U.S. patent application number 13/465187 was filed with the patent office on 2012-11-08 for casing block.
Invention is credited to Richard Wayne Watson.
Application Number | 20120280559 13/465187 |
Document ID | / |
Family ID | 47089781 |
Filed Date | 2012-11-08 |
United States Patent
Application |
20120280559 |
Kind Code |
A1 |
Watson; Richard Wayne |
November 8, 2012 |
Casing Block
Abstract
A preset recessed casing block for retaining a cutter bit is
provided that can be mass-produced and easily installed in the
casing of a core barrel. The block has a size and shape that
provides for quick and easy insertion and welding into a casing.
The block has a cavity that receives and retains a cutter bit while
allowing for the removal or extraction of the cutter bit when the
bit becomes worn or broken. Because the block is manufactured to
fit inside the casing, wear on the block is minimized and it's
lifetime extended. The cavity in the block and the shape of the
block itself may have different, preset angles and pitches, to
allow for the same size block to be placed in a variety of
locations around the casing, thereby enabling the manufacturer to
produce a variable, raking pattern of the cutter bits for improved
annulus cutting.
Inventors: |
Watson; Richard Wayne;
(Lakeside, CA) |
Family ID: |
47089781 |
Appl. No.: |
13/465187 |
Filed: |
May 7, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61483665 |
May 7, 2011 |
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Current U.S.
Class: |
299/106 ;
299/79.1 |
Current CPC
Class: |
E21C 35/18 20130101;
E21C 35/191 20200501 |
Class at
Publication: |
299/106 ;
299/79.1 |
International
Class: |
E21C 35/197 20060101
E21C035/197; E21C 35/18 20060101 E21C035/18 |
Claims
1. A device for retaining a cutter bit in a casing comprising: a
bottom, four sides, a top, and a cutter bit retaining section,
where the bottom and the four sides are capable of fitting into a
cavity of a casing.
2. The device of claim 1, wherein one of the four sides comprises
an opening through which a bottom of a shaft portion of a cutter
bit can be accessed, wherein this opening is a terminal cavity.
3. The device of claim 1, where the four sides are of equal length,
thereby making a square.
4. The device of claim 1, where the four sides have two sides of
one length and two sides of another length, thereby making a
rectangle.
5. The device of claim 1, wherein the device further comprises four
beveled edges, where there is a beveled edge between each of the
four sides, and where the beveled edges allow for welding material
to be inserted in between the device and the casing.
6. The device of claim 1, further comprising a trailing support
edge, where the trailing support edge is a raised section proximate
to the cutter bit retaining section.
7. The device of claim 1, where the device further comprises a
terminal cavity, where the terminal cavity is proximate to the
cutter bit retaining section, wherein the cutter bit retaining
section comprises a first retaining portion and a second retaining
portion, and wherein the terminal cavity has an opening.
8. The device of claim 7, wherein the cutter bit retaining section
is shaped to mate with a shank section of a cutter bit.
9. The device of claim 7, wherein the first retaining portion and
second retaining portion each have a diameter, where the diameter
of the first retaining portion is greater than the diameter of the
second retaining portion.
10. The device of claim 1, wherein the cutter bit retaining section
is manufactured in a low pitch.
11. The device of claim 1, wherein the cutter bit retaining section
is manufactured in a high pitch.
12. The device of claim 1, wherein the cutter bit retaining section
is manufactured in a medium pitch.
13. The device of claim 1, wherein the device is manufactured for
an inside position on a casing.
14. The device of claim 1, wherein the device is manufactured for a
middle position on a casing.
15. The device of claim 1, wherein the device is manufactured for
an outside position on a casing.
16. The device of claim 1, wherein the bottom of the device
comprises a flat base portion and two angled base portions, whereby
the flat base portion and angled base portions enable the same
device to be used for an inside position, middle position, or
outside position in a casing.
17. The device of claim 1, additionally comprising a terminal
cavity, wherein the terminal cavity is accessible though one of the
four sides.
18. The device of claim 17, wherein a cutter bit can be removed
from the device through the use of a wedge shaped tool.
19. The device of claim 1, wherein the cutter bit retaining section
is designed to accommodate a rotating cutter bit.
20. The device of claim 1, wherein the cutter bit retaining section
is designed to accommodate a non-rotating cutter bit.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent App. No. 61/483,665 filed on May 7, 2011, the entirety of
which is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was not federally sponsored.
BACKGROUND OF THE INVENTION
Field of the Invention
[0003] This invention relates to the general field of drilling
equipment for the foundation drilling and mining industries, and
more specifically toward a preset recessed casing block for
retaining a cutter bit. The invention provides a casing block that
can be mass-produced and easily installed in the casing of a core
barrel. The block can be molded or cut into a size and shape that
can be quickly and easily inserted into a casing, and welded into
place. The block has a cavity manufactured into it that is designed
to receive and retain a cutter bit, but still allow for the removal
or extraction of the cutter bit when the bit becomes worn or
broken. Because the block is manufactured to fit flush to the
surface of the casing, wear on the block is minimized and it's
lifetime is much greater than prior art blocks. The cavity in the
block can be manufactured with different, preset angles and
pitches, to allow for the same size of block to be placed in a
variety of locations around the casing, thereby enabling the
manufacturer to produce a variable, raking pattern of the cutter
bits for improved annulus cutting. This feature also provides
efficient initial placement, and replacement of blocks.
[0004] Foundation drilling and mining has evolved over time and
continues to be an essential industry for all modern civilizations.
In the effort to improve the production and quality of drilled
foundations, there has been huge investment, and advancement in the
equipment and tools of the trade.
[0005] One of the most common tools used by foundation drillers is
the core barrel. Core barrels are used to core through hard layers
of dirt and rock and are known for their ability to keep holes true
and straight.
[0006] The following invention provides important advancements in
the manufacturing and use of core barrel tools. The improved core
barrel has a "cutting end" that comprises a casing, which is a
metal substrate with a number of cavities. "Casing blocks" (or
simply "blocks") can be welded into the cavities, and cutter bits
can be inserted into the blocks. The blocks can have a side opening
that allows an operator to access the bottom portion of the cutter
bit to make removal easier than with currently practiced
methods.
[0007] The cutter teeth cut through rock and dirt as the core
barrel advances. Because of the hard earth into which the holes are
cut, the wear and tear on the cutter bits is considerable, and they
often break and/or wear out and have to be replaced. A high-quality
drilling rig can cost $1,000 or more per hour to operate, and
operations have to stop whenever the operator has to replace a
cutter bit and/or block. Thus, it is highly advantageous to have a
product that allows for a rapid and efficient replacement of blocks
and cutter bits.
[0008] Core barrels that use carbide cutter bits with recessed
blocks are the preferred design in the industry at present because
the blocks are protected from excess wear and impact by the
surrounding casing. Although preferred, they tend to be more
expensive and difficult to manufacture due to the additional
installation steps and fabrication required.
[0009] One of the most important and time-consuming steps is
setting the height, angle, and pitch of each cutter bit and block.
This procedure requires two fabricators to take numerous
measurements and do calculations to ensure that each cutter bit
block is in the proper location before it is welded into place. For
example, a cutter bit set to cut and located at the outside cutting
surface will have a much different ideal height, angle and pitch
than would a cutter bit set to cut and located on the inside
portion of the casing.
[0010] Under the prior art methods, one of the workers must take
three separate measurements while he adjusts and holds the block
into position. When he gives the "OK", a second worker must tack
weld the block to the casing. This current method has two
disadvantages. First, considering the high operating cost of even
an average sized drilling rig, any "down time" can translate into
thousands of dollars very quickly. Second, because two fabricators
are required, there has to be an additional person standing by to
assist the operator in case a cutter bit breaks or wears out.
[0011] Prior art blocks are designed to be welded to the edge of a
casing making them susceptible to wear and impact. Prior art blocks
are difficult to recess into casing and must have their height,
angle, and pitch manually set to cut clearances.
[0012] Thus there has existed a long-felt need for preset recessed
casing blocks that resist wear and impact, easy to manufacture and
install, and provide multiple heights, angles and pitches to allow
for use in a wide variety of situations.
SUMMARY OF THE INVENTION
[0013] The current invention provides just such a solution by
having a block capable of being placed in a cavity in a casing used
for core barrels and other drilling apparatus. The block is molded
or cut into a size and shape that can be quickly and easily
inserted into a casing, and welded into place. The block has a
cavity manufactured into it that can receive a cutter bit. Because
the block is manufactured to fit flush to the surface of the
casing, wear on the block in minimized. The cavity in the block can
be manufactured with different, preset angles and pitches to allow
for the same size of block to be placed in a variety of locations
around the casing, thereby enabling the manufacturer to produce a
variable raking pattern of the cutter bits for improved annulus
cutting. This feature also provides efficient initial placement,
and replacement of blocks.
[0014] An object of the invention is to provide the industry with a
preset recessed casing block that can be installed faster and
easier with only one worker needed to perform the work. The
invention comprises a square or rectangular outer shape to make it
easy to lay out and cut casing when installing. Each block is
designed to mount flush with the top edge of casing so there is no
need to measure or set the height. Each block is preset with
optional angles and pitches and only needs to be selected and
centered into the casing. Blocks can be preset to inside, outside,
middle cutter and other miscellaneous positions. All a worker will
need to do is cut the typical block size out the casing, choose a
block, (outside, inside, middle, etc.) and weld it into place.
[0015] A wedge shaped tool can be used to easily remove the cutter
bits from the blocks. By accessing the bottom of the cutter bit
through the hole in the side of the block, a worker can hammer or
otherwise push up on the cutter bit from the bottom, dislodging it
and popping it out the top of the block cavity. Blocks can be made
with or without the snap ring access hole in the side. The sides of
the block can be beveled to allow for welds. Block settings can be
purchased with different attack angles, and can be purchased preset
as outside, inside, middle, middle inside, middle outside, etc., or
any other of the preferred combinations of height, angle and pitch
found in different locations on the casing. Blocks can be made to
accept any type of cutter including rotating, non-rotating, and can
be made in different materials, shapes and sizes.
[0016] It is a principal object of the invention to provide a
casing block that is easily installed and removed from the casing
of a drilling apparatus.
[0017] It is another object of the invention is to provide a means
to allow cutter bits to be inserted and removed easily from the
casing block, which can be a recessed cavity in the block that is
shaped to accommodate a cutter bit.
[0018] It is an additional object of the invention that the casing
block be made in a variety of shapes to accommodate a variety of
casings and drilling plans.
[0019] It is a further object of the invention that the casing
block can be manufactured with a wide range of angles and pitches
with respect to the recessed cavity, such that a cutter bit with a
desired angle of attack can be inserted into a particular type of
casing block for a particular location on the casing.
[0020] It is also an object of this invention that the casing block
has beveled edges that allow for welding of the block into the
casing.
[0021] It is yet another object of this invention that the
invention allow for a more efficient drilling operation by reducing
the number of workers required to remove and replace a casing
block, and by allowing this work to be done more quickly than is
currently possible using the prior art materials and methods.
[0022] There has thus been outlined, rather broadly, the more
important features of the invention in order that the detailed
description thereof may be better understood, and in order that the
present contribution to the art may be better appreciated. There
are additional features of the invention that will be described
hereinafter and which will form the subject matter of the claims
appended hereto. The features listed herein and other features,
aspects and advantages of the present invention will become better
understood with reference to the following description and appended
claims.
BRIEF DESCRIPTION OF THE FIGURES
[0023] The accompanying drawings, which are incorporated in and
form a part of this specification, illustrate embodiments of the
invention and together with the description, serve to explain the
principles of this invention.
[0024] FIG. 1 is a perspective view of a casing block according to
selected embodiments of the current disclosure.
[0025] FIG. 2 is a partial bottom view of a core barrel with three
casing blocks secured thereto according to selected embodiments of
the current disclosure.
[0026] FIG. 3 is a partial bottom view of a core barrel with a
single middle casing block secured thereto according to selected
embodiments of the current disclosure.
[0027] FIG. 4 is a side view of a casing block secured to a core
barrel and a cutter bit according to selected embodiments of the
current disclosure.
[0028] FIG. 5 is a front view of a casing block according to
selected embodiments of the current disclosure.
[0029] FIG. 6 is a cutaway side view of a casing block according to
selected embodiments of the current disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Many aspects of the invention can be better understood with
the references made to the drawings below. The components in the
drawings are not necessarily drawn to scale. Instead, emphasis is
placed upon clearly illustrating the components of the present
invention. Moreover, like reference numerals designate
corresponding parts through the several views in the drawings.
[0031] FIG. 1 is a perspective view of a casing block according to
selected embodiments of the current disclosure. The casing block 10
has a cavity manufactured into it during production. The cavity of
the casing block 10 has two general parts, a retaining section 13,
designed to seat the bottom half of a cutter bit, and a terminal
cavity 12 designed to retain a snap ring on a cutter bit (not shown
in this figure), and to allow for a wedge-shaped implement to
easily pry loose any worn or broken cutter bits for removal and
replacement. The block 10 has a trailing support edge 14 that
provides support to the trailing edge of the cutter bit as it is
moved forward by the drilling rig. Each corner of the casing block
10 has a beveled edge 11 to allow for easy welding into openings in
the core barrel.
[0032] The casing blocks are generally made of steel, iron, or some
alloy, and are sometimes heat-treated. The common means by which
casing blocks are retained in the casing is to weld them in place,
although other means of attachment are contemplated.
[0033] FIG. 2 is a partial bottom view of a core barrel with three
casing blocks secured thereto according to selected embodiments of
the current disclosure. The left-most casing block 10 in this
figure is secured in the casing 51 of the core barrel 50 at an
inside position, whereby a cutter bit retained therein is angled
towards the inside of the core barrel. The center casing block 10
in this figure is secured in the casing 51 of the core barrel 50 at
a middle position, whereby a cutter bit retained therein is angled
in the same direction as the longitudinal axis of the core barrel.
The right-most casing block 10 in this figure is secured in the
casing 51 of the core barrel 50 at an outside position, whereby a
cutter bit retained therein is angled towards the outside of the
core barrel.
[0034] FIG. 3 is a partial bottom view of a core barrel with a
single middle casing block secured thereto according to selected
embodiments of the current disclosure. The casing block resides in
the casing 51. The retaining section 13 and the trailing support
edge 14 are visible in this figure, as well as the beveled edges 11
in each of its four outer corners.
[0035] FIG. 4 is a side view of a casing block secured to a core
barrel and a cutter bit according to selected embodiments of the
current disclosure. The function of the block can be seen in this
figure. As the drilling rig turns the drill bit, the casing
rotates, pushing the cutter bits against the soil and rock point
first. As the point of the cutter bit digs into the soil, the
trailing support edge 14 and the retaining section 13 keep the
cutter bit 40 at the proper angle and pitch to maximize the
efficiency of the cutting. It should be noted that the casing 51
has a variety of cutter bits located on different parts of the
casing, so that different casing blocks that have cavities that
point the cutter bit in different directions are needed. In an
ideal drilling setup, having cutter bits pointing downward, inward,
and outward to the sides produces maximum "raking" of the soil,
which results in maximum efficiency.
[0036] Over time, the cutter bit 40 will either break or wear out
and have to be replaced. When it becomes necessary to remove and
replace a cutter bit, the cutter bit is pulled out after removal of
the snap ring. Access for removing the snap ring is provided
through the terminal cavity 12. If after removing the snap ring the
cutter but 40 is still stuck in the casing block 10, the cutter bit
may be levered out by use of a wedge-shaped tool. The average
casing block will last through about fifteen to twenty cutter bits.
When it is time to replace the casing block, the welded portion is
cut through and the block removed. Another casing block can be
quickly installed in the cavity, welded into place, have a cutter
bit installed, and then the drilling operation can resume. This
method is considerably more efficient than the current method of
individually welding irregular shaped blocks and cutter bits into
the preferred combination of heights, angles and pitches.
[0037] The casing 51 has a cavity into which the casing block 10
has been inserted. There is adequate space between the edge of the
cavity of the casing 51 and the sides of the casing block 10 for
welding. The trailing support edge 14 buttresses the first
retaining portion 16 of the retaining section in the block 10 into
which the cutter bit 40 is inserted. The retaining portion 14
includes two different sections with two different diameters; the
second retaining portion 17, which is proximate to the terminal
cavity, has a smaller diameter than the first retaining portion 16.
The shank portion of the cutter bit 41, 42 (which also has two
different sections with two different diameters) rests on and is
retained by difference in diameter of the first retaining portion
16 and the second retaining portion 17.
[0038] The cutter bit 40 has two different shank sections: a first
shank section 41 and a second shank section 42. The first shank
section 41 has a larger diameter than the second shank section 42.
The distal end of the second shank section 42 includes an
indentation 44 (or groove) around its entire circumference. The
snap ring discussed above extends around this indentation 44. A
rotating protective sleeve 43 facilitates the rotation of the
cutter bit 40 within the casing block 10 while also reducing the
wear and tear on the casing block 10 from the rotation of the
cutter bit 40.
[0039] A more thorough description of the cutter bit can be found
in U.S. Pat. No. D601,592, U.S. patent application Ser. No.
12/465,851, and European Union Pat. No. 001113039-0001, all of
which, including any priority-related applications, are hereby
incorporated by reference.
[0040] FIG. 5 is a front view of a casing block according to
selected embodiments of the current disclosure. The bottom of the
casing block 10 includes a flat base portion 20 and two angled base
portions 19. The base angle 21, which is the difference in angle
between the flat base portion 20 and the angled base portion,
enables the casing block 10 to be installed into a core barrel at
that angle. In other words, the casing block 10 may be installed at
an angle into the cavity of a casing such that one of the angled
base portions mates flush with the bottom of the cavity. In this
manner, casing blocks, and thus cutter bits, may be quickly and
efficiently installed into a casing at one of three predetermined
orientations: middle, inner, and outer. It will be appreciated by
those in the art that different casing blocks may be manufactured
with different base angles. Furthermore, it will be appreciated by
those in the art that the same casing bock with two angled base
portions 19 may have different base angles 21 for each of the two
angled base portions 19.
[0041] FIG. 6 is a cutaway side view of a casing block according to
selected embodiments of the current disclosure. This view is taken
along line 6 shown in FIG. 5. The casing block 10 includes a
terminal cavity 12, a first retaining portion 16 and a second
retaining portion 17. The back end of the first retaining portion
16 is supported by the trailing support edge 14. The trailing
support edge 14 is a raised section proximate to the retaining
section. The pitch of the cutter bit is set by the angle of the
retaining section. A low pitch results in a cutter bit that is
relatively parallel to the top of the casing block. A high pitch
results in a cutter bat that is almost or actually perpendicular to
the top of the casing block. A medium pitch results in a cutter bit
that is somewhere between a low pitch and a high pitch.
[0042] It should be understood that while the preferred embodiments
of the invention are described in some detail herein, the present
disclosure is made by way of example only and that variations and
changes thereto are possible without departing from the subject
matter coming within the scope of the following claims, and a
reasonable equivalency thereof, which claims I regard as my
invention.
[0043] All of the material in this patent document is subject to
copyright protection under the copyright laws of the United States
and other countries. The copyright owner has no objection to the
facsimile reproduction by anyone of the patent document or the
patent disclosure, as it appears in official governmental records
but, otherwise, all other copyright rights whatsoever are
reserved.
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