Abstract: A drill bit and seal assembly therefor include a seal gland, an elastomeric sealing seal disposed in the seal gland and having a dynamic sealing surface and a static sealing surface, and at least one auxiliary elastomeric annular seal member disposed between the static sealing surface of the sealing seal and the seal gland. The auxiliary annular seal member serves to prevent relative movement of the sealing seal relative to the surfaces of the seal gland and to permit sealing seals of various cross-sections and shapes to adapt to and function with a conventionally sized and shaped gland. The auxiliary annular seal member is sized and configured and its material properties selected so as to impart the appropriate squeeze to the sealing seal to provide the desired contact pressure and footprint. Choice of the appropriate auxiliary seal member may permit the same sized seal to be employed in seal glands of differing sizes.

Abstract: A cutting element is disclosed having multiple cutting extensions extending from the base portion and separated by valleys. The cutting extensions of the cutting element include both crested and rounded shapes. The cutting extensions may differ in extension height, shape, extension angle, cant angle, and crest angle in other characteristics such as in material properties such as wear resistance, hardness and fracture toughness. The cutting elements have particular, but not exclusive, application in the nose portion of the cone cutters of a rolling cone bit.

Abstract: Disclosed is a seal assembly for dynamically sealing between rotatable members, such as employed to seal the rolling cone of a rock bit. One preferred assembly includes an energizer, first and second seal rings, and a cushioning ring having an L-shaped cross-section disposed about portions of one of the seal rings to seal and absorb impact loads and thereby protect the more-rigid seal rings.

Abstract: An energizer for a mechanical seal assembly for use in a drill bit is disclosed. The energizer is a composite of at least two resilient materials, one having a durometer hardness that is greater than the other. The material contacting a journal provides relatively high frictional forces so as to prevent the energizer from rotating in relation to adjacent components. The relatively softer resilient material provides the energizing force necessary to maintain a good dynamic seal between the metal seal rings. The energizer components may be separate components that engage one another upon assembly, or may be bonded together to form a ring prior to assembly into the drill bit.

Abstract: A cutter for a drill bit used in a geological formation includes a shaped ultra hard working surface. The cutter with the shaped working surface is mounted on a drill bit to provide desired cutting characteristics. The shaped working surface provides varied cutting characteristics depending upon the shape, and the characteristics can vary depending upon the depth of the cut.

Abstract: A roller cone drill bit is disclosed which includes a bit body adapted to be coupled to a drill string. A bearing journal depends from the bit body. A single roller cone is rotatably attached to the bearing journal. The roller cone is formed from steel and includes a plurality of cutting elements disposed at selected positions about the cone. At least one of the cutting elements has an extending body which has a first end coupled to the roller cone and a distal end extending away from the cone. The extending body is formed from steel. A super hard element is coupled to the distal end of the extending body to form a super hard cutting face for the cutting element.

Abstract: Cutter elements for use in rolling cones rock bits are disclosed having a crown that includes multiple, spaced-apart cusps for enhancing formation removal by creating overlapping Hertzian contact zones. The cusps may be partially dome-shaped, berm shaped or otherwise. The cutter elements provide multiple cutting edges for engaging the formation and may have differing radii and extension length as suitable for particular applications.

Abstract: Disclosed are a variety of arcuate-shaped inserts for drill bits, and in particular, for placement in rolling cone cutters of drill bits. The arcuate inserts include 360° or ring-shaped inserts, as well as inserts of smaller arcuate length. The arcuate inserts are suitable for use in all surfaces of the rolling cone cutter, and in other locations in drill bits, and may have specialized cutting surfaces and material enhancements to enhance their cutting duty performance. Certain arcuate inserts may include stress relieving discontinuities such that, upon assembly into the cone or during drilling, the arcuate inserts may fragment in a controlled and predicted manner into shorter arcuate lengths.

Abstract: Disclosed is a seal assembly for dynamically sealing between rotatable members such as a rolling cone of a rock bit. The assembly includes a seal ring having a facing surface of a relatively hard material, such as hardened steel or tungsten carbide, and a second seal ring of a softer material, the softer material being harder, however, than typical elastomers. Suitable materials for the relatively soft seal ring include tin, copper, aluminum, magnesium, lead and alloys thereof, as well as non-metallic materials such as nylon-zytel, acetal, and polypropylene. The relatively soft seal ring may be affixed to a third seal ring or maybe affixed directly to the cone steel, for example. The seal assembly provides potential for longer life relative to elastomeric seals and requires less axial space along the journal surfaces than certain conventional metal seal assemblies.

Abstract: Disclosed are a variety of arcuate-shaped inserts for drill bits, and in particular, for placement in rolling cone cutters of drill bits. The arcuate inserts include 360 degree or ring-shaped inserts, as well as inserts of smaller arcuate length. The arcuate inserts may include stress relieving discontinuities such that, upon assembly into the cone, the arcuate inserts fragment in a controlled and predicted manner into shorter arcuate lengths. The arcuate inserts are suitable for use in all surfaces of the rolling cone cutter, and in other locations in drill bits, and may have specialized cutting surfaces and material enhancements to enhance their cutting duty performance.

Abstract: Disclosed is a rolling cone cutter and drill bit employing multiple inserts retained as a cluster in an aperture in the cone cutter. Apertures in which the insert clusters are retained are multilobed apertures formed by intersecting bores formed in the cone steel. The apertures may also be created by forming spaced apart bores and milling regions of the cone steel that extends between the bores. The inserts in a cluster may be retained within the aperture to differing depths, may extend above the cone steel to differing extension lengths, and may have cutting portions having a variety of shapes. The inserts in a cluster may be made of different materials in order to optimize cutting duty.

Abstract: Cutter elements for use in rolling cones rock bits are disclosed having a crown that includes multiple, spaced-apart cusps for enhancing formation removal by creating overlapping Hertzian contact zones. The cusps may be partially dome-shaped, berm shaped or otherwise. The cutter elements provide multiple cutting edges for engaging the formation and may have differing radii and extension length as suitable for particular applications.

Abstract: PCD and PCBN composite constructions have an ordered structure of two or more material phases that are combined together in a packed or interwoven configuration. One of the material phases is formed from materials selected from the group consisting of: polycrystalline diamond, polycrystalline cubic boron nitride; carbides, borides, nitrides, and carbonitrides from groups IVA, VA, and VIA of the Periodic Table; and mixtures thereof. Another material phase is preferably formed from a material having a degree of ductility that is higher than that of the first material phase. Example second material phase materials include those selected from the group consisting of cermets, Co, Ni, Fe, W, Mo, Cu, Al, Nb, Ti, Ta, and mixtures thereof.

Abstract: Disclosed are a variety of arcuate-shaped inserts for drill bits, and in particular, for placement in rolling cone cutters of drill bits. The arcuate inserts include 360 degree or ring-shaped inserts, as well as inserts of smaller arcuate length. The arcuate inserts may include stress relieving discontinuities such that, upon assembly into the cone, the arcuate inserts fragment in a controlled and predicted manner into shorter arcuate lengths. The arcuate inserts are suitable for use in all surfaces of the rolling cone cutter, and in other locations in drill bits, and may have specialized cutting surfaces and material enhancements to enhance their cutting duty performance.

Abstract: PCD and PCBN composite constructions have an ordered structure of two or more material phases that are combined together in a packed or interwoven configuration. One of the material phases is formed from materials selected from the group consisting of: polycrystalline diamond, polycrystalline cubic boron nitride; carbides, borides, nitrides, and carbonitrides from groups IVA, VA, and VIA of the Periodic Table; and mixtures thereof. Another material phase is preferably formed from a material having a degree of ductility that is higher than that of the first material phase. Example second material phase materials include those selected from the group consisting of cermets, Co, Ni, Fe, W, Mo, Cu, Al, Nb, Ti, Ta, and mixtures thereof.

Abstract: A cutter element for use in a drill bit, comprising a substrate and a cutting layer. The substrate comprises a grip portion and an extension portion, where the grip portion has an insert axis and an extension portion including an interface surface having a first apex. The cutting layer is affixed to the interface surface and has a cutting surface having a second apex. The cutting layer is shaped such that when a plane passing through the first apex and lying parallel to the insert axis and normal to a radius from the insert axis, the plane divides the cutting layer into major and minor portions and the major portion has a major volume that is at least 60 percent of the total volume of said cutting layer. Alternative embodiments of the present invention include variations wherein the first and second apices do not coincide and wherein the interface surface of the substrate is not axisymmetric. Using these variations, cutter elements having sizeable variations in thickness are constructed.

Abstract: A cutter element for use in a drill bit, comprising a substrate and a plurality of layers thereon. The substrate comprises a grip portion and an extending portion. The layers are applied to the extending portion such that at least one of the layers is harder than at least one of the layers above it. The layers can include one or more layers of polycrystalline diamond and can include a layer in which the composition of the material changes with distance from the substrate.

Abstract: Composite constructions of this invention comprise an ordered microstructure made up of multiple structural units that can be the same or different, and that comprise at least a first structural phase and a second structural phase. The first structural phase comprises a hard material that is selected from the group consisting of cermet materials, PCD, PCBN and mixtures thereof. The second structural phase is in contact with the first phase and comprises a material that is different than that selected to form the first structural phase. Additionally, the second structural phase is in contact with at least a portion of the first structural phase. Composite constructions of this invention can also have a multi-layer structures comprising two or more layers, wherein at least one of the layers comprises a composite construction having an ordered microstructure made up of the multiple structural units described above.

Abstract: A cutter element for use in a drill bit, comprising a substrate and a plurality of layers thereon. The substrate comprises a grip portion and an extending portion. The layers are applied to the extending portion such that at least one of the layers is harder than at least one of the layers above it. The layers can include one or more layers of polycrystalline diamond and can include a layer in which the composition of the material changes with distance from the substrate.

Abstract: A cutter element for use in a drill bit, comprising a substrate and a plurality of layers thereon. The substrate comprises a grip portion and an extending portion. The layers are applied to the extending portion such that at least one of the layers is harder than at least one of the layers above it. The layers can include one or more layers of polycrystalline diamond and can include a layer in which the composition of the material changes with distance from the substrate.