Office Action 2: Notice of Allowance (2025-01-30)

CLAIMS:
AMENDMENTS TO THE CLAIMS

Listing of claims:

1\. (Currently Amended) A magnetic coupling mechanism in a downhole flow control tool, comprising:a first chamber configured to receive i) production fluids or ii) injection fluids;
a first component with a plurality of magnets located within the first chamber, and wherein the plurality of magnets are configured in a Halbach Array;
a second chamber ;
a second component with a plurality of magnets located within the second chamber, and
wherein the plurality of magnets are configured in a Halbach Array;
wherein the first chamber and the second chamber share a non-magnetic separation;
wherein the first component is magnetically coupled to the second component by a plurality of strong magnetic flux wherein the downhole flow control tool comprises a valve body with a flow path, an energy harvesting device, an adjustable valve, and a unit controller,
wherein the flow path comprises a first fluid port within a fluid chamber fluidically coupled to a second fluid port via at least one fluid duct,
wherein the energy harvesting device comprises a generator and a turbine assembly,
wherein the turbine assembly is fluidically coupled to the flow path and located between the second fluid port and the fluid chamber, and
wherein the turbine assembly is configured to induce rotation within the generator.

2\. (Original) The magnetic coupling mechanism of claim 1, wherein:
the plurality of magnets in the first component are configured to produce a weak magnetic flux directed away from the non-magnetic separation and a strong magnetic flux directed towards the non-magnetic separation.
3\. (Original) The magnetic coupling mechanism of claim 1, wherein:
the plurality of magnets in the second component are configured to produce a weak magnetic flux directed away from the non-magnetic separation and a strong magnetic flux directed towards the non-magnetic separation.
4\. (Original) The magnetic coupling mechanism of claim 1, wherein:
the first component is configured to axially translate; and
wherein the second component is biased to axially translate by the plurality of strong magnetic flux.
5\. (Original) The magnetic coupling mechanism of claim 1, wherein:
the first component is configured to rotationally translate; and
wherein the second component is biased to rotationally translate by the plurality of strong magnetic flux.
6\. (Original) The magnetic coupling mechanism of claim 1, wherein:
the first component and the second component are separated by the non-magnetic separation.

7-8. (Cancelled)

9\. (Currently Amended) The magnetic coupling mechanism of claim 1,wherein the first component and the second component are located within the energy harvesting device.

10\. (Currently Amended) The magnetic coupling mechanism of claim 1,wherein:the adjustable valve comprises a drive mechanism and a stem head;
wherein the drive mechanism is communicatively coupled to the unit controller;
wherein the stem head is located within a-the fluid chamber; and
wherein the drive mechanism is configured to position the stem head in i) a first position, ii) a second position, or iii) a third position.

11\. (Currently Amended) The magnetic coupling mechanism of claim 10, wherein the turbine assembly comprises a Halbach Array of magnets.

12\. (Currently Amended) A method of actuating a downhole mechanism by a magnetic coupling within a downhole tool assembly, comprising:positioning a first component in a first chamber, wherein the first component comprises a plurality of magnets, wherein the plurality of magnets are configured to produce a strong magnetic flux on a first side;

positioning a second component into a second chamber, wherein the second component comprises a plurality of magnets, wherein the plurality of magnets are configured to produce a strong magnetic flux on a second side;
wherein the first chamber and the second chamber are coupled by a non-magnetic separation;
wherein the first side ofthe first component is oriented towards the non-magnetic separation;
wherein the second side of the second component is oriented towards the non-magnetic separation;
magnetically coupling the strong magnetic flux on the first side of the first component to the strong magnetic flux on the second side of the second component; and
actuating the second component with the first component,
wherein the downhole tool assembly comprises a valve body with a flow path, an energy harvesting device, an adjustable valve, and a unit controller,
wherein the flow path comprises a first fluid port within a fluid chamber fluidically coupled to a second fluid port via at least one fluid duct,
wherein the energy harvesting device comprises a generator and a turbine assembly,
wherein the turbine assembly is fluidically coupled to the flow path and located between the second fluid port and the fluid chamber, and
wherein the turbine assembly is configured to induce rotation within the generator.

13\. (Currently Amended) The method of claim 12, wherein:the first chamber comprises a-the flow path for wellbore fluids.

14\. (Original) The method of claim 13, further comprising:rotating the first component with a flowrate of wellbore fluids; and
generating electrical power within the second chamber in response to a rotational motion of the second component.

15\. (Currently Amended) The method of claim 12, wherein:
 the second chamber comprises a-the flow path for wellbore fluids.

16\. (Original) The method of claim 13, further comprising:positioning a first component with an actuator into i) a first position, ii) a second position, or iii) a third position; and
changing a flowrate of wellbore fluids within the flow path with a second component in response to the position of the first component.

17\. (Original) The method of claim 13, wherein the wellbore fluids are i) production fluids or ii) injection fluids.

18\. (Currently Amended) A downhole flow control tool system, comprising:a first component in a first chamber, wherein the first component comprises a plurality of magnets, wherein the plurality of magnets are configured to produce a strong magnetic flux on a first side;

a second component in a second chamber, wherein the second component comprises a plurality of magnets, wherein the plurality of magnets are configured to produce a strong magnetic flux on a second side, and wherein the first chamber and the second chamber are coupled by a non-magnetic separation;
a magnetic coupling by the strong magnetic flux on the first side of the first component and the strong magnetic flux on the second side of the second component; and wherein the magnetic coupling is configured to actuate the second component with the first component,
a valve body with aflow path;
an energy harvesting device;
an adjustable valve; and
a unit controller,
wherein the flow path comprises a first fluid port within a fluid chamber fluidically coupled to a second fluid port via at least one fluid duct,
wherein the energy harvesting device comprises a generator and a turbine assembly,
wherein the turbine assembly is fluidically coupled to the flow path and located between the second fluid port and the fluid chamber, and
wherein the turbine assembly is configured to induce rotation within the generator.

19\. (Currently Amended) The downhole flow control tool system of claim 18, wherein actuating the second component with the first component further comprises:rotating the first component within a-the flow path with a flowrate of wellbore fluids; and
generating electrical power within the second chamber in response to a rotational motion of the second component.

20\. (Currently Amended) The downhole flow control tool system of claim 18, wherein actuating the second component with the first component further comprises:positioning a-the first component with an actuator into i) a first position, ii) a second position,or iii) a third positio;
and changing a flowrate of wellbore fluids within a-the flow path with a-thesecond component in response to the position of the first component.

OFFICE ACTION:
EXAMINER'S COMMENT
Notice of AIA  Status
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
Reasons for Allowance
Claims 1-6 and 9-20 are allowed.
The following is an examiner’s statement of reasons for allowance:
The closest prior art to claims 1, 12 and 18 is Agnihotri et al. (U.S. Publication No. 20180320482).
Claims 1, 12 and 18 now include all of the limitations of claim 8, as well as intervening claim 7,  which was indicated as having allowable subject matter detailed in the Non-final Rejection mailed on 08/28/2024. As such, claims 1, 12 and 18 are now allowable. See Allowable Subject Matter section in the Non-final Rejection mailed on 08/28/2024 for further explanation regarding allowability.
Any comments considered necessary by applicant must be submitted no later than the payment of the issue fee and, to avoid processing delays, should preferably accompany the issue fee.  Such submissions should be clearly labeled “Comments on Statement of Reasons for Allowance.”
Conclusion

APPLICANT REBUTTAL: REMARKS/ARGUMENTS Status of Claims:
Claims 1, 9-13, 15, and 18-20 are amended herein.
Claims 7-8 are canceled herein.
Thus, claims 1-6 and 9-20 are currently pending in this application.
The amendments are supported by the original specification, for example, Fig. 3. Accordingly, no new matter has been added by way of present submissions. Applicant hereby requests further examination and reconsideration of the presently claimed application.
Information Disclosure Statement
Applicant thanks the Examiner for review and consideration of the Information Disclosure Statement filed on March 8, 2024.
Examiner Interview
Applicant thanks the Examiner for the courtesy of the telephonic interview conducted on November 8, 2024, the substance of which is accurately reflected in the amendments and related remarks set forth in this response.
Allowable Subject Matter
Applicant thanks the Examiner for indicating that claims 8 and 9 would be allowable if rewritten to overcome the rejections under 35 U.S.C. 112(b) and to include all of the limitations of the base claim and any intervening claims. Independent claims 1, 12, and 18 are amended herein to incorporate the allowable subject matter of claim 8 including intervening claim 7.
Objections - Drawings
The drawings were objected to as failing to show every feature specified in the claims. This objection is moot in view of the claim amendments.
Claim Rejections - 35 USC § 112
Claims 11, 15, and 20 were rejected under 35 U.S.C. 112(a) as failing to comply with the written description requirement. Claims 1-11, 15, and 20 were rejected under 35 U.S.C. 112(b) as being indefinite. These rejections are respectfully traversed but are moot in view of the claim amendments.
Claim Rejections - 35 USC § 102
Claims 1-6, 12-14, and 16-19 were rejected under 35 U.S.C. 102(a)(1) as being anticipated by Agnihotri et al., U.S. Patent Application Publication No. 2018/0320482 (hereinafter "Agnihotri"). These rejections are respectfully traversed but are moot in view of the claim amendments.
Claim Rejections - 35 USC § 103
Claims 7 and 10 were rejected under 35 U.S.C. 103 as being unpatentable over Agnihotri in view of Frosell et al., U.S. Patent Application Publication No. 2019/0010783 (hereinafter "Frosell"). These rejections are respectfully traversed but are moot in view of the claim amendments.
CONCLUSION


CITED REFERENCE SUMMARIES: Ref US20180320482: Claims:
What is claimed is: 1. A magnetic coupling of a downhole tool comprising: a first annular array of magnetic sections; a second annular array of magnetic sections coupled to the first annular array by a magnetic field that transfers rotational motion from the first annular array to the second annular array; and a barrier disposed between the first annular array and the second annular array, the barrier including an erosion-resistant layer. 2. The magnetic coupling of claim 1, wherein: the first annular array has a first outer diameter; the second annular array has a second outer diameter approximately equal to the first outer diameter; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately parallel to the common axis of rotation. 3. The magnetic coupling of claim 1, wherein: the first annular array has an inner diameter; the second annular array has an outer diameter smaller than the inner diameter; the second annular array is disposed within the inner diameter of the first annular array; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately perpendicular to the common axis of rotation. 4. The magnetic coupling of claim 1, wherein the erosion-resistant layer includes a layer of titanium. 5. The magnetic coupling of claim 1, wherein the second annular array comprises a plurality of permanent magnets. 6. The magnetic coupling of claim 5, wherein a magnet among the plurality of permanent magnets is a samarium cobalt magnet. 7. The magnetic coupling of claim 1, wherein the second annular array comprises a plurality of electromagnetic coils. 8. The magnetic coupling of claim 7, further comprising a bootstrap circuit for energizing the plurality of electromagnetic coils, the bootstrap circuit comprising: a battery; and a first diode coupled to the battery, the first diode permitting the battery to supply electrical current to the plurality of electromagnetic coils. 9. The magnetic coupling of claim 8, the bootstrap circuit further comprising: a current source coupled to the second annular array, the current source configured to transform rotation of the second annular array into electrical current; and a second diode coupled to the current source, the second diode permitting the current source to supply electrical current to the plurality of electromagnetic coils. 10. A drilling system comprising: a drill string; a magnetic coupling located within the drill string, the magnetic coupling including: a first annular array of magnetic sections; a second annular array of magnetic sections coupled to the first annular array by a magnetic field that transfers rotational motion from the first annular array to the second annular array; a barrier disposed between the first annular array and the second annular array, the barrier having an erosion-resistant layer; a motor coupled to the first annular array; and a load coupled to the second annular array. 11. The drilling system of claim 10, wherein: the first annular array has a first outer diameter; the second annular array has a second outer diameter approximately equal to the first outer diameter; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately parallel to the common axis of rotation. 12. The drilling system of claim 10 wherein: the first annular array has an inner diameter; the second annular array has an outer diameter smaller than the inner diameter; the second annular array is disposed within the inner diameter of the first annular array; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately perpendicular to the common axis of rotation. 13. The drilling system of claim 10, wherein the erosion-resistant layer includes a layer of titanium. 14. The drilling system of claim 10, wherein the second annular array comprises a plurality of permanent magnets. 15. The drilling system of claim 10, wherein a magnet among the plurality of permanent magnets is a samarium cobalt magnet. 16. The drilling system of claim 10, wherein the second annular array comprises a plurality of electromagnetic coils. 17. The drilling system of claim 16, further comprising a bootstrap circuit for energizing the plurality of electromagnetic coils, the bootstrap circuit comprising: a battery; and a first diode coupled to the battery, the first diode permitting the battery to supply electrical current to the plurality of electromagnetic coils. 18. The drilling system of claim 17, the bootstrap circuit further comprising: a current source coupled to the plurality of electromagnetic coils; and a second diode coupled to the current source, the second diode permitting the current source to supply current to the plurality of electromagnetic coils. 19. The drilling system of claim 10, wherein the load is a generator. 20. A method of bootstrapping a magnetic coupling of a downhole tool, comprising: rotating a first annular array of magnetic sections in a magnetic coupling; supplying current from a battery to an electromagnetic coil located within a second annular array of magnetic sections in the magnetic coupling; coupling the first annular array to the second annular array using a magnetic field produced by the electromagnetic coil; transferring rotational motion from the first annular array to the second annular array using the magnetic field; transferring rotational motion from the second annular array to an alternating current (AC) source configured to transform rotational motion into electrical current; and supplying electrical current from the AC source to the electromagnetic coil. 21. The method of claim 20, wherein the magnetic coupling includes a barrier disposed between the first annular array and the second annular array, the barrier including an erosion-resistant layer. 22. The method of claim 20, wherein: the first annular array has a first outer diameter; the second annular array has a second outer diameter approximately equal to the first outer diameter; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately parallel to the axis of rotation. 23. The method of claim 20, wherein: the first annular array has an inner diameter; the second annular array has an outer diameter smaller than the inner diameter; the second annular array is disposed within the inner diameter of the first annular array; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately perpendicular to the axis of rotation.
A magnetic coupling of a downhole tool comprising: a first annular array of magnetic sections; a second annular array of magnetic sections coupled to the first annular array by a magnetic field that transfers rotational motion from the first annular array to the second annular array; and a barrier disposed between the first annular array and the second annular array, the barrier including an erosion-resistant layer.
The magnetic coupling of claim 1, wherein: the first annular array has a first outer diameter; the second annular array has a second outer diameter approximately equal to the first outer diameter; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately parallel to the common axis of rotation.
The magnetic coupling of claim 1, wherein: the first annular array has an inner diameter; the second annular array has an outer diameter smaller than the inner diameter; the second annular array is disposed within the inner diameter of the first annular array; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately perpendicular to the common axis of rotation.
The magnetic coupling of claim 1, wherein the erosion-resistant layer includes a layer of titanium.
The magnetic coupling of claim 1, wherein the second annular array comprises a plurality of permanent magnets.
The magnetic coupling of claim 5, wherein a magnet among the plurality of permanent magnets is a samarium cobalt magnet.
The magnetic coupling of claim 1, wherein the second annular array comprises a plurality of electromagnetic coils.
The magnetic coupling of claim 7, further comprising a bootstrap circuit for energizing the plurality of electromagnetic coils, the bootstrap circuit comprising: a battery; and a first diode coupled to the battery, the first diode permitting the battery to supply electrical current to the plurality of electromagnetic coils.
The magnetic coupling of claim 8, the bootstrap circuit further comprising: a current source coupled to the second annular array, the current source configured to transform rotation of the second annular array into electrical current; and a second diode coupled to the current source, the second diode permitting the current source to supply electrical current to the plurality of electromagnetic coils.
A drilling system comprising: a drill string; a magnetic coupling located within the drill string, the magnetic coupling including: a first annular array of magnetic sections; a second annular array of magnetic sections coupled to the first annular array by a magnetic field that transfers rotational motion from the first annular array to the second annular array; a barrier disposed between the first annular array and the second annular array, the barrier having an erosion-resistant layer; a motor coupled to the first annular array; and a load coupled to the second annular array.
The drilling system of claim 10, wherein: the first annular array has a first outer diameter; the second annular array has a second outer diameter approximately equal to the first outer diameter; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately parallel to the common axis of rotation.
The drilling system of claim 10 wherein: the first annular array has an inner diameter; the second annular array has an outer diameter smaller than the inner diameter; the second annular array is disposed within the inner diameter of the first annular array; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately perpendicular to the common axis of rotation.
The drilling system of claim 10, wherein the erosion-resistant layer includes a layer of titanium.
The drilling system of claim 10, wherein the second annular array comprises a plurality of permanent magnets.
The drilling system of claim 10, wherein a magnet among the plurality of permanent magnets is a samarium cobalt magnet.
The drilling system of claim 10, wherein the second annular array comprises a plurality of electromagnetic coils.
The drilling system of claim 16, further comprising a bootstrap circuit for energizing the plurality of electromagnetic coils, the bootstrap circuit comprising: a battery; and a first diode coupled to the battery, the first diode permitting the battery to supply electrical current to the plurality of electromagnetic coils.
The drilling system of claim 17, the bootstrap circuit further comprising: a current source coupled to the plurality of electromagnetic coils; and a second diode coupled to the current source, the second diode permitting the current source to supply current to the plurality of electromagnetic coils.
The drilling system of claim 10, wherein the load is a generator.
A method of bootstrapping a magnetic coupling of a downhole tool, comprising: rotating a first annular array of magnetic sections in a magnetic coupling; supplying current from a battery to an electromagnetic coil located within a second annular array of magnetic sections in the magnetic coupling; coupling the first annular array to the second annular array using a magnetic field produced by the electromagnetic coil; transferring rotational motion from the first annular array to the second annular array using the magnetic field; transferring rotational motion from the second annular array to an alternating current (AC) source configured to transform rotational motion into electrical current; and supplying electrical current from the AC source to the electromagnetic coil.
The method of claim 20, wherein the magnetic coupling includes a barrier disposed between the first annular array and the second annular array, the barrier including an erosion-resistant layer.
The method of claim 20, wherein: the first annular array has a first outer diameter; the second annular array has a second outer diameter approximately equal to the first outer diameter; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately parallel to the axis of rotation.
The method of claim 20, wherein: the first annular array has an inner diameter; the second annular array has an outer diameter smaller than the inner diameter; the second annular array is disposed within the inner diameter of the first annular array; the first annular array and the second annular array are configured to rotate about a common axis of rotation; and the magnetic field is oriented approximately perpendicular to the axis of rotation.