Abstract: A robust transmission element for transmitting information between downhole tools, such as sections of drill pipe, in the presence of hostile environmental conditions, such as heat, dirt, rocks, mud, fluids, lubricants, and the like. The transmission element maintains reliable connectivity between transmission elements, thereby providing an uninterrupted flow of information between drill string components. A transmission element is mounted within a recess proximate a mating surface of a downhole drilling component, such as a section of drill pipe. The transmission element may include an annular housing forming a trough, an electrical conductor disposed within the trough, and an MCEI material disposed between the annular housing and the electrical conductor.

Abstract: Apparatus and methods to improve signal coupling in downhole inductive transmission elements to reduce the dispersion of magnetic energy at the tool joints and to provide consistent impedance and contact between transmission elements located along the drill string. A transmission element for transmitting information between downhole tools is disclosed in one embodiment of the invention as including an annular core constructed of a magnetically conductive material. The annular core forms an open channel around its circumference and is configured to form a closed channel by mating with a corresponding annular core along an annular mating surface. The mating surface is polished to provide improved magnetic coupling with the corresponding annular core. An annular conductor is disposed within the open channel.

Abstract: A transmission line assembly for transmitting information along a downhole tool comprising a pin end, a box end, and a central bore traveling between the pin end and the box end, is disclosed in one embodiment of the invention as including a protective conduit. A transmission line is routed through the protective conduit. The protective conduit is routed through the central bore and the ends of the protective conduit are routed through channels formed in the pin end and box end of the downhole tool. The protective conduit is elastically forced into a spiral or other non-linear path along the interior surface of the central bore by compressing the protective conduit to a length within the downhole tool shorter than the protective conduit.

Abstract: A robust transmission element for transmitting information between downhole tools, such as sections of drill pipe, in the presence of hostile environmental conditions, such as heat, dirt, rocks, mud, fluids, lubricants, and the like. The transmission element maintains reliable connectivity between transmission elements, thereby providing an uninterrupted flow of information between drill string components. A transmission element is mounted within a recess proximate a mating surface of a downhole drilling component, such as a section of drill pipe. To close gaps present between transmission elements, transmission elements may be biased with a “spring force,” urging them closer together.

Abstract: An expandable eccentric reamer for placement in a drill string up-hole of a conventional drill bit. The reamer blade is actuated by drilling fluid pressure to radially extend to a drill out diameter greater than a pass-through diameter. The reamer body is shaped to have an eccentric outer surface configuration to accommodate the reamer blade therein. The reamer blade acts as a piston arm in response to drilling fluid pressure and moves along a shaft anchored in a hump region that forms an eccentricity in the outer surface configuration of the body. The reamer blade has an outer edge configuration that positions the cutters thereon to prevent them from engaging a casing of a well borehole upon deployment.

Abstract: Apparatus and methods for integrating transmission cable into the body of selected downhole tools, such as drilling jars, having variable or changing lengths. A wired downhole-drilling tool is disclosed in one embodiment of the invention as including a housing and a mandrel insertable into the housing. A coiled cable is enclosed within the housing and has a first end connected to the housing and a second end connected to the mandrel. The coiled cable is configured to stretch and shorten in accordance with axial movement between the housing and the mandrel. A clamp is used to fix the coiled cable with respect to the housing, the mandrel, or both, to accommodate a change of tension in the coiled cable.

Abstract: A robust data transmission element for transmitting information between downhole components, such as sections of drill pipe, in the presence of hostile environmental conditions, such as heat, dirt, rocks, mud, fluids, lubricants, and the like. The data transmission element components include a generally U-shaped annular housing, a generally U-shaped magnetically conductive, electrically insulating element such as ferrite, and an insulated conductor. Features on the magnetically conducting, electrically insulating element and the annular housing create a pocket when assembled. The data transmission element is filled with a polymer to retain the components within the annular housing by filling the pocket with the polymer. The polymer can bond with the annular housing and the insulated conductor but preferably not the magnetically conductive, electrically insulating element.

Abstract: A transmission line for downhole tools that make up all or part of a tool string for drilling and production of oil, gas, and geothermal wells that can withstand the dynamic gravitational forces and other accelerations associated with downhole excavations. The transmission line has a metal tube, or outer conductor, that houses a coaxial wire inner conductor. A non-metallic dielectric material is interposed between the inner and outer conductors. The outer and inner conductors and the dielectric are sufficiently compressed together so that independent motion between them is abated. Compression of the components of the transmission line may be achieved by drawing the transmission through one or more dies in order to draw down the outer conductor onto the dielectric, or by expanding the inner conductor against the dielectric using a mandrel or hydraulic pressure. Non-metallic bead segments may be used in aid of the compression necessary to resist the dynamic forces and accelerations of drilling.

Abstract: A coaxial cable electrical connector more specifically an internal coaxial cable connector placed within a coaxial cable and its constituent components. A coaxial cable connector is in electrical communcation with an inductive transformer and a coaxial cable. The connector is in electrical communication with the outer housing of the inductive transfonner. A generally coaxial center conductor, a portion of which could be the coil in the inductive transformer, passes through the connector, is electrically insulated from the connector, and is in electrical communication with the conductive care of the coaxial cable. A plurality of bulbous pliant tabs on the coaxial cable connector mechanically engage the inside diameter of the coaxial cable thus grounding the transformer to the coaxial cable. The coaxial cable and inductive transformer are disposed within downhole tools to transmit electrical signals between downhole tools within a drill string.

Abstract: The present invention is generally directed to a tool for obtaining downhole measurements and methods of using such a tool. In one illustrative embodiment the tool comprises a body, at least one strain gauge cavity in the body, the strain gauge cavity having a strain gauge mounting surface that is located at a position such that a region of approximately zero strain due to at least one downhole operating condition exists on the mounting surface when the tool is subjected to downhole operating conditions, and a strain gauge operatively coupled to the mounting face above the region of approximately zero strain.

Abstract: An electrical contact system for transmitting information across tool joints while minimizing signal reflections that occur at the tool joints includes a first electrical contact comprising an annular resilient material. An annular conductor is embedded within the annular resilient material and has a surface exposed from the annular resilient material. A second electrical contact is provided that is substantially equal to the first electrical contact. Likewise, the second electrical contact has an annular resilient material and an annular conductor. The two electrical contacts configured to contact one another such that the annular conductors of each come into physical contact. The annular resilient materials of each electrical contact each have dielectric characteristics and dimensions that are adjusted to provide desired impedance to the electrical contacts.

Abstract: A robust transmission element for transmitting information between downhole tools, such as sections of drill pipe, in the presence of hostile environmental conditions, such as heat, dirt, rocks, mud, fluids, lubricants, and the like. The transmission element maintains reliable connectivity between transmission elements, thereby providing an uninterrupted flow of information between drill string components. A transmission element is mounted within a recess proximate a mating surface of a downhole drilling component, such as a section of drill pipe. To close gaps present between transmission elements, transmission elements may be biased with a “spring force,” urging them closer together.

Abstract: A drill pipe having a box end having a tapered thread, and an internal shoulder and an external face for engagement with a drill pipe pin end having a tapered mating thread, and an external shoulder and an external face adapted for data acquisition or transmission. The relative dimensions of the box and pin ends are precisely controlled so that when the tool joint is made up, a repeatable reference plane is established for transmitting power and tuning downhole sensors, transducers, and means for sending and receiving data along the drill string. When the power or data acquisition and transmission means are located in the tool joint, the dimensions of the tool joint are further proportioned to compensate for the loss of cross-sectional area in order maintain the joints ability to sustain nominal makeup torque.

Abstract: The present invention provides a superhard polycrystalline diamond or diamond-like element with greatly improved resistance to thermal degradation without loss of impact strength. Collectively called PCD elements, these elements are formed with a binder-catalyzing material in a high-temperature, high-pressure process. The PCD element has a plurality of partially bonded diamond or diamond-like crystals forming at least one continuous diamond matrix, and the interstices among the diamond crystals forming at least one continuous interstitial matrix containing a catalyzing material. The element has a working surface and a body, where a portion of the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and the remaining interstitial matrix contains the catalyzing material.

Abstract: Disclosed is a method for manufacturing a polycrystalline diamond or diamond-like element with greatly improved wear resistance without loss of impact strength. These elements are formed with a binder-catalyzing material in a high-temperature, high-pressure (HTHP) process. The PCD element has a body with a plurality of bonded diamond or diamond-like crystals forming a continuous diamond matrix that has a diamond volume density greater than 85%. Interstices among the diamond crystals form a continuous interstitial matrix containing a catalyzing material. The diamond matrix table is formed and integrally bonded with a metallic substrate containing the catalyzing material during the HTHP process. The diamond matrix body has a working surface, where a portion of the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material, and the remaining interstitial matrix contains the catalyzing material.

Abstract: A method for forming a superhard polycrystalline diamond or diamond-like element with greatly improved resistance to thermal degradation without loss of impact strength. Collectively called PCD elements, these elements are formed with a binder-catalyzing material in a high-temperature, high-pressure process. The PCD element has a plurality of partially bonded diamond or diamond-like crystals forming at least one continuous diamond matrix, and the interstices among the diamond crystals forming at least one continuous interstitial matrix containing a catalyzing material. The element has a working surface and a body, where a portion of the interstitial matrix in the body adjacent to the working surface is substantially free of the catalyzing material to a depth from the working surface, the remaining interstitial matrix contains the catalyzing material, causing a 950 degrees C. temperature at the working surface to be less than 750 degrees C. at the depth.

Abstract: The invention is a mechanism for retaining an electrical transmission line. In one embodiment of the invention it is a system for retaining an electrical transmission line within down hole components. In accordance with one aspect of the invention, the system includes a plurality of downhole components, such as sections of pipe in a drill string. The system also includes a coaxial cable running between the first and second end of a drill pipe, the coaxial cable having a conductive tube and a conductive core within it. The invention allows the electrical transmission line to with stand the tension and compression of drill pipe during routine drilling cycles.

Abstract: The threaded connection between the pin and the box ends of two pipes is sealed externally and internally to protect the threads in the connection from exposure to corrosive fluids. Seals are provided at each axial end of the threads. The external seals may be formed by metal-to-metal engagement between the pin and box or may be provided by an annular, elastomeric ring engaging the pin and box of the connection. A threaded compression ring may be used to compress the elastomeric seal between the pin and box. The seals protect dynamically loaded threaded connections from fatigue-induced failure in corrosive environments.

Abstract: The present invention is generally directed to a tool for obtaining weight-on-bit (WOB) measurements and methods of using such a tool. In one illustrative embodiment the tool comprises a body, at least one strain gauge cavity in the body, the strain gauge cavity having a strain gauge mounting surface that is located at a position such that a region of approximately zero axial strain due to downhole pressures during drilling operations exists on the mounting surface when the tool is subjected to downhole pressures during drilling operations, and a weight-on-bit strain gauge operatively coupled to the mounting face above the region of approximately zero axial strain.

Abstract: A liner for an annular downhole component is comprised of an expandable metal tube having indentations along its surface. The indentations are formed in the wall of the tube either by drawing the tube through a die, by hydroforming, by stamping, or roll forming and may extend axially, radially, or spirally along its wall. The indentations accommodate radial and axial expansion of the tube within the downhole component. The tube is inserted into the annular component and deformed to match an inside surface of the component. The tube may be expanded using a hydroforming process or by drawing a mandrel through the tube. The tube may be expanded in such a manner so as to place it in compression against the inside wall of the component. The tube is useful for improving component hydraulics, shielding components from contamination, inhibiting corrosion, and preventing wear to the downhole component during use. It may also be useful for positioning conduit and insulated conductors within the component.