Leached Cutter And Method For Improving The Leaching Process

Abstract

A method to leach a component that includes a polycrystalline structure. The method includes obtaining the component having the polycrystalline structure. The polycrystalline structure includes catalyst material deposited therein. The method also includes performing a leaching process on the polycrystalline structure to an intermediate leaching depth. The leaching process removes at least a portion of the catalyst material from the polycrystalline structure and forms one or more by-product materials deposited therein. The method also includes performing a cleaning process on the polycrystalline structure, which removes at least a portion of the by-product materials. The leaching process and the cleaning process are iteratively continued until the intermediate leaching depth reaches a desired leaching depth, both of which are measured from one end of the polycrystalline structure. The desired leaching depth is greater than at least one intermediate leaching depth.

1 . A leached cutter, comprising:
 a substrate; and   a cutting table coupled to a surface of the substrate, the cutting table comprising a cutting surface, a side surface extending from the perimeter of the cutting surface towards a perimeter of the surface of the substrate, and a polycrystalline structure formed therethrough, the polycrystalline structure, comprising:
 an unleached layer positioned adjacent to the substrate and comprising a plurality of catalyst material deposited therein; and 
 a leached, layer positioned adjacent to the unleached layer, the leached layer having at least a portion of the catalyst material and a portion of a by-product material removed from therein, 
   wherein the leached layer is formed by the method comprising:
 performing a leaching process on the polycrystalline structure until, at least a portion of the catalyst material is removed from an intermediate leaching depth of the polycrystalline structure, the leaching process forming the by-product material that deposited within the intermediate leaching depth of the polycrystalline structure; 
 performing a cleaning process on the polycrystalline structure until at least a portion of the by-product, material is removed from the intermediate leaching depth of the polycrystalline structure; and 
 continuing iteratively performing the leaching process and performing the cleaning process on the polycrystalline structure until the intermediate leaching depth reaches a desired leaching depth, 
   wherein a different intermediate leaching depth is reached during each successive leaching process and each different intermediate leaching depth progresses towards the desired leaching depth, and   wherein the desired leaching depth is greater than at least one intermediate leaching depth.   
     
     
         2 . The leached cutter of  claim 1 , wherein, continuing iteratively performing the leaching process and performing the cleaning process on the polycrystalline structure until the intermediate leaching depth reaches a desired leaching depth comprises performing the leaching process last. 
     
     
         3 . The leached cutter of  claim 1 , wherein continuing iteratively performing the leaching process and performing the cleaning process on the polycrystalline structure until the intermediate leaching depth reaches a desired leaching depth comprises performing the cleaning process last. 
     
     
         4 . The leached cutter of  claim 1 , wherein continuing iteratively performing the leaching process and performing the cleaning process on the polycrystalline structure comprises performing the leaching process and performing the cleaning process on the polycrystalline structure in an alternating manner. 
     
     
         5 . The leached cutter of  claim 1 , wherein the leaching process comprises immersing at least a portion of the polycrystalline structure into an acidic solution, 
     
     
         6 . The leached cutter of  claim 1 , wherein the cleaning process comprises immersing at least a portion of the polycrystalline structure into a cleaning fluid. 
     
     
         7 . The leached cutter of  claim 6 , wherein the cleaning fluid comprises de-ionized water. 
     
     
         8 . The leached cutter of  claim 1 , wherein the intermediate depth is measured from at least a portion of the cutting surface towards an interior of the polycrystalline structure. 
     
     
         9 . The leached carter of  claim 1 , wherein the intermediate depth is measured from at least a portion of the side surface towards an interior of the polycrystalline structure, 
     
     
         10 . The leached cutter of  claim 1 , wherein the cleaning process is performed from at least, a portion of the side surface. 
     
     
         11 . The leached cutter of  claim 1 , wherein the cleaning process is performed from at least a portion of the cutting surface. 
     
     
         12 . A leaching method for removing at least a portion of a catalyst material from within a polycrystalline structure, the catalyst material being removed from the polycrystalline structure to a desired leaching depth within the polycrystalline structure, the method comprising:
 obtaining a component comprising a polycrystalline structure, the poly crystalline structure comprising a first end, a second end opposite the first end, and a side surface extending from the perimeter of the first end to a perimeter of the second end;   performing a leaching process on the polycrystalline structure until at least a portion of the catalyst material is removed from an intermediate leaching depth, of the polycrystalline structure the leaching process forming at least some by-product materials deposited within the intermediate leaching depth of the polycrystalline structure, the intermediate leaching depth being measured from a surface of the polycrystalline structure;   performing a cleaning process on the polycrystalline structure until at least a portion of the by-product materials is removed from the intermediate leaching depth of the polycrystalline structure;, and   continuing iteratively performing the leaching process and performing the cleaning process on foe polycrystalline structure until the intermediate leaching depth reaches a desired leaching depth, the desired leaching depth being measured from the surface of the polycrystalline structure,   wherein a different intermediate leaching depth is reached during each leaching process and each different intermediate leaching depth progresses towards the desired leaching depth, and   wherein the desired leaching depth is greater than at least one intermediate leaching depth.   
     
     
         13 . The leaching method of  claim 11 , wherein the surface of the polycrystalline structure comprises, at least a portion of the side surface of the polycrystalline structure. 
     
     
         14 . The leaching method of  claim 11 , wherein the surface of the polycrystalline structure comprises at least a portion of the first end of the polycrystalline structure. 
     
     
         15 . The leaching method of  claim 11 , wherein continuing iteratively performing the leaching process and performing the cleaning process on the polycrystalline structure until the intermediate leaching depth reaches a desired leaching depth comprises performing the leaching process last. 
     
     
         16 . The leaching method of  claim 11 , wherein continuing iteratively performing the leaching process arid performing the cleaning process on the polycrystalline structure until the intermediate leaching depth reaches a desired leaching depth comprises performing the cleaning process last. 
     
     
         17 . The leaching method of  claim 11 , wherein the intermediate depth is measured from at least a portion of the cutting surface towards an interior of the polycrystalline structure, 
     
     
         18 . The leaching method of  claim 11 , wherein the intermediate depth is measured from at least a portion of the side surface towards an interior of the polycrystalline structure. 
     
     
         19 . The leaching method of  claim 11 , wherein the cleaning process is performed from at least a portion of the side surface. 
     
     
         20 . The leaching method of  claim 11 , wherein the cleaning process is performed from at least a portion of the cutting surface. 
     
     
         21 . A drill bit, comprising:
 a leached cutter, comprising:
 a substrate; and 
 a cutting table coupled to a surface of the substrate, the cutting table comprising a cutting surface, a side surface extending from the perimeter of the cutting surface towards a perimeter of the surface of the substrate, and a polycrystalline structure formed therethrough, the polycrystalline structure, comprising:
 an unleached layer positioned adjacent to the substrate and comprising a plurality of catalyst material deposited therein; and 
 a leached layer positioned adjacent to the unleached layer, the leached layer having at least a portion of the catalyst material and a portion of a by-product material removed from therein, 
 
   wherein the leached layer is formed by the method comprising:
 performing a leaching process on the polycrystalline structure until at least a portion of the catalyst material is removed from an intermediate leaching depth of the polycrystalline structure, the leaching process forming the by-product material that deposited within the intermediate leaching depth of the polycrystalline structure; 
 performing a cleaning process on the polycrystalline structure until at least a portion of the by-product material is removed from the intermediate leaching depth of the polycrystalline structure; and 
 continuing iteratively performing the leaching process and performing the cleaning process on the polycrystalline structure until the intermediate leaching depth reaches a desired leaching depth, 
   wherein a different intermediate leaching depth is reached during each successive leaching process and each different intermediate leaching depth progresses towards the desired leaching, depth, and   wherein the desired leaching depth is greater than at least one intermediate leaching depth.   
     
     
         22 . The drill bit of  claim 21 , wherein continuing iteratively performing the leaching process and performing the cleaning process on the polycrystalline structure until the intermediate leaching depth reaches a desired leaching depth comprises performing the leaching process last. 
     
     
         23 . The drill bit of  claim 21 , wherein continuing iteratively performing the leaching process and performing the cleaning process on the polycrystalline structure until the intermediate leaching depth reaches a desired leaching depth comprises performing the cleaning process last 
     
     
         24 . The drill bit of  claim 21 , wherein the intermediate depth is measured from at least a portion of the cutting surface towards an interior of the polycrystalline structure. 
     
     
         25 . The drill bit of  claim 21 , wherein the intermediate depth is measured from at least a portion of the side surface towards an interior of the polycrystalline structure. 
     
     
         26 . The drill bit of  claim 21 , wherein the cleaning process is performed from at least a portion of the side surface. 
     
     
         27 . The drill bit of  claim 21 , wherein the cleaning process is performed from-at least a portion of the cutting surface.