Patents Assigned to Varel International Ind., L.P.
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Patent number: 8365846Abstract: A front face of a diamond table mounted to a substrate is processed to introduce a material which comingles with or semi-alloys with or partially displaces interstitial catalyst binder in a thermal channel to a desired depth. The material is selected to be less thermally expandable than the catalyst binder and/or more thermally conductive than the catalyst binder and/or having a lower heat capacity than the catalyst binder.Type: GrantFiled: March 2, 2010Date of Patent: February 5, 2013Assignee: Varel International, Ind., L.P.Inventors: Alfazazi Dourfaye, Michael R. Reese, William W. King
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Publication number: 20130020135Abstract: A drill tool includes a cone mounted for rotation on a bearing shaft that extends from a bit head. The cone has a first planar base surface opposed to a second planar base surface of the bit head. A first annular groove is formed in the first planar base surface, and a second annular groove is formed in the second planar base surface. The first and second annular grooves are at least partially aligned with each other. The combination of the first and second annular grooves form a first annular gland. A protector ring is inserted into the first annular gland, and functions to divide a fluid path between the bearing shaft of the drill tool and an external environment into a plurality of parallel fluid paths that pass around the protector ring. Each parallel fluid path includes a convolution defined by a plurality of fluid direction changing corners.Type: ApplicationFiled: July 18, 2011Publication date: January 24, 2013Applicant: Varel International, Ind., L.P.Inventor: Thomas Gallifet
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Publication number: 20130014999Abstract: A disc cutter and a downhole tool including disc cutters therein. The disc cutter is disc-shaped and includes a lower portion and an upper portion. The lower portion is fabricated using a substrate material. At least a portion of the upper portion's perimeter is fabricated using at least one of polycrystalline diamond, synthetic diamond grit, natural diamond grit, and cubic boron nitride. According to certain exemplary embodiments, the disc cutter also includes an intermediate layer, which is fabricated from the substrate material, extending outwardly from at least a portion of the lower portion to a distal end positioned within the upper portion. In alternative exemplary embodiments, the disc cutter is disc-shaped and includes an inner portion made of substrate material, an outer portion made of at least one of polycrystalline diamond, synthetic diamond grit, natural diamond grit, and cubic boron nitride, and a channel extending orthogonally through the inner portion.Type: ApplicationFiled: July 13, 2012Publication date: January 17, 2013Applicant: Varel International Ind., L.P.Inventor: William W. King
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Patent number: 8347683Abstract: Surface texturing is employed to modify the topography of one or more surfaces (radial or cylindrical) of the sealing system for a roller cone rock bit. The surface texturing results in a dimpled surface which retains additional lubricant helpful in reducing friction in the boundary and mixed lubrication regimes. Shot peening is disclosed as one method for texturing the desired surface.Type: GrantFiled: March 6, 2009Date of Patent: January 8, 2013Assignee: Varel International Ind., L.P.Inventor: Xiaobin Lu
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Publication number: 20130001100Abstract: A catalyst removal apparatus and method for removing catalyst from a polycrystalline cutter. The cutter includes a substrate and a cutting table. The apparatus includes a tank forming a cavity therein, an electrolyte fluid occupying the cavity, the cutter, a covering surrounding at least a portion of the cutter's sidewall and extending from at least the substrate's top surface towards the bottom surface, a cathode submersed within the fluid, and a power source. The cutting table is submersed within the fluid and positioned near the cathode, thereby forming a gap therebetween. The power source is coupled to the cutter and the cathode and electrolyzes the fluid to react with the catalyst in the cutting table to produce a salt. The salt dissolves in the fluid and is removed from the cutter. Optionally, a transducer is sonically coupled to the cutter and emits vibrations to remove salt from the cutting table.Type: ApplicationFiled: June 26, 2012Publication date: January 3, 2013Applicant: Varel International Ind., L.P.Inventors: Gary M. Thigpen, Federico Bellin, Michael R. Reese
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Patent number: 8327944Abstract: An assembly is provided to attach a whipstock to a mill/drill bit. The assembly includes an upper collar adapted for installation around a shank of the mill/drill bit. At least one connecting member is mounted at a first end to the upper collar. The connecting member extends downwardly from the upper collar and is adapted to fit within a junkslot of the mill/drill bit to which the upper collar is attached. A whipstock attachment structure is mounted to a second end of the at least one connecting member.Type: GrantFiled: May 27, 2010Date of Patent: December 11, 2012Assignee: Varel International, Ind., L.P.Inventors: William W. King, Michael R. Reese, Steven W. Drews
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Patent number: 8327956Abstract: A PDC bit includes a plurality of blades including primary blades and secondary blades. The included primary blades are set with PDC cutters in accordance with a “single set” methodology. The included secondary blades, however, are set with PDC cutters using a type of “plural set” methodology such that the radial positions of cutters on a secondary blade match the radial positions of cutters on a single set primary which is immediately preceding that secondary blade. Plural secondary blades can be positioned to follow a single primary blade, and the cutters on those plural secondary blades will have radial positions matching the cutters of the immediately preceding single set primary blade.Type: GrantFiled: December 11, 2009Date of Patent: December 11, 2012Assignee: Varel International, Ind., L.P.Inventors: Steven W. Drews, Cary Maurstad
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Patent number: 8322174Abstract: Surface texturing is employed to modify the topography of one or more surfaces (radial or cylindrical) of the sealing system for a roller cone rock bit. The surface texturing results in a dimpled surface which retains additional lubricant helpful in reducing friction in the boundary and mixed lubrication regimes. Shot peening is disclosed as one method for texturing the desired surface.Type: GrantFiled: June 30, 2011Date of Patent: December 4, 2012Assignee: Varel International Ind., L.P.Inventor: Xiaobin Lu
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Publication number: 20120285101Abstract: A high-energy treated cutter comprising a substrate having a top surface, an outer region, and an inner core and a wear resistant layer coupled to the top surface. The high-energy treatment alters the substrate's physical properties so that the inner core provides greater toughness and the outer region provides greater hardness, and greater abrasion resistance. The layer is protected prior to commencement of the treatment. In one embodiment, a cover is positioned to surround the layer and then the cutter undergoes treatment, wherein the cutter is subjected to impact forces with other cutters. In another embodiment, the cutter is positioned within a recess formed in a tray table, thereby providing protection to the layer. The cutter is secured in place via vacuum, glue, or weight. A spray nozzle applies shot material directed to the substrate of the cutter, thereby applying the impact forces to alter the substrate's properties.Type: ApplicationFiled: July 27, 2012Publication date: November 15, 2012Applicant: Varel International Ind., L.P.Inventors: Michael R. Reese, Kelly O. Malone
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Patent number: 8252226Abstract: A high-energy treated cutter comprising a substrate having a top surface, an outer region, and an inner core and a wear resistant layer coupled to the top surface. The high-energy treatment alters the substrate's physical properties so that the inner core provides greater toughness and the outer region provides greater hardness, and greater abrasion resistance. The layer is protected prior to commencement of the treatment. In one embodiment, a cover is positioned to surround the layer and then the cutter undergoes treatment, wherein the cutter is subjected to impact forces with other cutters. In another embodiment, the cutter is positioned within a recess formed in a tray table, thereby providing protection to the layer. The cutter is secured in place via vacuum, glue, or weight. A spray nozzle applies shot material directed to the substrate of the cutter, thereby applying the impact forces to alter the substrate's properties.Type: GrantFiled: September 9, 2009Date of Patent: August 28, 2012Assignee: Varel International Ind., L.P.Inventors: Michael R. Reese, Kelly O. Malone
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Publication number: 20120193151Abstract: A drill tool comprises includes a bit body, at least one bearing shaft extending from the bit body and a cone mounted for rotation on the bearing shaft. The bearing system for the tool includes a radial thrust bearing from which cone pumping pressure pulsation originates. A lubricant sealing system including an annular seal gland and a seal ring retained within the annular seal gland functions to retain lubricant in the bearing system. The tool further includes a lubricant cone pumping pressure restrictor system formed by an annular gland (separate from the annular seal gland) and a pressure restricting ring retained within the annular gland. The lubricant cone pumping pressure restrictor system is positioned between the radial thrust bearing system and the lubricant sealing system and is adapted to attenuate cone pumping lubricant pressure pulsation from acting on the seal ring retained within the annular seal gland.Type: ApplicationFiled: January 28, 2011Publication date: August 2, 2012Applicant: Varel International, Ind., L.P.Inventors: David Harrington, Thomas Gallifet, Xiaobin Lu
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Patent number: 8210286Abstract: A drill bit includes a plurality of continuous segments impregnated with diamond that are each mounted to form a corresponding blade. The regions between the blades define a plurality of fluid passages on the bit face. The blades extend radially outwardly to the gage. The continuous segments may be either straight or spiral in design. Furthermore, the design of the segments supports varying one or more of: diamond content, width, back rake angle and/or relief angle along a length of the segment.Type: GrantFiled: May 2, 2011Date of Patent: July 3, 2012Assignee: Varel International, Ind., L.P.Inventors: Alfazazi Dourfaye, Michel De Reynal
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Patent number: 8196683Abstract: A drill bit includes a plurality of continuous segments impregnated with diamond that are each mounted to form a corresponding blade. The regions between the blades define a plurality of fluid passages on the bit face. The blades extend radially outwardly to the gage. The continuous segments may be either straight or spiral in design. Furthermore, the design of the segments supports varying one or more of: diamond content, width, back rake angle and/or relief angle along a length of the segment.Type: GrantFiled: July 26, 2011Date of Patent: June 12, 2012Assignee: Varel International, Ind., L.P.Inventors: Alfazazi Dourfaye, Michel de Reynal
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Publication number: 20120138365Abstract: A PDC bit includes a plurality of blades. A blade includes a primary cutter row and a secondary cutter row. Primary PDC cutters on the primary cutter row are set in accordance with a single set methodology. Backup PDC cutters on the secondary cutter row are set in accordance with a methodology wherein a radial position of each backup PDC cutter in the secondary cutter row is offset from a radial position of each primary PDC cutter in the primary cutter row. The blade further includes a tertiary cutter row. Additional backup PDC cutters on the tertiary cutter row are set in accordance with a methodology wherein a radial position of each additional backup PDC cutter in the tertiary cutter row is offset from a radial position of each primary PDC cutter in the primary cutter row. The backup cutter setting methodology is effectively radially positions the included backup PDC cutters (in the secondary cutter row and/or tertiary cutter row) between primary PDC cutters in the primary cutter row.Type: ApplicationFiled: December 6, 2010Publication date: June 7, 2012Applicant: VAREL INTERNATIONAL, IND., L.P.Inventors: Cary Andrew Maurstad, Zane Michael Pettiet
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Patent number: 8191656Abstract: A cutter is configured with a diamond table made from a thin hard facing material layer of polycrystalline diamond bonded to a backing layer made from cemented tungsten carbide. The face of the diamond table includes a concavity formed with a curved shape wherein at least a portion of the face in a center of the cutter is recessed with respect to at least some portion of the face about the perimeter of the cutter. This concave curved shape is formed in the diamond table itself such that the diamond table has a varying thickness depending on the implemented concavity.Type: GrantFiled: June 4, 2010Date of Patent: June 5, 2012Assignee: Varel International, Ind., L.P.Inventors: Alfazazi Dourfaye, Bruno Cuillier
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Patent number: 8162081Abstract: A force balanced asymmetric drilling reamer comprising a plurality of blades, each blade having at least one cutter section and a gage section. The cutter section is designed to have a plurality of cutting devices for cutting through swelling formations and cutting free sloughing formations. The gage section has a full bore diameter with gage elements flushly coupled to gage section's outer surface. The blades may be curve/concave shaped or boomerang/chevron shaped, which thereby agitate the cutting beds. At least a portion of the drilling reamer's diameter is incrementally force balanced, starting from the outermost diameter, so that the net radial force is less than 10% of weight on bit with respect to the center of rotation. This balancing allows a greater cutter longevity and provides for a better wellbore condition. Optionally, at least a portion of the drilling reamer's surface may be treated by nitriding for repelling the cuttings.Type: GrantFiled: August 14, 2009Date of Patent: April 24, 2012Assignee: Varel International Ind., L.P.Inventors: Brian D. Ballard, William W. King
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Publication number: 20120080236Abstract: A rotary cone drill bit includes: a body, a leg depending from the body, a bearing shaft extending from the leg and a cone mounted to the bearing shaft. The leg includes a surface edge that is subject to wear during operation of the bit. A bottom surface of a hard material plate having an edge is attached to a conforming surface of the leg in a position where the edge of the hard material plate defines at least a portion of the surface edge of the leg. The attachment of the surfaces is made using a flowable material such as a brazing material.Type: ApplicationFiled: October 1, 2010Publication date: April 5, 2012Applicant: VAREL INTERNATIONAL, IND., L.P.Inventor: Inpeng Bouaphanh
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Publication number: 20120080237Abstract: A rotary cone drill bit includes: a body, a leg depending from the body, a bearing shaft extending from the leg and a cone mounted to the bearing shaft. The leg includes a surface location that is subject to wear during operation of the bit. A bottom surface of a hard material plate is attached to a substantially conforming surface of the leg at the location subject to wear. The attachment of the conforming surfaces is made using a flowable material such as a brazing material.Type: ApplicationFiled: October 1, 2010Publication date: April 5, 2012Applicant: VAREL INTERNATIONAL, IND., L.P.Inventor: Inpeng Bouaphanh
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Publication number: 20120080238Abstract: A rotary cone drill bit includes: a body, a leg depending from the body, a bearing shaft extending from the leg and a cone mounted to the bearing shaft. The leg includes a leading edge (at an outer surface or shoulder surface, for example) that is subject to wear during operation of the bit. A bottom surface of a hard material plate having an edge is attached to a conforming surface of the leg in a position where the edge of the hard material plate defines at least a portion of the leading edge of the leg. The attachment of the surfaces is made using a flowable material such as a brazing material.Type: ApplicationFiled: June 9, 2011Publication date: April 5, 2012Applicant: VAREL INTERNATIONAL, IND., L.P.Inventor: Inpeng Bouaphanh
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Patent number: 8132633Abstract: A self positioning cutter element and cutter pocket for use in a downhole tool having one or more cutting elements. The self positioning cutter element includes a substrate and a wear resistant layer coupled to the substrate. The cutter element includes a cutting surface, a coupling surface, and a longitudinal side surface forming the circumferential perimeter of the cutter element and extending from the cutting surface to the coupling surface. The cutter element has one or more indexes formed on at least a portion of the coupling surface. In some embodiments, the index also is formed on at least a portion of the longitudinal side surface. Hence, the coupling surface is not substantially planar. Additionally, at least a portion of the longitudinal side surface does not form a substantially uniform perimeter. The cutter pocket also is indexed to correspond and couple with the indexing of the cutter element.Type: GrantFiled: May 26, 2009Date of Patent: March 13, 2012Assignee: Varel International Ind., L.P.Inventors: Bruno Cuillier De Maindreville, Gilles Gallego, Anthony Salliou