number and size of islands 1650 and the exact
position for each of the islands 1650 can depend on, for example,
the application of the cutter assembly 1600.
[0147] Turning to FIGS. 47-49, the cutter assembly 1700 can have a
substrate 1702 with a generally cylindrical shape. The substrate
1702 can have two parts 1702a and 1702b. The substrate part 1702a
can have a surface 1704a and an opposite surface 1705a that can be
opposite to surface 1704a. The surface 1704a can be an end surface,
and the surface 1705a can be another end surface. The substrate
part 1702a can also have a flank surface 1706a. The surface 1704a,
the surface 1705a, or both surfaces 1704a and 1705a can be
substantially perpendicular to the flank surface 1706a. The flank
surface 1706a can meet the surface 1704a so that a common boundary
between the surface 1704a and the flank surface 1706a defines a
peripheral edge 1708a of the surface 1704a. The surface 1704a can
be a substantially planar surface. The surface 1705a can also be a
substantially planar surface. The flank surface 1706a can provide
the substrate part 1702a with a generally circular cross-sectional
shape. In other embodiments, the substrate part 1702a can have a
cross-sectional shape that can be triangular, can be similar to a
polygon, and/or can have any regular or irregular shape besides
circular.
[0148] The substrate part 1702b can have a surface 1704b. The
surface 1704b can be an end surface. The surface 1704b can be
shaped to receive surface 1705a of substrate part 1702a. The
substrate 1702b can also have a flank surface 1706b. The surface
1704b can be substantially perpendicular to the flank surface
1706b. The flank surface 1706b can meet the surface 1704b so that a
common boundary between the surface 1704b and the flank surface
1706b defines a peripheral edge 1708b of the surface 1704b. The
surface 1704b can be a substantially planar surface. The flank
surface 1706h can provide the substrate part 1702b with a generally
circular cross-sectional shape. In other embodiments, the substrate
part 1702b can have a cross-sectional shape that can be triangular,
can be similar to a polygon, and/or can have any regular or
irregular shape besides circular.
[0149] The substrate par 1702a can include a pocket 1710. The
pocket 1710 can have an opening 1712. The opening 1712 can be
disposed on the surface 1705a of the substrate part 1702a. The
pocket 1710 can extend from the opening 1712 on the surface 1704 to
an interior of the substrate part 1702a. The pocket 1710 can have a
shape that can receive at least a portion of the at least one
island 1750.
[0150] The at least one island 1750 can have a generally
cylindrical shape. The at least one island 1750 can have an end
surface 1752, a flank surface 1754, and an opposite end surface
1756. The end surface 1752 can be a planar surface that can be
substantially perpendicular to the flank surface 1754. The opposite
end surface 1756 can also be a planar surface that is substantially
perpendicular to the flank surface 1754. The at least one island
1750 can be disposed in the pocket 1710 of the substrate part
1702a. The at least one island 1750 can be disposed in the pocket
1710 of the substrate part 1702a so that the opposite end surface
1756 of the at least one island 1750 is substantially co-planar
with surface 1705a of the substrate part 1702a, the flank surface
1754 extends into the interior of the substrate part 1702a, and the
end surface 1752 is disposed within the interior of the substrate
part 1702a. The end surface 1752 can be a cutting surface, or the
end surface 1752 and the flank surface 1754 together can form a
cutting surface.
[0151] In the construction shown in FIGS. 47-49, there are three
islands 1750 spaced equally apart from each other and equidistant
from a center of the surface 1705a and equidistant from the surface
1704a. However, in other constructions, there may be more or less
than the three islands 1750 shown. Also, the exact position of each
of the island 1750 with respect to each other, the center of the
surface 1705a, or the surface 1704a can be different from that
shown in FIGS. 47-49. Also, the exact size of the islands 1750 can
be different. The exact number and size of islands 1750 and the
exact position for each of the islands 1750 can depend on, for
example, the application of the cutter assembly 1700.
[0152] Turning to FIGS. 50-52, the cutter assembly 1800 can have a
substrate 1802 with a generally cylindrical shape. The substrate
1802 can have a surface 1804. The surface 1804 can be an end
surface. The substrate 1802 can also have a flank surface 1806. The
surface 1804 can be substantially perpendicular to the flank
surface 1806. The flank surface 1806 can meet the surface 1804 so
that a common boundary between the surface 1804 and the flank
surface 1806 defines a peripheral edge 1808 of the surface 1804.
The surface 1804 can be a substantially planar surface. The flank
surface 1806 can provide the substrate 1802 with a generally
circular cross-sectional shape. In other embodiments, the substrate
1802 can have a cross-sectional shape that can be triangular, can
be similar to a polygon, and/or can have any regular or irregular
shape besides circular.
[0153] The substrate 1802 can include a pocket 1810. The pocket
1810 can have an opening 1812. The opening 1812 can be disposed on
the surface 1804 of the substrate 1802. The pocket 1810 can extend
from the opening 1812 on the surface 1804 to an interior of the
substrate 1802. The pocket 1810 can have a shape that can receive
at least a portion of the at least one island 1850.
[0154] The at least one island 1850 can have a generally
cylindrical shape. The at least one island 1850 can have an end
surface 1852, a flank surface 1854, and an opposite end surface
1856. The end surface 1852 can be a planar surface that can be
substantially perpendicular to the flank surface 1854. The opposite
end surface 1856 can also be a planar surface that is substantially
perpendicular to the flank surface 1854. The at least one island
1850 can be disposed in the pocket 1810 of the substrate 1802. The
at least one island 1850 can be disposed in the pocket 1810 of the
substrate 1802 so that the end surface 1852 of the at least one
island 1850 is not co-planar with surface 1804 of the substrate
1802 but below the surface 1804 of the substrate. A substrate part
1858 can be disposed in the pocket 1810 on the end surface 1852 of
the at least one island 1850. The substrate part 1858 can also
extend to the opening 1812 of the pocket 1810 and can be
substantially co-planar with the surface 1804 of the substrate
1802. The substrate part 1858 can be made of the same material as
the substrate 1802. Alternatively, the substrate part 1858 and the
substrate 1802 can be made from different materials. The at least
one island 1850 can also be disposed in the pocket 1810 of the
substrate 1802 so that the flank surface 1854 extends into the
interior of the substrate 1802 and the end surface 1852 is disposed
within the interior of the substrate 1802. The end surface 1852 can
alternatively have a convexity such that the end surface 1852 can
protrude from the surface 1804 of the substrate 1802. In a further
alternative, the end surface 1852 can have a concavity such that
the end surface 1852 can sag from the surface 1804 toward an
interior of the substrate 1802. The end surface 1852 can be a
cutting surface, or the end surface 1852 and the flank surface 1854
together can form a cutting surface.
[0155] In the construction shown in FIGS. 50-52, there are three
islands 1850 spaced equally apart from each other and equidistant
from a center of the surface 1804. However, in other constructions,
there may be more or less than the three islands 1850 shown. Also,
the exact position of each of the island 1850 with respect to each
other or the center of the surface 1804 can be different from that
shown in FIGS. 50-52. Also, the exact size of the islands 1850 can
be different. The exact number and size of islands 1850 and the
exact position for each of the islands 1850 can depend on, for
example, the application of the cutter assembly 1800. Also in the
construction shown in FIGS. 50-52, there are three substrate parts
1858 of the same thickness. However, in other constructions, there
may be substrate parts 1858 of different thickness and the exact
position of the each of the island 1850 with respect to surface
1804 can be different from that shown in FIGS. 50-52.
[0156] Turning to FIGS. 53-55, the cutter assembly 1900 can have a
substrate 1902 with a generally cylindrical shape. The substrate
1902 can have a surface 1904. The surface 1904 can be an end
surface. The substrate 1902 can also have a flank surface 1906. The
surface 1904 can be substantially perpendicular to the flank
surface 1906. The flank surface 1906 can meet the surface 1904 so
that a common boundary between the surface 1904 and the flank
surface 1906 defines a peripheral edge 1908 of the surface 1904.
The surface 1904 can be a substantially planar surface. The flank
surface 1906 can provide the substrate 1902 with a generally
circular cross-sectional shape. In other embodiments, the substrate
1902 can have a cross-sectional shape that can be triangular, can
be similar to a polygon, and/or can have any regular or irregular
shape besides circular.
[0157] The substrate 1902 can include a groove 1914. The groove
1914 may be able to delay contact of the substrate 1902 when the at
least one island 1950 is substantially worn. The groove 1914 can
disposed on the flank surface 1906. The groove 1914 can penetrate
towards an interior of the substrate 1902. The groove 1914 can be
shaped like the letter "V", an open polygonal shape, or an open
semi-circle as shown in FIGS. 53-55. The groove 1914 can have a
length that extends throughout the flank surface 1906 so that the
groove 1914 extends entirely around an outer periphery of the
substrate 1902. Alternatively, the groove 1914 can extend only
through a portion of the flank surface 1906 so that the groove 1914
extends only partially around an outer periphery of the substrate
1902. The groove 1914 can extend substantially straight or meander
across the flank surface 1906.
[0158] The substrate 1902 can include a pocket 1910. The pocket
1910 can have an opening 1912. The opening 1912 can be disposed on
the surface 1904 of the substrate 1902. The pocket 1910 can extend
from the opening 1912 on the surface 1904 to an interior of the
substrate 1902. The pocket 1910 can have a shape that can receive
at least a portion of the at least one island 1950.
[0159] The at least one island 1950 can have a generally
cylindrical shape. The at least one island 1950 can have an end
surface 1952, a flank surface 1954, and an opposite end surface
1956. The end surface 1952 can be a planar surface that can be
substantially perpendicular to the flank surface 1954. The opposite
end surface 1956 can also be a planar surface that is substantially
perpendicular to the flank surface 1954. The at least one island
1950 can be disposed in the pocket 1910 of the substrate 1902. The
at least one island 1950 can be disposed in the pocket 1910 of the
substrate 1902 so that the end surface 1952 of the at least one
island 1950 is substantially co-planar with surface 1904 of the
substrate 1902, the flank surface 1954 extends into the interior of
the substrate 1902, and the opposite end surface 1956 is disposed
within the interior of the substrate 1902. The end surface 1952 can
alternatively have a convexity such that the end surface 1952 can
protrude from the surface 1904 of the substrate 1902. In a further
alternative, the end surface 1952 can have a concavity such that
the end surface 1952 can sag from the surface 1904 toward an
interior of the substrate 1902. The end surface 1952 can be a
cutting surface, or the end surface 1952 and the flank surface 1954
together can form a cutting surface.
[0160] In the construction shown in FIGS. 53-55, there are three
islands 1950 spaced equally apart from each other and equidistant
from a center of the surface 1904. However, in other constructions,
there may be more or less than the three islands 1950 shown. Also,
the exact position of each of the island 1950 with respect to each
other or the center of the surface 1904 can be different from that
shown in FIGS. 35-55. Also, the exact size of the islands 1950 can
be different. The exact number and size of islands 1950 and the
exact position for each of the islands 1950 can depend on, for
example, the application of the cutter assembly 1900.
[0161] Referring to FIG. 56, a method 2000 of manufacturing the
cutter with at least one island is shown. The method 2000 can
include providing at least one island, step 2002; treating the at
least one island, step 2004; providing a substrate, step 2006;
forming a surface circumscribed by a peripheral edge on the
substrate, step 2008; forming at least one pocket with an opening
on the surface and spaced apart from the peripheral edge such that
the at least one pocket extends from the opening towards an
interior of the substrate and has a shape that engages with the at
least one island, step 2010; disposing the at least one island in
the at least one pocket, step 2012; and coupling the at least one
island to the at least one pocket, step 2014. Alternatively, in
step 2010, the at least one pocket can be formed within the
substrate.
[0162] The step of providing the at least one island can further
comprise forming the at least one island from a polycrystalline
diamond made from at least one of a high pressure high temperature
process, a chemical vapor deposition process, and a physical vapor
deposition process. The step of providing the at least one island
can further comprise forming the at least one island from a portion
of a polycrystalline diamond.
[0163] The method 2000 can further comprise coating the at least
one island. The method 2000 can alternatively further comprise
encasing the at least one island. The method can further comprise
coupling the at least island to the at least one pocket. The at
least one island can be coupled to the at least one pocket by press
fit, gluing, brazing, bonding, clamping, mechanical interlocking,
or welding.
[0164] The step of treating the at least one island can further
comprise partially leaching the at least one island. Alternatively,
the step of treating the at least one island can further comprise
substantially fully leaching the at least one island.
[0165] The step of disposing the at least one island in the at
least one pocket can further comprise disposing the at least one
island such that a cutting surface of the at least one island is
substantially flush with the surface of the substrate. The step of
disposing the at least one island in the at least one pocket can
further comprise disposing the at least one island such that a
cutting surface of the at least one island protrudes outward from
the surface of the substrate. The step of disposing the at least
one island in the at least one pocket further comprises disposing
the at least one island such that a cutting surface of the at least
one island projects towards the interior of the substrate.
[0166] The method 2000 can also further comprise providing a
cutting surface that has a generally circular shape on the at least
one island. Alternatively, the method 2000 can further comprise
providing a cutting surface that has a generally ovalular shape on
the at least one island. In another alternative, the method 2000
can further comprise providing a cutting surface that has a
generally triangular shape. In yet another alternative, the method
2000 can further comprise providing a cutting surface that has a
generally polygonal shape.
[0167] The method 2000 can further comprise forming at least one
other pocket on the surface symmetrically with respect to the at
least one pocket; and disposing at least one other island in the at
least one other pocket. Alternatively, the method 2000 can further
comprise forming at least one other pocket on the surface
unsymmetrically with respect to the at least one pocket and
disposing at least one other island in the at least one other
pocket. In another alternative, the method 2000 can further
comprise forming at least one other pocket on the surface spaced
apart from the at least one pocket and disposing at least one other
island in the at least one other pocket. In yet another
alternative, the method 2000 can further comprise forming at least
one other pocket on the surface with a second opening conjoined
with the opening of the at least one pocket and disposing at least
one other island in the at least one other pocket.
[0168] The method 2000 can further include forming a planar
surface, a concave surface, a dome-shaped surface, a chiseled
surface, or a wavy surface with the surface of the substrate and a
cutting surface of the at least one island.
[0169] The step of providing the substrate can include forming the
substrate so as to provide a substrate 102 . . . 1902, as described
above and as shown in FIGS. 1-55. Also, the step of providing a
substrate can further comprise forming the substrate from carbide,
tungsten carbide composite, tungsten carbide composite held up by
an eta-phase, polycrystalline cubic boron nitride, polycrystalline
diamond, or a combination of two or more of the aforementioned.
[0170] The step of providing the at least one pocket can be include
forming the at least one pocket so as to provide at least one
pocket 110 . . . 1910, as described above and as shown in FIGS.
1-55.
[0171] The step of providing the at least one island can be include
forming the at least one island so as to provide at least one
island 150 . . . 1950, as described above and as shown in FIGS.
1-55. The step of providing the at least one island can further
comprise forming the at least one island from polycrystalline
diamond, polycrystalline diamond compact, diamond, cubic boron
nitride, polycrystalline cubic boron nitride, diamond-silicon
carbide composite material, polycrystalline diamond composite,
chemical vapor deposition diamond, or a combination of two or more
of the aforementioned.
[0172] Referring to FIG. 57, a method 2100 of manufacturing the
cutter with at least one island is shown. The method 2000 of
manufacturing can include providing a PCD piece from a high
pressure, high temperature (HPHT) process, step 2102.
Alternatively, the PCD can be provided from a chemical vapor
deposition (CVD), a physical vapor deposition (PVD), or some other
suitable process. The method can also include forming a smaller PCD
part from the PCD piece, step 2104. The method can further include
fully or partially leaching the cobalt out of the PCD part, step
2106. The PCD part can then be coated with, for example, a tungsten
coating, or the PCD part can be press fitted into a casing, such as
a metal casing. The PCD part with or without a coating or a casing
can then be coupled to the substrate, step 2108. The coupling can
be by, for example, gluing, brazing, bonding, welding, clamping,
mechanical locking, or any other suitable coupling.
[0173] For the purposes of promoting an understanding of the
principles of the invention, reference has been made to the
embodiments illustrated in the drawings, and specific language has
been used to describe these embodiments. However, no limitation of
the scope of the invention is intended by this specific language,
and the invention should be construed to encompass all embodiments
that would normally occur to one of ordinary skill in the art. The
terminology used herein is for the purpose of describing the
particular embodiments and is not intended to be limiting of
exemplary embodiments of the invention.
[0174] The use of any and all examples, or exemplary language
(e.g., "such as") provided herein, is intended merely to better
illuminate the invention and does not pose a limitation on the
scope of the invention unless otherwise claimed. No item or
component is essential to the practice of the invention unless the
element is specifically described as "essential" or "critical". The
words "mechanism" and "element" are used broadly and are not
limited to mechanical or physical embodiments, but may include
software routines in conjunction with processors, etc. It will also
be recognized that the terms "comprises," "comprising," "includes,"
"including," "has," and "having," as used herein, are specifically
intended to be read as open-ended terms of art. The use of the
terms "a" and "an" and "the" and similar referents in the context
of describing the invention (especially in the context of the
following claims) are to be construed to cover both the singular
and the plural, unless the context clearly indicates otherwise. In
addition, it should be understood that although the terms "first,"
"second," etc. may be used herein to describe various elements,
these elements should not be limited by these terms, which are only
used to distinguish one element from another. Furthermore,
recitation of ranges of values herein are merely intended to serve
as a shorthand method of referring individually to each separate
value falling within the range, unless otherwise indicated herein,
and each separate value is incorporated into the specification as
if it were individually recited herein.
[0175] Numerous modifications and adaptations will be readily
apparent to those of ordinary skill in this art without departing
from the spirit and scope of the present invention as defined by
the following claims. Therefore, the scope of the invention is
defined not by the detailed description of the invention but by the
following claims, and all differences within the scope will be
construed as being included in the invention.
[0176] Although described in connection with preferred embodiments
thereof, it will be appreciated by those skilled in the art that
additions, deletions, modifications, and substitutions not
specifically described may be made without department from the
spirit and scope of the invention as defined in the appended
claims.
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