Apparatus for leaching a volume of a superabrasive element

Abstract

Apparatus for leaching a volume of a superabrasive element include a first electrical connection configured to be operably coupled to a superabrasive element, a leaching assembly for electrically connecting a procession solution to the superabrasive element to remove at least a portion of the at least one interstitial constituent from only a portion of the superabrasive element, and a second electrical connection configured to be operably coupled to the leaching assembly.

What is claimed is: 
     
         1 . An apparatus for leaching a volume of a superabrasive element, the apparatus comprising:
 a first electrical connection configured to be operably coupled to a superabrasive element comprising a plurality of bonded superabrasive grains and at least one interstitial constituent;   a reservoir for holding a processing solution for leaching at least a portion of the at least one interstitial constituent from only a portion of the superabrasive element;   a second electrical connection configured to be operably coupled to the processing solution, the apparatus configured to generate a voltage between the first electrical connection and the second electrical connection; and   a transfer medium configured to be in contact with the superabrasive element, the transfer medium sized and configured to leach at least a portion of a side region of the superabrasive element and only a portion of a superabrasive face of the superabrasive element.   
     
     
         2 . The apparatus of  claim 1 , wherein the transfer medium is further sized and configured to leach a chamfer extending between the side region and the superabrasive face of the superabrasive element. 
     
     
         3 . The apparatus of  claim 2 , wherein the transfer medium includes a recess configured to prevent or limit contact between a portion of the transfer medium and a portion of the superabrasive element. 
     
     
         4 . The apparatus of  claim 3 , wherein the recess of the transfer medium is configured to be positioned at a central portion of the superabrasive face of the superabrasive element. 
     
     
         5 . The apparatus of  claim 3 , wherein the recess of the transfer medium is configured to allow only peripheral areas of the superabrasive face of the superabrasive element to contact the transfer medium. 
     
     
         6 . The apparatus of  claim 3 , wherein the recess of the transfer medium is configured to extend laterally a distance of about 50% to about 90% of the superabrasive face of the superabrasive element. 
     
     
         7 . The apparatus of  claim 3 , wherein the recess of the transfer medium is configured to allow at least a portion of one or more of the superabrasive face, a lateral surface, or a chamfer of the superabrasive element to contact the transfer medium. 
     
     
         8 . The apparatus of  claim 1 , wherein the transfer medium is sized and configured to leach the superabrasive face to a depth that is less than a depth that the side region of the superabrasive element is leached. 
     
     
         9 . The apparatus of  claim 1 , wherein the transfer medium is sized and configured to leach the superabrasive element to define a leached ring shape, a portion of the superabrasive face defining the leached ring shape having a depth that is less than a depth of a portion of the side region defining the leached ring shape. 
     
     
         10 . The apparatus of  claim 1 , wherein the transfer medium includes at least one of a gel, a solid material, a porous paper, a sponge, a porous filter, a membrane, a cation exchange resin, or a solid polymer electrode. 
     
     
         11 . An apparatus for leaching a volume of a superabrasive element, the apparatus comprising:
 a first electrical connection configured to be operably coupled to a superabrasive element comprising a plurality of bonded superabrasive grains and at least one interstitial constituent;   a second electrical connection configured to be operably coupled to a processing solution; and   a transfer element configured to be in contact with the superabrasive element in order to conduct electricity via the processing solution to the superabrasive element, the processing solution for leaching at least a portion of the at least one interstitial constituent from only a portion of the superabrasive element, the transfer element sized and configured to leach the superabrasive element to produce a leached volume of the superabrasive element exhibiting a ring shape.   
     
     
         12 . The apparatus of  claim 11 , wherein the transfer element is sized and configured to leach the superabrasive element such that the ring shape of the superabrasive element exhibits a depth at a superabrasive face of the superabrasive element that is less than a depth that a portion of a side region of the superabrasive element is leached. 
     
     
         13 . The apparatus of  claim 11 , wherein the transfer element includes a recess configured to limit contact between a portion of the transfer element and a superabrasive face of the superabrasive element. 
     
     
         14 . The apparatus of  claim 11 , wherein the transfer element is configured to extend along only a portion of a superabrasive face of the superabrasive element and along a portion of a side surface of the superabrasive element. 
     
     
         15 . The apparatus of  claim 14 , wherein the transfer element is configured to extend along a chamfer of the superabrasive element between the superabrasive face and the side surface of the superabrasive element. 
     
     
         16 . The apparatus of  claim 13 , wherein the transfer element is configured to extend laterally a distance of 50% or less of a superabrasive face of the superabrasive element. 
     
     
         17 . An apparatus for leaching a volume of a superabrasive element, the apparatus comprising:
 a first electrical connection configured to be operably coupled to a superabrasive element comprising a plurality of bonded superabrasive grains and at least one interstitial constituent;   a leaching assembly for electrically connecting a processing solution to the superabrasive element to remove at least a portion of the at least one interstitial constituent from only a portion of the superabrasive element; and   a second electrical connection configured to be operably coupled to the leaching assembly.   
     
     
         18 . The apparatus of  claim 17 , wherein the leaching assembly comprises a transfer medium configured to be in contact with the superabrasive element, the transfer medium sized and configured to leach an outer periphery of the superabrasive element and only a portion of a superabrasive face of the superabrasive element with the processing solution. 
     
     
         19 . The apparatus of  claim 18 , wherein the leaching assembly further comprises a reservoir for supplying the processing solution to the transfer medium. 
     
     
         20 . The apparatus of  claim 18 , wherein the transfer medium includes at least one of a gel or a solid material.