U.S. patent application number 14/585716 was filed with the patent office on 2015-07-02 for no-waterway or single waterway drill bits and systems and methods for using same.
The applicant listed for this patent is Longyear TM, Inc.. Invention is credited to Cody A. Pearce, Michael D. Rupp.
Application Number | 20150184465 14/585716 |
Document ID | / |
Family ID | 53481137 |
Filed Date | 2015-07-02 |
United States Patent
Application |
20150184465 |
Kind Code |
A1 |
Pearce; Cody A. ; et
al. |
July 2, 2015 |
No-Waterway Or Single Waterway Drill Bits And Systems And Methods
For Using Same
Abstract
A drill bit for forming a hole in a formation. The drill bit has
a shank and an annular crown that cooperate to define an interior
space that receives water or other drilling fluid. The annular
crown defines inner channels spaced circumferentially about an
inner surface of the crown and outer channels spaced
circumferentially about an outer surface of the crown. The annular
crown can completely circumferentially enclose the interior space
of the drill bit, or the annular crown can be provided with a
single waterway extending between the inner and outer surfaces of
the crown.
Inventors: |
Pearce; Cody A.; (Midvale,
UT) ; Rupp; Michael D.; (Murray, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Longyear TM, Inc. |
South Jordan |
UT |
US |
|
|
Family ID: |
53481137 |
Appl. No.: |
14/585716 |
Filed: |
December 30, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61921847 |
Dec 30, 2013 |
|
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|
Current U.S.
Class: |
175/393 |
Current CPC
Class: |
E21B 10/02 20130101;
E21B 10/42 20130101; E21B 10/61 20130101; E21B 10/605 20130101 |
International
Class: |
E21B 10/61 20060101
E21B010/61; E21B 3/00 20060101 E21B003/00; E21B 10/42 20060101
E21B010/42 |
Claims
1. A drill bit for forming a hole in a formation, the drill bit
having a longitudinal axis and comprising: a shank; an annular
crown having a cutting face, an inner surface, and an outer
surface, the full face crown and the shank cooperating to define an
interior space about the longitudinal axis, wherein the annular
crown defines a plurality of inner channels spaced
circumferentially about the inner surface of the annular crown,
wherein the annular crown defines a plurality of outer channels
spaced circumferentially about the outer surface of the annular
crown, and wherein the annular crown completely circumferentially
encloses the interior space.
2. The drill bit of claim 1, wherein the annular crown does not
comprise a waterway extending radially from the inner surface of
the annular crown to the outer surface of the annular crown.
3. The drill bit of claim 1, wherein the annular crown has a radial
thickness between the inner surface and the outer surface, wherein
each inner channel of the plurality of inner channels has a radial
dimension less than the radial thickness of the annular crown, and
wherein each outer channel of the plurality of outer channels has a
radial dimension less than the radial thickness of the annular
crown.
4. The drill bit of claim 3, wherein the ratio between the radial
thickness of the annular crown and the radial dimension of the
plurality of inner channels ranges from about 1.5:1 to about
3.5:1.
5. The drill bit of claim 4, wherein the ratio between the radial
thickness of the annular crown and the radial dimension of the
plurality of outer channels ranges from about 1.5:1 to about
3.5:1.
6. The drill bit of claim 3, wherein the radial dimension of the
plurality of inner channels is greater than the radial dimension of
the plurality of outer channels.
7. The drill bit of claim 1, wherein the number of inner channels
is the same as the number of outer channels.
8. The drill bit of claim 1, wherein the number of inner channels
is greater than the number of outer channels.
9. The drill bit of claim 1, wherein the number of inner channels
is less than the number of outer channels.
10. The drill bit of claim 1, wherein each outer channel of the
plurality of outer channels is positioned circumferentially between
sequential inner channels of the plurality of inner channels.
11. The drill bit of claim 1, wherein the annular crown comprises a
single waterway extending radially from the inner surface of the
annular crown to the outer surface of the annular crown.
12. A drilling system comprising: a drill rig; a drill string
configured to be secured to and rotated by the drill rig; and a
drill bit for forming a hole in a formation, the drill bit having a
longitudinal axis and comprising: a shank; an annular crown having
a cutting face, an inner surface, and an outer surface, the full
face crown and the shank cooperating to define an interior space
about the longitudinal axis, wherein the annular crown defines a
plurality of inner channels spaced circumferentially about the
inner surface of the annular crown, wherein the annular crown
defines a plurality of outer channels spaced circumferentially
about the outer surface of the annular crown, and wherein the
annular crown completely circumferentially encloses the interior
space.
13. The drilling system of claim 12, wherein the annular crown of
the drill bit does not comprise a waterway extending radially from
the inner surface of the annular crown to the outer surface of the
annular crown.
14. The drilling system of claim 12, wherein the annular crown of
the drill bit has a radial thickness between the inner surface and
the outer surface, wherein each inner channel of the plurality of
inner channels has a radial dimension less than the radial
thickness of the annular crown, and wherein each outer channel of
the plurality of outer channels has a radial dimension less than
the radial thickness of the annular crown.
15. The drilling system of claim 14, wherein the ratio between the
radial thickness of the annular crown of the drill bit and the
radial dimension of the plurality of inner channels of the annular
crown ranges from about 1.5:1 to about 3.5:1.
16. The drilling system of claim 15, wherein the ratio between the
radial thickness of the annular crown of the drill bit and the
radial dimension of the plurality of outer channels of the drill
bit ranges from about 1.5:1 to about 3.5:1.
17. The drilling system of claim 14, wherein the radial dimension
of the plurality of inner channels of the drill bit is greater than
the radial dimension of the plurality of outer channels of the
drill bit.
18. The drilling system of claim 12, wherein the number of inner
channels of the drill bit is the same as the number of outer
channels of the drill bit.
19. The drilling system of claim 12, wherein the number of inner
channels of the drill bit is greater than the number of outer
channels of the drill bit.
20. The drilling system of claim 12, wherein the number of inner
channels of the drill bit is less than the number of outer channels
of the drill bit.
21. The drilling system of claim 12, wherein each outer channel of
the plurality of outer channels of the drill bit is positioned
circumferentially between sequential inner channels of the
plurality of inner channels of the drill bit.
22. The drilling system of claim 12, wherein the annular crown
comprises a single waterway extending radially from the inner
surface of the annular crown to the outer surface of the annular
crown.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims priority to U.S. Provisional Patent
Application No. 61/921,847, filed Dec. 30, 2013, which is
incorporated by reference herein in its entirety.
FIELD
[0002] This invention relates to drill bits for forming a hole in a
formation, and, more particularly, to annular drill bits for
forming a hole in a formation.
BACKGROUND
[0003] Existing drill bits typically have a central waterway and a
series of channels or slots that provide fluid communication
between a side surface of the bit and the central waterway. These
channels and/or slots decrease the efficiency of cooling and
flushing at the bit face. The channels and/or slots also limit the
height of the crown of the bit--if a crown with the channels and/or
slots is made too tall, the crown will fail during drilling. Thus,
the presence of the channels and/or slots effectively decreases the
lifespan of existing drill bits, thereby increasing the cost of
drill bit production.
[0004] Many drilling areas, such as South America and Australia,
have limited water supplies. In these areas, it can be challenging
to perform drilling operations using conventional drill bits, which
require large amounts of water. Even in areas with larger water
supplies, water trucks are required to haul water to the drill
site, thereby increasing the cost of drilling operations.
[0005] Thus, there is a need in the pertinent art for stronger
drill bits that improve flushing and cooling, as compared to
existing drill bits. There is a further need in the pertinent art
for drill bits that require less water (or other drilling fluid)
than conventional drill bits, thereby decreasing the cost of
drilling operations.
SUMMARY
[0006] Described herein is a drill bit for forming a hole in a
formation. The drill bit has a longitudinal axis, a shank, and an
annular crown. The annular crown has a cutting face, an inner
surface, and an outer surface. The annular crown and the shank
cooperate to define an interior space about the longitudinal axis.
The interior space can be configured to receive water or other
drilling fluid during use of the drill bit.
[0007] In one aspect, the annular crown can define a plurality of
inner channels spaced circumferentially about the inner surface of
the annular crown and extending radially outwardly away from the
longitudinal axis. The annular crown can also define a plurality of
outer channels spaced circumferentially about the outer surface of
the annular crown and extend radially inwardly toward the
longitudinal axis. The annular crown can completely
circumferentially enclose the interior space. In exemplary aspects,
the annular crown does not have waterways extending radially
between the outer surface of the annular crown and the interior
space. Systems for forming a hole in a formation using the drill
bit are also described.
[0008] Additional advantages of the invention will be set forth in
part in the description which follows, and in part will be obvious
from the description, or may be learned by practice of the
invention. The advantages of the invention will be realized and
attained by means of the elements and combinations particularly
pointed out in the appended claims. It is to be understood that
both the foregoing general description and the following detailed
description are exemplary and explanatory only and are not
restrictive of the invention, as claimed.
DETAILED DESCRIPTION OF THE FIGURES
[0009] These and other features of the preferred embodiments of the
invention will become more apparent in the detailed description in
which reference is made to the appended drawings wherein:
[0010] FIG. 1A is a perspective view of an exemplary drill bit
having no waterways or notches, as disclosed herein. FIG. 1B is a
top view of the drill bit of FIG. 1A.
[0011] FIG. 2A is a perspective view of an exemplary drill bit
having a single waterway as disclosed herein. FIG. 2B is a top view
of the drill bit of FIG. 2A.
[0012] FIG. 3 is a perspective view of an exemplary drill bit
having a single waterway as disclosed herein.
[0013] FIG. 4 is a perspective view of an exemplary drill bit
having a single waterway as disclosed herein, showing a raised
central portion of the crown of the drill bit with respective inner
and outer portions that respectively adjoin the inner and outer
surfaces being lowered relative to the raised central portion.
[0014] FIG. 5 is a perspective view of an exemplary drill bit
having a single waterway as disclosed herein, showing a lowered
central portion of the crown of the drill bit with respective inner
and outer portions that respectively adjoin the inner and outer
surfaces being raised relative to the lowered central portion.
[0015] FIG. 6 depicts an exemplary drill bit having no waterways or
notches, as disclosed herein, before and after use of the drill bit
in drilling operations.
[0016] FIG. 7 is a perspective view of any exemplary drill bit
having a single outer channel, a single inner channel, and a single
waterway as disclosed herein.
[0017] FIG. 8 is a perspective view of the drill bit of FIG. 7.
[0018] FIG. 9 depicts an exemplary drilling system comprising a
drill bit as disclosed herein.
DETAILED DESCRIPTION
[0019] The present invention can be understood more readily by
reference to the following detailed description, examples,
drawings, and claims, and their previous and following description.
However, before the present devices, systems, and/or methods are
disclosed and described, it is to be understood that this invention
is not limited to the specific devices, systems, and/or methods
disclosed unless otherwise specified, as such can, of course, vary.
It is also to be understood that the terminology used herein is for
the purpose of describing particular aspects only and is not
intended to be limiting.
[0020] The following description of the invention is provided as an
enabling teaching of the invention in its best, currently known
embodiment. To this end, those skilled in the relevant art will
recognize and appreciate that many changes can be made to the
various aspects of the invention described herein, while still
obtaining the beneficial results of the present invention. It will
also be apparent that some of the desired benefits of the present
invention can be obtained by selecting some of the features of the
present invention without utilizing other features. Accordingly,
those who work in the art will recognize that many modifications
and adaptations to the present invention are possible and can even
be desirable in certain circumstances and are a part of the present
invention. Thus, the following description is provided as
illustrative of the principles of the present invention and not in
limitation thereof.
[0021] As used throughout, the singular forms "a," "an" and "the"
include plural referents unless the context clearly dictates
otherwise. Thus, for example, reference to "a channel" can include
two or more such channels unless the context indicates
otherwise.
[0022] Ranges can be expressed herein as from "about" one
particular value, and/or to "about" another particular value. When
such a range is expressed, another aspect includes from the one
particular value and/or to the other particular value. Similarly,
when values are expressed as approximations, by use of the
antecedent "about," it will be understood that the particular value
forms another aspect. It will be further understood that the
endpoints of each of the ranges are significant both in relation to
the other endpoint, and independently of the other endpoint.
[0023] As used herein, the terms "optional" or "optionally" mean
that the subsequently described event or circumstance may or may
not occur, and that the description includes instances where said
event or circumstance occurs and instances where it does not.
[0024] The word "or" as used herein means any one member of a
particular list and also includes any combination of members of
that list.
[0025] Described herein with reference to FIGS. 1A-3 is a drill bit
10 for forming a hole in a formation. The drill bit 10 has a
longitudinal axis LA. In exemplary aspects, the drill bit 10 can
comprise a shank 20 and an annular crown 30. It is contemplated
that the drill bits disclosed herein can increase the strength of
the drill bit compared to conventional drill bits. It is further
contemplated that the increased strength of the drill bits can
permit manufacturing of taller drill bits than are conventionally
manufactured, thereby increasing the lifespan of the drill bits.
This, in turn, can greatly decrease the costs associated with the
production of drill bits (compared to conventional drill bit
production). It is still further contemplated that the drill bits
disclosed herein can provide improved flushing and cooling relative
to conventional drill bits, which comprise slots or windows
extending between an outer surface of the drill bit and a central
waterway (interior space) of the drill bit. Thus, it is
contemplated that the drill bits disclosed herein can operate more
efficiently than conventional drill bits.
[0026] More particularly, it is contemplated that, during operation
of the drill bits disclosed herein, substantially all of the water
(or other drilling fluid) can contact the face of the drill bit. It
is further contemplated that the wearing of diamonds in
conventional drill bits is due to the high friction and heat caused
by the rock of a formation. It is further contemplated that the
faster the rock cuttings are flushed from the face of the drill bit
to the outer diameter of the drill bit, the less regrinding and/or
re-cutting of the formation will be encountered, thereby increasing
the production and cutting life of the drill bit. It is still
further contemplated that this improvement in flushing and cooling
can reduce the abrading of matrix which can increase the diamond
exposure by increasing the matrix tail that supports diamonds on
the bit face. It is still further contemplated that this can create
a larger displacement of formation by the exposed diamond and the
creation of more secondary fracturing of the formation being
drilled, thereby leading to increased drilling performance.
[0027] It is further contemplated that the drill bits disclosed
herein can be easier to manufacture than conventional drill bits.
It is contemplated that the methods of manufacturing the drill bits
disclosed herein can employ reduced amounts of cold pressing
cycles, placing of face waterways and/or windows, and/or
hand-setting face waterways and/or windows.
[0028] It is still further contemplated that the efficiency of
flushing and cooling provided by the drill bits disclosed herein
can reduce the amount of water required for drilling operations. In
exemplary aspects, it is contemplated that the drill bits disclosed
herein can be ideally suited for usage in areas with limited water
supplies, such as South America and Australia.
[0029] In one aspect, the annular crown 30 can have a cutting face
32 that adjoins an outer circumferential surface 34 and an inner
circumferential surface 35. It is contemplated that the annular
crown 30 and the shank 20 can cooperate to define an interior space
25 about the longitudinal axis LA. It is further contemplated that
the interior space 25 can be configured to receive water or other
drilling fluid during use of the drill bit 10. In one aspect, the
water or other drilling fluid can be supplied to the interior space
25 at a desired pressure.
[0030] In still another aspect, the annular crown 30 can completely
circumferentially enclose the interior space 25. Optionally, in
exemplary aspects, as shown in FIGS. 1 and 3, the annular crown 30
does not comprise a waterway extending radially between the outer
surface 34 of the annular crown and the inner surface 35 (and the
interior space 25).
[0031] However, in other optional aspects (discussed further
below), it is contemplated that the annular crown 30 can comprise a
single waterway extending from an inner surface of the annular
crown to the outer surface of the annular crown, thereby providing
communication between the exterior of the drill bit and the
interior space 25. In these aspects, it is contemplated that the
single waterway can optionally be a notch extending from the
cutting face of the annular crown toward the shank along at least a
portion of the axial length of the annular crown. Optionally, it is
contemplated that the notch can extend along the entire axial
length of the annular crown until it reaches the shank. When the
annular crown 30 comprises a single waterway, it is contemplated
that the single waterway can buffer the pressure spike experienced
at the cutting face and decrease the maximum pressure required at
the cutting face. It is further contemplated that the single
waterway can be selectively sized depending upon the pressure
and/or velocity required for a particular drilling application. In
use, it is contemplated that drill bits having a single waterway
(e.g., a single notch) as disclosed herein can be easier to control
in operation than conventional drill bits having a plurality of
waterways. It is further contemplated that the use of a single
waterway (e.g., a single notch) can ensure that the drill bit is
stronger than conventional bits, which have a plurality of
waterways. In particular, it is contemplated that by using only a
single waterway, the possibility of lever action, which typically
occurs at the location of a waterway, is significantly reduced.
Whereas conventional drill bits use a plurality of waterways that
are balanced relative to a center point of the drill bit, it is
further contemplated that the use of a single waterway yields
unexpected beneficial results as disclosed herein. It is still
further contemplated that the single waterway disclosed herein can
function as a pressure release mechanism and can have little or no
impact on the cooling of the drill bit or the fluid flow proximate
the drill bit. This is contrary to conventional drill bits, which
use a plurality of waterways to cool the drill bit and promote more
efficient fluid flow proximate the drill bit.
[0032] In an additional aspect, the inner surface of the annular
crown 30 can define at least one inner channel 36 extending
radially outwardly away from the longitudinal axis LA. In exemplary
aspects, it is contemplated that the at least one inner channel 36
can comprise a plurality of inner channels 36 spaced
circumferentially about the inner surface of the annular crown and
extending radially outwardly away from the longitudinal axis LA.
Optionally, in some exemplary aspects, the plurality of inner
channels 36 can be substantially equally circumferentially spaced
about the inner surface of the annular crown 30. In one aspect, it
is contemplated that the plurality of inner channels 36 can
optionally be substantially equally sized. In other aspects, it is
contemplated that at least one of the inner channels can have a
different size than at least one other inner channel. As used
herein, the "size" of an inner channel 36 generally refers to the
two-dimensional area of the channel, as measured within a plane
that is substantially perpendicular to the longitudinal axis of the
drill bit 10.
[0033] In another aspect, it is contemplated that, in cross-section
to the longitudinal axis LA, the area of the surface of the
plurality of the inner channels 36 to the percentage of the area of
the inner circumferential surface 35 can range between about 10% to
about 80%. Optionally, the area of the surface of the plurality of
the inner channels 36 to the percentage of the area of the inner
circumferential surface 35 can range between about 25% to about
65%, between about 45% to about 60%, or about 55%.
[0034] In a further aspect, the outer surface of the annular crown
30 can define at least one outer channel 38 extending radially
inwardly toward the longitudinal axis LA. In exemplary aspects, it
is contemplated that the at least one outer channel 38 can comprise
a plurality of outer channels 38 spaced circumferentially about the
outer surface of the annular crown and extending radially inwardly
toward the longitudinal axis LA. In other exemplary aspects, it is
contemplated that the annular crown 30 can have an outer diameter
that is greater than an outer diameter of the shank 20 such that
the annular crown projects radially outwardly relative to the
shank. Optionally, in some exemplary aspects, the plurality of
outer channels 38 can be substantially equally circumferentially
spaced about the outer surface 34 of the annular crown 30. In one
aspect, it is contemplated that the plurality of outer channels 38
can optionally be substantially equally sized. In other aspects, it
is contemplated that at least one of the outer channels can have a
different size than at least one other outer channel. As used
herein, the "size" of an outer channel 38 generally refers to the
two-dimensional area of the channel, as measured within a plane
that is substantially perpendicular to the longitudinal axis of the
drill bit 10.
[0035] In one aspect, the annular crown can have a radial thickness
between the inner surface and the outer surface that corresponds to
difference between the outer diameter and the inner diameter of the
annular crown. In this aspect, it is contemplated that each inner
channel of the plurality of inner channels can have a radial
dimension (substantially corresponding to a radial depth relative
to the inner surface) that is less than the radial thickness of the
annular crown. It is further contemplated that each outer channel
of the plurality of outer channels can have a radial dimension
(substantially corresponding to a radial depth relative to the
outer surface) that is less than the radial thickness of the
annular crown. In exemplary aspects, it is contemplated that the
ratio between the radial thickness of the annular crown and the
radial dimension of the plurality of inner channels can range from
about 1.25:1 to about 15:1 and, more preferably, can range from
about 1.5:1 to about 3.5:1. In exemplary aspects, it is
contemplated that the ratio between the radial thickness of the
annular crown and the radial dimension of the plurality of outer
channels can range from about 1:25:1 to about 15:1 and, more
preferably, can range from about 1.5:1 to about 3.5:1. In
additional exemplary aspects, it is contemplated that the radial
dimension of the plurality of inner channels can be greater than
the radial dimension of the plurality of outer channels. In various
exemplary, non-limiting aspects, it is contemplated that the radial
dimension of inner and outer channels can range from about 0.050
inches to about 0.30 inches and, more preferably, from about 0.090
inches to about 0.250 inches.
[0036] In one aspect, the number of inner channels can be the same
as the number of outer channels. In another aspect, it is
contemplated that the number of inner channels can be greater than
the number of outer channels. In a further aspect, it is
contemplated that the number of inner channels can be less than the
number of outer channels.
[0037] In exemplary aspects, it is contemplated that an inner
diameter of the annular crown, which generally corresponds to the
distance of a line extending from a first point on the inner
surface of the crown to an opposed second point on the inner
surface of the crown, with the line passing through a center point
of the crown that coincides with the longitudinal axis LA, can
range from about 0.9 inches to about 8 inches. For crowns having a
substantially circular cross-section, this inner diameter can
correspond to an inner circumference ranging from about 2.8 inches
to about 25.1 inches. In these aspects, it is contemplated that an
inner channel can be provided for every 1 to 2.5 inches along the
inner circumference. However, it is contemplated that annular
crowns having larger or smaller inner diameters and inner
circumferences can be used. In some exemplary aspects, it is
contemplated that the number of inner channels can range from 3 to
16 inner channels. However, it is contemplated that some exemplary
annular crowns can have up to about 40 inner channels. In some
exemplary aspects, it is contemplated that the inner diameter of
the annular crown can vary about the inner surface. In additional
exemplary aspects, it is contemplated that the annular crown can
have a non-circular profile, such as, for example and without
limitation, an elliptical profile. In these aspects, it is
contemplated that the inner circumference of the annular crown can
correspond to the total arcuate dimension defined by the inner
surface of the annular crown as it extends completely around the
longitudinal axis LA of the crown.
[0038] Optionally, as shown in FIGS. 1A-3, it is contemplated that
each outer channel of the plurality of outer channels can be
positioned circumferentially between sequential inner channels of
the plurality of inner channels. It is further contemplated that
the annular crown can optionally have a substantially serpentine
radial profile. In exemplary optional aspects, it is contemplated
that each outer channel can be substantially aligned with a
respective inner channel along a line extending through the
longitudinal axis LA across the diameter of the annular crown
(perpendicular to the longitudinal axis LA). In these aspects, it
is further contemplated that each inner channel can be
substantially aligned with a respective outer channel along a line
extending through the longitudinal axis LA across the diameter of
the annular crown (perpendicular to the longitudinal axis LA).
[0039] In one optional exemplary aspect, as shown in FIG. 4, it is
contemplated that at least one outer channel can substantially
overlap with at least one inner channel such that a line extending
radially from the longitudinal axis LA passes through both an inner
channel and an outer channel. In this aspect, it is contemplated
that the at least one outer channel of the crown can optionally
comprise a single outer channel. It is further contemplated that
the at least one inner channel of the crown can optionally comprise
a single inner channel.
[0040] In additional aspects, each channel 36, 38 of the plurality
of inner channels and the plurality of outer channels can have a
width. Optionally, in these aspects, it is contemplated that each
channel 36, 38 of the plurality of inner channels and the plurality
of outer channels can have a variable width. For example, the width
of each outer channel 38 can optionally decrease from the outer
surface of the full face crown moving radially inwardly toward the
longitudinal axis. Thus, it is contemplated that each channel 38 of
the plurality of channels can be inwardly tapered moving toward the
longitudinal axis LA. In another exemplary aspect, it is
contemplated that the inner and outer channels can be substantially
U-shaped channels.
[0041] In exemplary aspects, it is contemplated that the annular
crown 30 can have a plurality of circumferentially spaced outer
portions 40 that define the outer surface (and outer diameter) of
the annular crown. In these aspects, it is contemplated that a
respective outer channel 38 can be positioned between adjacent
outer portions 40 of the plurality of outer portions. In other
exemplary aspects, it is contemplated that the annular crown 30 can
have a plurality of circumferentially spaced inner portions 42 that
define the inner surface (and inner diameter) of the annular crown.
In these aspects, it is contemplated that a respective inner
channel 36 can be positioned between adjacent inner portions 42 of
the plurality of inner portions.
[0042] Optionally, in some exemplary aspects, it is contemplated
that an outer surface of the shank 20 can define at least one flute
(or groove) extending substantially parallel to the longitudinal
axis LA of the bit 10. In these aspects, each flute of the at least
one flute of the outer surface of the shank can optionally
correspond to a rounded groove extending radially from the outer
surface of the shank 20 toward an inner surface of the shank. As
shown in FIG. 3, it is contemplated that each flute of the at least
one flute of the outer surface of the shank 20 can optionally be
positioned in fluid communication with a respective outer channel
38 of the annular crown 30.
[0043] Optionally, in further exemplary aspects, it is contemplated
that the inner surface of the shank 20 can define at least one
flute (or groove) extending substantially parallel to the
longitudinal axis LA of the bit 10. In these aspects, each flute of
the at least one flute of the inner surface of the shank can
optionally correspond to a rounded groove extending radially from
the inner surface of the shank 20 toward an outer surface of the
shank. It is contemplated that each flute of the at least one flute
of the inner surface of the shank 20 can optionally be positioned
in fluid communication with a respective inner channel 36 of the
annular crown 30.
[0044] As further described above, in some optional aspects, and as
shown in FIGS. 2A-2B and 4, it is contemplated that the annular
crown 30 can comprise a single waterway extending from an inner
surface of the annular crown to the outer surface of the annular
crown. In these aspects, it is contemplated that the single
waterway can be configured to increase the velocity of drilling
fluid at the waterway entrance, and thereby, provide improved
flushing of cuttings.
[0045] In exemplary aspects, it is contemplated that the single
waterway can be an axially-tapered waterway (tapered relative to
the longitudinal axis of the drill bit). In these aspects, it is
contemplated that the axially-tapered waterway can ensure that the
opening of the waterway in the inner surface of the drill bit can
be smaller than the opening of the waterway in the outer surface of
the drill bit. Thus, the waterway can act like a nozzle by
increasing the velocity of the drilling fluid at the waterway
entrance in the inner surface of the drill bit. The capability of
the axially-tapered waterway to increase the velocity of the
drilling fluid at the waterway entrance can provide increased
flushing of cuttings, and can help prevent clogging of the
waterway. Furthermore, it is contemplated that the axially-tapered
waterway can provide improved flow of drilling fluid without
significantly sacrificing bit body volume at the inside diameter or
reducing the cutting surface of the bit face. Thus, it is
contemplated that the axially-tapered waterway can provide for
increased drilling performance and increased drilling life.
[0046] In some aspects, it is contemplated that the single waterway
can be an axially- and radially-tapered waterway, or in other
words, a double-tapered waterway. It is contemplated that such a
double-tapered waterway can help ensure that the waterway increases
in dimension in each axis as it extends from the inner surface of
the drill bit to the outer surface of the drill bit. It is
contemplated that the increasing size of the double-tapered
waterway can reduce the likelihood of debris lodging within the
waterway, and thus, increase the drilling performance of the drill
bit. It is further contemplated that the double-tapered waterway
can allow for a smaller waterway opening at the inside diameter,
while still allowing for a large waterway opening at the outside
diameter of the drill bit. It is contemplated that this
configuration can allow for an increase in the amount of matrix
material at the inside diameter, and thus, help increase the life
of the drill bit while also providing effective flushing. It is
further contemplated that the increased life of such a drill bit
can reduce drilling costs by reducing the need to trip a drill
string from the bore hole to replace a prematurely worn drill
bit.
[0047] As shown in FIGS. 2A-2B, the single waterway can be a notch
112 defined by at least three surfaces 112a, 112b, 112c. In
particular, the notch 112 can be defined by a first side surface
112a, an opposing side surface 112b, and a top surface 112c.
Optionally, it is contemplated that each of the sides surfaces
112a, 112b can extend from the inner surface of the crown to the
outer surface of the crown in a direction generally normal to the
inner surface of the crown. Thus, it is contemplated that the width
of the notch 112 at the outer surface of the crown can be
approximately equal to the width of the notch 112 at the inner
surface of the crown. In other words, the circumferential distance
between the first side surface 112a and the second side surface
112b of the notch 112 at the outer surface can be approximately
equal to the circumferential distance between the first side
surface 112a and the second side surface 112b of the notch 112 at
the inner surface. Alternatively, in other optional aspects, and as
explained in greater detail below, it is contemplated that one or
more of the side surfaces 112a, 112b can have a radial and/or a
circumferential taper.
[0048] It is contemplated that the notch 112 can have any shape
that allows it to operate as intended. In particular, it is
contemplated that the shape and configuration of the notch 112 can
be altered depending upon the characteristics desired for the drill
bit and/or the characteristics of the formation to be drilled. For
example, it is contemplated that the notch can optionally have a
rectangular shape when viewed from cutting face. Alternatively, in
other optional aspects, it is contemplated that the notch can have
a square, triangular, circular, trapezoidal, polygonal, or
elliptical shape or any combination thereof.
[0049] It is further contemplated that the notch 112 can have any
width or length that allows it to operate as intended. In exemplary
aspects, it is contemplated that the notch 112 can have a length
(i.e., distance from the inner surface to the outer surface) that
is greater than its width (i.e., distance between opposing side
surfaces 112a and 112b). In alternative implementations of the
present invention, however, the notch 112 can have a width greater
than its length, or a width that is approximately equal to its
length.
[0050] As mentioned previously, the waterway (i.e., notch 112) can
be axially tapered. In exemplary aspects, the top surface 112c of
the notch 112 can taper from the inner surface to the outer surface
in a direction generally from the cutting face toward the shank. In
other words, it is contemplated that the height or longitudinal
dimension of the notch 112 can increase as the notch 112 extends
from the inner surface to the outer surface of the crown. Thus, in
some exemplary aspects, the longitudinal dimension of the notch 112
at the outer surface can be greater than the longitudinal dimension
of the notch 112 at the inner surface. In other words, the notch
112 can extend into the cutting face a first distance at the inner
surface and extend into the cutting face a second distance at the
outer surface, where the second distance is greater than the first
distance.
[0051] It is contemplated that the axial-taper of the notch 112 can
help ensure that the opening of the notch 112 at the inner surface
is smaller than the opening of the notch 112 at the outer surface
of the crown. It is further contemplated that this difference in
opening sizes can increase the velocity of drilling fluid at the
inner surface as it passes to the outer surface of the crown. Thus,
as explained above, the axial-taper of the notch 112 can provide
for more efficient flushing of cuttings and cooling of the cutting
face. Furthermore, it is contemplated that the increasing size of
the notch can also help ensure that debris does not jam or clog in
the notch 112 as drilling fluid forces it from the inner surface to
the outer surface.
[0052] Additionally, it is contemplated that the axial-taper of the
notch 112 can provide the notch 112 with increasing size without
reducing the size of the cutting face. It is further contemplated
that an increased surface area of the cutting face can provide for
more efficient drilling. Furthermore, it is contemplated that the
axial-taper of the notch can provide for increased flushing and
cooling, while also not decreasing the volume of crown material at
the inner surface. It is still further contemplated that the
increased volume of crown material at the inner surface can help
increase the drilling life of the drill bit.
[0053] Optionally, in exemplary aspects, it is contemplated that
the crown can define at least one inner flute positioned in fluid
communication with the notch 112. In these aspects, it is
contemplated that the at least one inner flute can extend from the
shank axially along the inner surface of the crown to the notch
112. It is further contemplated that the at least one inner flute
can help direct drilling fluid to the notch 112. In another
optional aspect, it is contemplated that the at least one inner
flute can extend from the shank to the cutting face, or even along
the shank.
[0054] Optionally, in other exemplary aspects, it is contemplated
that the drill bit can comprise at least one outer flute. In these
aspects, it is contemplated that the at least one outer flute can
extend radially from the outer surface toward the inner surface of
the crown. It is contemplated that the at least one outer flute can
help direct drilling fluid along the outer surface of the drill bit
from the notch toward the shank. Optionally, it is contemplated
that the at least one outer flute can extend from the notch 112
axially along the outer surface to the shank. In another optional
aspect, it is contemplated that the at least one outer flute can
extend from the cutting face to the shank, or even along the
shank.
[0055] As mentioned previously, in exemplary aspects, the single
waterway 112 can be a double-tapered waterway. In these aspects,
the notch 112 can have a radial taper in addition to an axial
taper. In some aspects, the second side surface 112b of the notch
112 can taper from the inner surface to the outer surface in a
direction generally clockwise around the circumference of the
cutting face. As used herein, the terms "clockwise" and
"counterclockwise" refer to directions relative to the longitudinal
axis of a drill bit when viewing the cutting face of the drill bit.
Thus, the width of the notch 112 can increase as the notch 112
extends from the inner surface to the outer surface of the crown.
Thus, in some aspects, the width of the notch 112 at the outer
surface can be greater than the width of the notch 112 at the inner
surface. In other words, the circumferential distance between the
first side surface 112a and the second side surface 112b of the
notch 112 at the outer surface can be greater than the
circumferential distance between the first side surface 112a and
the second side surface 112b of the notch 112 at the inner
surface.
[0056] In operation, it is contemplated that the radial taper of
the notch 112 can ensure that the opening of the notch 112 at the
inner surface is smaller than the opening of the notch 112 at the
outer surface of the crown. It is further contemplated that this
difference in opening sizes can increase the velocity of drilling
fluid at the inner surface as it passes to the outside surface of
the crown. Thus, as explained above, it is contemplated that the
radial taper of the notch 112 can provide for more efficient
flushing of cuttings and cooling of the cutting face. Furthermore,
it is contemplated that the increasing width of the notch 112 can
also help ensure that debris does not jam or clog in the notch 112
as drilling fluid forces it from the inner surface to the outer
surface.
[0057] Optionally, in some aspects, the radial taper of the notch
112 can be formed by a tapered second side surface 112b.
Alternatively, in other aspects, it is contemplated that the first
side surface 12a can be tapered. For example, it is contemplated
that the first side surface 12a can taper from the inner surface to
the outer surface in a direction generally counter-clockwise around
the circumference of the cutting face. Optionally, in some aspects,
the first side surface 112a and the second side surface 112b can
both comprise a taper extending from the inner surface to the outer
surface in a direction generally clockwise around the circumference
of the cutting face. In these aspects, it is contemplated that the
radial taper of the second side surface 112b can have a larger
taper than the first side surface 112a in a manner that the width
of the notch 112 increases as the notch 112 extends from the inner
surface to the outer surface.
[0058] Optionally, in exemplary aspects, the top surface 112c of
the notch 112 can taper from the inner surface to the outer surface
in a direction generally from the cutting face toward the shank. In
other words, it is contemplated that the longitudinal dimension of
the notch 112 can increase as the notch 112 extends from the inner
surface to the outer surface of the crown. Thus, in some aspects,
it is contemplated that the longitudinal dimension of the notch 112
at the outer surface can be greater than the longitudinal dimension
of the notch 112 at the inner surface. In other words, it is
contemplated that the notch 112 can extend into the cutting face a
first distance at the inner surface and extend into the cutting
face a second distance at the outer surface, where the second
distance is greater than the first distance.
[0059] In use, it is contemplated that the axial taper of the notch
112 can help ensure that the opening of the notch 112 at the inner
surface is smaller than the opening of the notch at the outer
surface of the crown. It is contemplated that this difference in
opening sizes can increase the velocity of drilling fluid at the
inside surface as it passes to the outer surface of the crown.
Thus, as explained above, it is contemplated that the axial-taper
of the notch 112 can provide for more efficient flushing of
cuttings and cooling of the cutting face. Furthermore, it is
contemplated that the increasing size of the notch 112 can also
help ensure that debris does not jam or clog in the notch 112 as
drilling fluid forces it from the inner surface to the outer
surface.
[0060] In exemplary aspects, it is contemplated that the
double-tapered notch 112 can ensure that the notch 112 increases in
dimension in each axis (i.e., both radially and axially) as it
extends from the inner surface of the drill bit to the outer
surface. The increasing size of the double-tapered notch 112 can
reduce the likelihood of debris lodging within the notch 112, and
thus, increase the drilling performance of the drill bit.
Furthermore, as previously discussed, it is contemplated that the
increasing size of the double-tapered notch 112 can help maximize
the volume of matrix material at the inner surface, and thereby can
increase the life of the drill bit by reducing premature drill bit
wear at the inner surface.
[0061] In exemplary aspects, the drill bits 10 disclosed herein can
be diamond-impregnated bits, with the diamonds impregnated within a
matrix. In these aspects, it is contemplated that each drill bit 10
can comprise a plurality of selected materials, with each material
being provided as a selected weight percentage of the drill bit. It
is contemplated that each drill bit 10 can comprise carbon (not
including diamond) in any desired amount, such as, for example and
without limitation, an amount ranging from about 0.00% to about
7.00% by weight of the drill bit. In exemplary aspects, the carbon
of the drill bits 10 can be provided as at least one of carbon
powder and carbon fibers. It is further contemplated that each
drill bit 10 can comprise chromium in any desired amount, such as,
for example and without limitation, an amount ranging from about
0.00% to about 1.00% by weight of the drill bit. It is further
contemplated that each drill bit 10 can comprise cobalt in any
desired amount, such as, for example and without limitation, an
amount ranging from about 0.00% to about 1.00% by weight of the
drill bit. Optionally, it is further contemplated that each drill
bit 10 can comprise copper in any desired amount, such as, for
example and without limitation, an amount ranging from about 0.00%
to about 30.00% by weight of the drill bit. It is further
contemplated that each drill bit 10 can comprise iron in any
desired amount, such as, for example and without limitation, an
amount ranging from about 50.00% to about 90.00% by weight of the
drill bit. It is further contemplated that each drill bit 10 can
comprise manganese in any desired amount, such as, for example and
without limitation, an amount ranging from about 0.00% to about
8.00% by weight of the drill bit. It is further contemplated that
each drill bit 10 can comprise molybdenum in any desired amount,
such as, for example and without limitation, an amount ranging from
about 0.00% to about 0.20% by weight of the drill bit. It is
further contemplated that each drill bit 10 can comprise nickel in
any desired amount, such as, for example and without limitation, an
amount ranging from about 0.00% to about 6.00% by weight of the
drill bit. It is further contemplated that each drill bit 10 can
comprise silicon in any desired amount, such as, for example and
without limitation, an amount ranging from about 0.00% to about
0.50% by weight of the drill bit. It is further contemplated that
each drill bit 10 can comprise silicon carbide in any desired
amount, such as, for example and without limitation, an amount
ranging from about 0.00% to about 2.00% by weight of the drill bit.
It is further contemplated that each drill bit 10 can comprise
silver in any desired amount, such as, for example and without
limitation, an amount ranging from about 0.00% to about 12.00% by
weight of the drill bit. It is further contemplated that each drill
bit 10 can comprise tin in any desired amount, such as, for example
and without limitation, an amount ranging from about 0.00% to about
6.00% by weight of the drill bit. It is further contemplated that
each drill bit 10 can comprise tungsten in any desired amount, such
as, for example and without limitation, an amount ranging from
about 0.00% to about 41.00% by weight of the drill bit. It is
further contemplated that each drill bit 10 can comprise tungsten
carbide in any desired amount, such as, for example and without
limitation, an amount ranging from about 0.00% to about 35.00% by
weight of the drill bit. It is further contemplated that each drill
bit 10 can comprise zinc in any desired amount, such as, for
example and without limitation, an amount ranging from about 0.00%
to about 24.00% by weight of the drill bit. It is further
contemplated that the matrix of the full face drill bits disclosed
herein can be configured to form supporting structures behind the
diamonds within the drill bits, thereby preventing the polishing of
the impregnated diamonds during operation.
[0062] It is further contemplated to radially vary the composition
of the matrix to provide a more consistent wear across the
operative drilling face of the crown of the drill. In one aspect,
it is contemplated that the crown can be divided between at least
three integrally adjoining sections that extend from the inner
surface of the crown to the outer surface of the crown in a
direction generally normal to the inner surface of the crown. The
first section is generally cylindrical in shape and extends
outwardly from the formed inner surface of the crown to a first
surface spaced radially a desired distance from the inner surface.
The third, outer, section is generally cylindrical in shape and
extends inwardly from the formed outer surface of the crown to a
third surface spaced radially a desired distance from the outer
surface. Finally, in this example, at least one second section is
provided that is generally cylindrical and extends radially between
and is integrally formed thereto the first and second sections. In
one aspect, the at least one second section can comprise a single
second section or a plurality of radially layered second sections.
In this example, at least one of the plurality of radially layered
second sections would have a matrix composition that wears at a
rate that differs from at another of the radially layered second
sections. In an exemplary aspect, as a conventional bit wears more
proximate the inner and outer surfaces of the crown in operation
due to the decreased support of the diamonds or other cutting
elements that are impregnated within the matrix near the respective
inner and outer diameters, it is contemplated that the respective
first and third sections could be formed from a matrix composition
that has a higher wear rate that the at least one second section.
Forming the second section of a matrix material that has a
decreased wear is beneficial as the bit will require less energy
and create a more uniform wear pattern across the crown in
operation.
[0063] In exemplary aspects, and with reference to FIG. 5, the
drill bits disclosed herein can be provided as part of a drilling
system 500. In these aspects, it is contemplated that the drilling
system 500 can comprise a drill head 510, a mast 520, a drill rig
530, and a drill string 550 configured to be secured to and rotated
by the drill rig, as are conventionally known in the art. It is
further contemplated that a drill bit 560 can be operatively
coupled to an end of the drill string 550. For example, it is
contemplated that a drill bit 10 as disclosed herein can be coupled
to the drill string 550. In operation, as the drill string 550 is
rotated and pushed by the drill rig 530, it is contemplated that
the drill bit 560 (corresponding to a drill bit 10 as disclosed
herein) can grind away materials in a formation 570.
[0064] In use, it is contemplated that the absence (or
minimization) of waterway slots or windows in the disclosed drill
bits can increase the strength of the drill bits (as compared to
conventional drill bits having such slots or windows). It is
further contemplated that the drill bits disclosed herein can
permit improved efficiency of flushing and improved cooling of the
drill bit by increasing the velocity of the cooling fluid proximate
the bit face and directing the fluid across the bit face without
losing fluid to the waterway slots, channels, or windows.
[0065] Due to the increased strength and improved flushing
efficiency of the annular drill bits disclosed herein, it is
contemplated that the disclosed annular drill bits can show less
wear and have an increased functional product life compared to
known drill bits. It is further contemplated that the increased
strength and flushing of the disclosed full face drill bits can
permit the manufacture of taller annular crowns, thereby further
extending the functional product life of the drill bits.
Experimental Examples
[0066] In one experimental example, during normal operation, an
annular drill bit as disclosed herein was shown to require about
25% less water than conventional drill bits.
[0067] In another experimental example, during normal operation, an
annular drill bit as disclosed herein was shown to experience a
fluid velocity at its face that is over three times higher than the
velocity experienced at the face of conventional drill bit
designs.
[0068] In still another experimental example, it was shown that a
drill bit having no waterway, as disclosed herein, had a
substantially constant velocity at any impregnation depth.
Exemplary Aspects
[0069] In exemplary aspects, a drill bit for forming a hole in a
formation is provided, the drill bit having a longitudinal axis and
comprising: a shank; an annular crown having a cutting face, an
inner surface, and an outer surface, the full face crown and the
shank cooperating to define an interior space about the
longitudinal axis, wherein the annular crown defines a plurality of
inner channels spaced circumferentially about the inner surface of
the annular crown, wherein the annular crown defines a plurality of
outer channels spaced circumferentially about the outer surface of
the annular crown, and wherein the annular crown completely
circumferentially encloses the interior space.
[0070] In another exemplary aspect, the annular crown does not
comprise a waterway extending radially from the inner surface of
the annular crown to the outer surface of the annular crown. In an
alternative exemplary aspect, the annular crown comprises a single
waterway extending radially from the inner surface of the annular
crown to the outer surface of the annular crown.
[0071] In another exemplary aspect, the annular crown can have a
radial thickness between the inner surface and the outer surface,
wherein each inner channel of the plurality of inner channels has a
radial dimension less than the radial thickness of the annular
crown, and wherein each outer channel of the plurality of outer
channels has a radial dimension less than the radial thickness of
the annular crown.
[0072] In another exemplary aspect, the ratio between the radial
thickness of the annular crown and the radial dimension of the
plurality of inner channels can range from about 1.5:1 to about
3.5:1.
[0073] In another exemplary aspect, the ratio between the radial
thickness of the annular crown and the radial dimension of the
plurality of outer channels can range from about 1.5:1 to about
3.5:1.
[0074] In another exemplary aspect, the radial dimension of the
plurality of inner channels can be greater than the radial
dimension of the plurality of outer channels.
[0075] In another exemplary aspect, the number of inner channels
can be the same as the number of outer channels.
[0076] In another exemplary aspect, the number of inner channels
can be greater than the number of outer channels.
[0077] In another exemplary aspect, the number of inner channels
can be less than the number of outer channels.
[0078] In another exemplary aspect, each outer channel of the
plurality of outer channels can be positioned circumferentially
between sequential inner channels of the plurality of inner
channels.
[0079] In additional exemplary aspects, a drilling system can be
provided, the drilling system comprising: a drill rig; a drill
string configured to be secured to and rotated by the drill rig;
and a drill bit for forming a hole in a formation, the drill bit
having a longitudinal axis and comprising: a shank; an annular
crown having a cutting face, an inner surface, and an outer
surface, the full face crown and the shank cooperating to define an
interior space about the longitudinal axis, wherein the annular
crown defines a plurality of inner channels spaced
circumferentially about the inner surface of the annular crown,
wherein the annular crown defines a plurality of outer channels
spaced circumferentially about the outer surface of the annular
crown, and wherein the annular crown completely circumferentially
encloses the interior space.
[0080] In another exemplary aspect, the annular crown of the drill
bit does not comprise a waterway extending radially from the inner
surface of the annular crown to the outer surface of the annular
crown. In an alternative exemplary aspect, the annular crown
comprises a single waterway extending radially from the inner
surface of the annular crown to the outer surface of the annular
crown.
[0081] In another exemplary aspect, the annular crown of the drill
bit can have a radial thickness between the inner surface and the
outer surface, wherein each inner channel of the plurality of inner
channels has a radial dimension less than the radial thickness of
the annular crown, and wherein each outer channel of the plurality
of outer channels has a radial dimension less than the radial
thickness of the annular crown.
[0082] In another exemplary aspect, the ratio between the radial
thickness of the annular crown of the drill bit and the radial
dimension of the plurality of inner channels of the annular crown
can range from about 1.5:1 to about 3.5:1.
[0083] In another exemplary aspect, the ratio between the radial
thickness of the annular crown of the drill bit and the radial
dimension of the plurality of outer channels of the drill bit can
range from about 1.5:1 to about 3.5:1.
[0084] In another exemplary aspect, the radial dimension of the
plurality of inner channels of the drill bit can be greater than
the radial dimension of the plurality of outer channels of the
drill bit.
[0085] In another exemplary aspect, the number of inner channels of
the drill bit can be the same as the number of outer channels of
the drill bit.
[0086] In another exemplary aspect, the number of inner channels of
the drill bit can be greater than the number of outer channels of
the drill bit.
[0087] In another exemplary aspect, the number of inner channels of
the drill bit can be less than the number of outer channels of the
drill bit.
[0088] In another exemplary aspect, each outer channel of the
plurality of outer channels of the drill bit can be positioned
circumferentially between sequential inner channels of the
plurality of inner channels of the drill bit.
[0089] Although several embodiments of the invention have been
disclosed in the foregoing specification, it is understood by those
skilled in the art that many modifications and other embodiments of
the invention will come to mind to which the invention pertains,
having the benefit of the teaching presented in the foregoing
description and associated drawings. It is thus understood that the
invention is not limited to the specific embodiments disclosed
hereinabove, and that many modifications and other embodiments are
intended to be included within the scope of the appended claims.
Moreover, although specific terms are employed herein, as well as
in the claims which follow, they are used only in a generic and
descriptive sense, and not for the purposes of limiting the
described invention, nor the claims which follow.
* * * * *