Reamer with polycrystalline diamond compact inserts

A reamer device that uses polycrystalline diamond compact (PDC) cutting elements mounted to the reamer blades. The device includes a body that defines a cutting face, a gage region and an extended end, and includes multiple blades disposed along the gage region of the body. Each of the multiple blades multiple planar surfaces, and a plurality of cutting elements positioned along the length of each of the multiple blades. The cutting elements disposed along second and third planar surfaces of each blade being slightly offset from the other blades such that in application the rotating multiple blades cause an upwardly spiraling effect.

CROSS REFERENCES TO RELATED APPLICATIONS

U.S. Provisional Application for Patent No. 62/129,506, filed Mar. 6, 2015, with title “Reamer with Polycrystalline Diamond Compact Inserts” which is hereby incorporated by reference. Applicant claims priority pursuant to 35 U.S.C. Par. 119(e)(i).

STATEMENTS AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

Not Applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is generally related to drilling methods, and more particularly, to drilling methods and devices used in drilling. More particularly, this application relates to a reamer device for using polycrystalline diamond compact (PDC), in reamers and other drilling equipment.

2. Brief Description of Prior Art

Many drilling processes for drilling wells for oil and gas production are currently known and used. Methods and devices for using polycrystalline diamond compact (PDC) inserts in reamers, and other drilling equipment used in drilling are similarly known.

The PDC drilling relevant to the present invention is generally set up with PDC cutters mounted to blades. Many methods for defining the setting patterns for such PDC cutters are known in the art. The goals to be achieved with respect to any PDC cutter pattern include: enhancing the force balancing of the reamer; improving the cleaning of the face; evening out the wear of the cutters across the face; and, improving the durability of the reamer.

While the prior art patterns and methods for setting the locations of PDC cutters provide drill equipment with satisfactory performance, it is nonetheless recognized that there is room for improvement, especially in connection with providing a reamer having better performance ability. The present invention proposes a pattern and method for setting the locations of PDC cutters in drilling equipment that provides for improved cutting and durability.

SUMMARY OF THE INVENTION

The preferred embodiment is directed to a reamer device that uses polycrystalline diamond compact (PDC) cutting elements mounted to the reamer blades. The PDC device generally defines a multiple blade design having a plurality of PDC cutting elements set along the length of each of the blades. The device body includes a cutting face, a gage region and an extended end. Each of the blades are disposed at the cutting face region, and extend through the gage region and end at the extended end.

Each of the blades define a first slanted top surface that is approximately parallel with a first slanted surface of the device body. The blade further defines a second top surface that includes a first planar surface having a first height, a shoulder, and a second planar surface having a second height. The blade further defines a third top surface that is approximately parallel with a third slanted surface of the device body.

A plurality of cutting elements are positioned along the length of each of the blades. The first slanted top surface may include round-shaped PDC cutters set in a staggered pattern with rows of cutters offset in a lateral direction from adjacent rows, to provide full coverage of the first slanted top surface. The first planar surface similarly includes round-shaped PDC cutters in a staggered pattern with rows of cutters offset in a lateral direction from adjacent rows, to provide full coverage of the first planar surface. The second planar surface preferably includes substantially round-shaped PDC cutters in a linear, tracking pattern, one behind another in a row in the direction of reamer rotation. Similarly, the third slanted top surface includes substantially round-shaped PDC cutters in a linear, tracking pattern, one behind another in a row in the direction of reamer rotation.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is directed to drilling equipment that use polycrystalline diamond compact (PDC) cutting elements mounted to blades. The present PDC device generally defines a multiple blade design having a plurality of PDC cutting elements set along the length of each of the blades. The multiple blades having the plurality of PDC cutting elements effectively form the cutting face of the device. In the broadest context, the PDC cutting device of the present invention consists of components configured and correlated with respect to each other so as to attain the desired objective.

According to embodiments of the present invention, the device designated as numeral10includes a reamer body12having a longitudinal axis14extending axially therethrough (seeFIG. 3). The body12includes a first connector15and a second connector17. The first connector15and second connector17of the device10can be threaded connectors for threaded coupling with different components in a drilling operation.

As illustrated, the first and second connectors15,17can each be a female thread that can work cooperatively with a male thread of a drilling component to couple the device10to a section of the drilling component. Similarly, the first and second connectors15,17can be a male thread that can work cooperatively with a female thread of a drilling component to couple the device to that section of the drilling component.

In the illustrations, blades1,2,3,4,5and6comprise the multiple blades of the device10. Each of the blades are similarly constructed having the same embodiments. As such, only the elements on the first blade1will be described, it being understood that the other multiple blades, blades2,3,4,5and6in the drawings, are substantially identical except as will be discussed, and disclosed inFIG. 5. Further, while the device illustrated includes six (6) blades, it should be understood the device may be constructed with less or more blades all having the same embodiments as will be disclosed.

For purposes of illustration, the reamer body12can be described as including an upper face20, a gage region25and an extended end30that is adjacent the second connector17. The extended end30opposite from the upper face20which is adjacent the first connector15.

The upper face20refers to the area of the cutting device10substantially facing in the opposite direction of reaming. The gage region25of the device10having a generally conical or bullet-shaped gage region25, may cut or maintain the gage, or outer diameter of the wellbore being reamed, and thus may engage a sidewall of the wellbore.

The cutting device10includes multiple blades that as will be explained, each continue from the upper face20region, and extend through the gage region25and end at the extended end30.

The gage region25of the body12has a substantially cylindrical configuration from which the multiple blades radially extend. As illustrated, the substantially cylindrical region does not account for the blades themselves but just considers the body structure from which the blades extend. However, as will be described, a critical feature of the present device is how each of the blades similarly extend the length of the device10and generally follows the conical-shaped body structure or outline of the body12.

The body structure of the reamer body12, for purposes of illustration (seeFIG. 1), are divided in a first section “S1” that includes the upper face20region, a second section “S2” that generally defines the upper portion of the gage region25, and a third section “S3” that includes the remaining portion of the gage region25and extends to the extended end30.

The first section S1defines a first end31A and a second end31B. As shown, the body12of the first section S1defines a sloped area31C. Accordingly, the first end31A has a circumference that is less than the circumference at point31B that generally defines the sloped surface31C. The first section S1surface being sloped from the first end31A to the second end31B.

The second section S2defines a first end32A (adjacent the second end31B of the first section S1) and a second end32B. More particularly, the second section S2defines a generally planar surface32C.

The third section S3defines a first end33A (adjacent the second end32B of the second section S2) and a second end33B, with a distinct shoulder34at the junction of sections S2and S3. As illustrated, the first end33A has a circumference that is greater than the circumference at point33B such that the third section S3defines a sloped surface33C that generally extends from point33A to point33B. The third section S3being downwardly sloped from the first end33A to the second end33B.

The reamer body12further includes a plurality of blow holes7. More particularly, the reamer body12includes a blow hole7in the second and third sections S2and S3, respectively, of the body12and disposed between each of the multiple blades.

As described, the reamer body12transitions uniformly from the cutting face20to the extended end30by a radiused, curved, angled or other shaped transition.

The multiple blades are similarly disposed. In particular, each of the blades extend the approximate length L of the gage region25(sections S1and S2) of the reamer body12and generally follow the orientation of the surfaces32C,33C. Each of the blades can be integral to the body12, or physically attached and separated from the body12with, for example, bolts (not shown).

Referring to blade1, as illustrated, the blade generally extends from point32A to point33B (sections S2and S3) of the reamer body12. However, it is also within the scope of the present disclosure that the blades may extend into the upper face (first section S1).

In the second section S2, the blade1defines a first planar surface40that extends the approximate length of section S2. The first planar surface40further includes a shoulder portion41that junctions with a second planar surface42that defines a portion of the first planar surface40. The second planar surface42extending from the shoulder41to the defined end32B of the second section S2.

As illustrated, the upper end of the blade is approximately adjacent to point32A and includes a wall44that is radiused or otherwise transitioned from the base of the blade (the reamer body) to point33B adjacent the extended end30. For example, the blade1may include a sloped and/or substantially perpendicular wall extending the reamer body12from point32A to point33B. The portion of the blade in section S2(upper end) having a first height or distance between the blade's surface40and planar surface32C of the body. The selected portion of the blade in section S3(lower end) having a second height or distance between the blade's surface50and planar surface33C of the body such that, as already described, each blade defines a sloped wall that is perpendicular to the reamer body12.

The first planar surface40includes round-shaped PDC cutters45in a staggered pattern with rows of cutters offset in a lateral direction from adjacent rows. The defined second planar surface42preferably includes substantially round-shaped PDC cutters46in a linear, tracking pattern, one behind another in a row in the direction of reamer rotation.

The blade further defines a third planar surface50that extends from point33A to point33B. The third planar surface50defines an edge51that extends the length of the third planar surface. The edge51being sized and shaped like the second planar surface42, and is configured as a continuation of the second planar surface42defined in the second section S2. The edge51preferably includes substantially round-shaped PDC cutters55in a linear, tracking pattern, one behind another in a row in the direction of reamer rotation.

FIG. 5is an illustration that focuses on the gage region25for each of the blades1,2,3,4,5,6, and particularly shows the edge51on each of the blades in a side-by-side orientation in order to better see the positioning of the cutting elements55on each of the blades.

As illustrated the cutting elements55on each blade is slightly offset from the cutting elements on the adjacent blade, such that the elements55on blade1are not in line with the cutting elements55on blade2, and blade2cutting elements are similarly not in line with the cutting elements on blade3and so on.

In the preferred embodiment, each row of cutters are shifted approximately 150 thousands of an inch toward the upper end “UE” which is adjacent the first planar surface40. With this orientation, during application, the cutting elements55of the rotating blades appear to continuously spiral up to the approximate upper face20of the body12. The Applicant has found this spiraling effect results in a more efficient drilling.

Each blade therefore includes an area that is defined by the second planar surface42and the edge51that includes a continuous row of round-shaped PDC cutters (cutters46and55) one behind another in the direction of reamer rotation.

As generally described, a plurality of cutting elements45,46and55are positioned on each of the surfaces40,42and50of the blades. The cutting elements can be made in a variety of shapes and configurations. For example, the PDC cutters45can be round, square, rectangular or any other geometric configuration. Similarly, the cutters46and55can be of any geometric configuration as well. The PDC cutters can further have any size corresponding with the length, diameter, and wall thickness of the reamer device10.

Generally, the cutting elements preferred in the present invention have either a round shape or, in some instances, a more elongated, substantially round shape. The cutting elements commonly comprise of a super abrasive material, commonly referred to as “polycrystalline diamond compact” (PDC) cutting elements or cutters. The plurality of PDC cutting elements may be provided within cutting element pockets generally designated60formed in rotationally leading surfaces of each of the multiple blades.

As illustrated, the first planar surface40includes round-shaped PDC cutters45set in a staggered pattern with rows offset in a lateral direction from adjacent rows, to provide full coverage of the first planar surface40.

The second planar surface42includes round-shaped PDC cutters46provided within cutting element pockets60in a linear, tracking pattern, one behind another in a row in the direction of reamer rotation. Similarly, the third planar surface50, and more particularly edge51of surface50, includes substantially round-shaped PDC cutters55provided within cutting element pockets60in a linear, tracking pattern, one behind another in a row in the direction of reamer rotation.

As such, the plurality of cutting elements extend the length L of the multiple blades extending from the approximate upper face20along the gage region25to the extended end30in the various patterns described. It is now further understood that each of the PDC cutters provided on each of the multiple blades as disclosed, are positioned at a same radial distance from the axis14of the reamer body12as corresponding ones of the PDC cutters on blade1.

The PDC cutters may be substantially flush with the surface as with the cutters provided on the first planar surface40, or the PDC cutters may be exposed as depicted on the surfaces42and50in order to enhance the reamer action.

Although the above description contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. As such, it is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the claims.

It would be obvious to those skilled in the art that modifications may be made to the embodiments described above without departing from the scope of the present invention. Thus the scope of the invention should be determined by the appended claims in the formal application and their legal equivalents, rather than by the examples given.