EARTHBORING TOOLS, NOZZLES, AND ASSOCIATED STRUCTURES, APPARATUS, AND METHODS

Abstract

An earth-boring tool includes at least one blade including at least one cutting element, at least one junk slot positioned adjacent the at least one blade, and a nozzle positioned in the at least one junk slot. The nozzle includes an outlet and an extension extending from a surface of the at least one junk slot to the outlet. The extension elevates the outlet to a position within a circumference of the at least one cutting element.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a national phase entry under 35 U.S.C. § 371 of International Patent Application PCT/US2023/073210, filed Aug. 31, 2023, designating the United States of America and published as International Patent Publication WO 2024/050454 A1 on Mar. 7, 2024, which claims the benefit under Article 8 of the Patent Cooperation Treaty of U.S. Provisional Patent Application Ser. No. 63/374,203, filed Aug. 31, 2022.

TECHNICAL FIELD

Embodiments of the present disclosure generally relate to earth-boring operations. In particular, embodiments of the present disclosure relate to earth-boring tools, nozzles, and associated structures, apparatus, and methods.

BACKGROUND

Wellbore drilling operations may involve the use of an earth-boring tool at the end of a long string of pipe commonly referred to as a drill string. An earth-boring tool may be used for drilling through formations, such as rock, dirt, sand, tar, etc. In some cases, the earth-boring tool may be configured to drill through additional elements that may be present in a wellbore, such as cement, casings (e.g., a wellbore casing), discarded or lost equipment (e.g., fish, junk, etc.), packers, etc. In some cases, earth-boring tools may be configured to drill through plugs (e.g., fracturing plugs, bridge plugs, cement plugs, etc.). In some cases, the plugs may include slips or other types of anchors and the earth-boring tool may be configured to drill through the plug and any slip, anchor, and other component thereof.

A fluid may be supplied into the wellbore during the wellbore drilling operation. The fluid may be used to cool and/or clean the earth-boring tool and/or related cutting elements. For example, the fluid may cool the earth-boring tool and carry cuttings and debris away from the earth-boring tool. Fluid pressure in the wellbore may be controlled to different pressures for different types of drilling operations. For example, in overbalanced drilling, the fluid pressure in the wellbore may be maintained above the pressure of the fluid in the earth formation to substantially prevent ingress of the fluids from the formation into the wellbore during the drilling operation. In some cases, the fluid pressure in the wellbore may be maintained below the fluid pressure of the formation. Lower fluid pressures may increase the efficiency of the drilling operation; however, this may allow fluid from the formation to enter the wellbore.

BRIEF SUMMARY

Embodiments of the disclosure may include a nozzle for use in an earth-boring tool. The nozzle may include an inlet, an interface complementary to a nozzle receiving cavity of an earth-boring tool, an outlet, and an extension extending from the interface to the outlet. The extension may be configured to position the outlet a distance away from a mounting surface of the earth-boring tool.

Another embodiment of the disclosure may include an earth-boring tool including at least one blade including at least one cutting element, at least one junk slot positioned adjacent the at least one blade, and a nozzle positioned in a recess in the at least one junk slot. The nozzle including an outlet and an extension extending from a surface of the at least one junk slot to the outlet. The extension elevating the outlet to a position within a circumference of the at least one cutting element.

Another embodiment of the disclosure may include a cutting element. The cutting element may include one or more fluid passages defined within the cutting element. The cutting element may further include one or more fluid outlets through a surface of the cutting element, the one or more fluid outlets operatively coupled to the one or more fluid passages. The one or more fluid passages may include a path formed through additive manufacturing.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming embodiments of the present disclosure, the advantages of embodiments of the disclosure may be more readily ascertained from the following description of embodiments of the disclosure when read in conjunction with the accompanying drawings in which:

FIG. 1 illustrates a perspective view of an earth-boring tool in accordance with embodiments of the disclosure;

FIG. 2 illustrates an enlarged cross-sectional view of the earth-boring tool of FIG. 1;

FIGS. 3A and 3B illustrate perspective views of nozzles in accordance with embodiments of the disclosure;

FIG. 4 illustrates a schematic view of a nozzle coupled to an earth-boring tool in accordance with embodiments of the disclosure;

FIGS. 5, 6, 7, and 8A-8B illustrate schematic views of different nozzle arrangements in accordance with embodiments of the disclosure;

FIG. 9 illustrates an internal view of a mold for forming the earth-boring tool of FIG. 1;

FIG. 10 illustrates a schematic view of an earth-boring tool in accordance with embodiments of the disclosure;

FIG. 11 illustrates a schematic view of a blade of an earth-boring tool in accordance with embodiments of the disclosure;

FIGS. 12A and 12B illustrate schematic views of a blade of an earth-boring tool in accordance with embodiments of the disclosure; and

FIGS. 13A-13H illustrate schematic views of cutting elements in accordance with embodiments of the disclosure.

DETAILED DESCRIPTION

The illustrations presented herein are not meant to be actual views of any particular earth-boring system or component thereof but are merely idealized representations employed to describe illustrative embodiments. The drawings are not necessarily to scale.

As used herein, the term “earth-boring tool” means and includes any type of bit or tool used for drilling during the formation or enlargement of a wellbore in a subterranean formation. For example, earth-boring tools include fixed-cutter bits, roller cone bits, percussion bits, core bits, eccentric bits, bicenter bits, reamers, mills, drag bits, hybrid bits (e.g., rolling components in combination with fixed cutting elements), and other drilling bits and tools known in the art.

As used herein, the term “substantially” in reference to a given parameter means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. For example, a parameter that is substantially met may be at least about 90% met, at least about 95% met, at least about 99% met, or even at least about 100% met. In another example, an angle that is substantially met may be within about +/−15°, within about +/−10°, within about +/−5°, or even within about 0°.

As used herein, relational terms, such as “first,” “second,” “top,” “bottom,” etc., are generally used for clarity and convenience in understanding the disclosure and accompanying drawings and do not connote or depend on any specific preference, orientation, or order, except where the context clearly indicates otherwise.

As used herein, terms such as ahead and behind are used in reference to a direction of movement of the associated element. For example, as a drill string moves into a borehole the bottom of the borehole is ahead of the elements of the drill string and the surface is behind the elements of the drill string. In another example, in relation to a cutting element on a rotating earth-boring tool a portion of the formation that has not yet been contacted by the cutting element is ahead of the cutting element whereas a portion of the formation that has already been contacted by the cutting element is behind the cutting element.

As used herein, the term “and/or” means and includes any and all combinations of one or more of the associated listed items.

As used herein, the terms “vertical” and “lateral” refer to the orientations as depicted in the figures.

During a drilling operation fluid may be supplied into the wellbore to cool and/or clean the earth-boring tool and related cutting elements. The pressure of the fluid in the wellbore may be used to substantially prevent reservoir fluids (e.g., fluids stored in the formation, such as gas, oil, water, etc.) from entering the wellbore during the drilling operation, this is commonly referred to as overbalance drilling. High fluid pressure in the wellbore may reduce the efficiency of the drilling operation. For example, maintaining the fluid pressure above the pressure of the reservoir fluids may increase the strength of the formation near the wall of the wellbore. The increased strength of the formation may reduce the efficiency of the drilling operation by reducing the cutting depth and rate of penetration (ROP) of the earth-boring tool.

Referring to FIG. 1, a perspective view of an earth-boring tool 100 is shown. The earth-boring tool 100 may have blades 102 in which a plurality of cutting elements 108 may be secured. The cutting elements 108 may have a cutting table defining a cutting face 112 which may form the cutting edge of the blade 102. The cutting elements 108 may also include a substrate 114 configured to support the cutting table. The substrate 114 may be secured to a cutting pocket in the blade 102, such as through welding, soldering, brazing, etc., securing the cutting elements 108 to the blade 102.

The earth-boring tool 100 may rotate about a longitudinal axis of the earth-boring tool 100. When the earth-boring tool 100 rotates the cutting face 112 of the cutting elements 108 may contact the earth formation and remove material. The material removed by the cutting faces 112 may then be removed through the junk slots 104. The earth-boring tool 100 may include nozzles 106 which may introduce fluid, such as water or drilling mud, into the area around the blades 102 to aid in removing the sheared material and other debris from the area around the blades 102 and/or to cool the cutting elements 108 and the blade 102 to increase the efficiency of the earth-boring tool 100.

The fluid may enter the wellbore through the nozzles 106. The nozzles 106 may be coupled to a pressurized fluid supplied through the drill string. The pressure of the fluid in the borehole may be controlled through the pressure of the fluid being supplied through the drill string and the nozzles 106. Reducing a distance between the nozzles 106 and a formation may facilitate weakening or failure of the material of the formation by infiltrating pores in the formation material with the fluid. For example, a formation's bulk strength may increase at greater depths due to a confining pressure. Delivering a high-pressure fluid directly onto the formation locally weakens the bulk strength of the formation and cuttings, which may increase the amount of material removed, depth of cut, and/or rate of penetration of the associated earth-boring tool 100.

The nozzles 106 of the earth-boring tool 100, may be concentrated near a nose region 110 of the earth-boring tool 100. Positioning the nozzles 106 near the nose region 110 of the earth-boring tool 100 may facilitate reducing the strength of the formation immediately ahead of the earth-boring tool 100 during a drilling operation. In some embodiments, the nozzles 106 are directed to a shoulder region 120. In other embodiments, the nozzles 106 are directed to both the nose region 110 and the shoulder region 120. In each configuration, the cutting elements 108 in the respective nose region 110 and/or shoulder region 120 pass through a pressurized region of the formation where the mechanical cutting forces are reduced due to the fluid pressure, which may result in an increased depth of cut, or rate of penetration.

The nozzles 106 may be positioned within the junk slots 104 of the earth-boring tool 100. The nozzles 106 may include an extension 118 configured to position an outlet 116 of the nozzles 106 near the cutting elements 108 on an adjacent blade 102. For example, the extension 118 may position the outlet 116 within a cutting path of the cutting elements 108 defined by the circumference of the cutting faces 112 of the adjacent cutting elements 108. The extension 118 extends away from a base of the associated junk slot 104 such that the outlet 116 is positioned close to the formation.

FIG. 2 illustrates an enlarged cross-section of the earth-boring tool 100 where the nozzle 106 is coupled to the earth-boring tool 100 in a junk slot 104. The extension 118 of the nozzle 106 may position the outlet 116 a distance 202 from a cutting edge 204 of the adjacent cutting elements 108. The distance 202 may facilitate the fluid leaving the outlet 116 to impinge on the formation at a high velocity while maintaining a distance between the formation and the nozzle 106, such that the nozzle 106 does not contact the formation and is not covered by debris from the formation. The distance 202 may substantially prevent the outlet 116 from being damaged by contact with the formation or from being clogged with debris from the formation. The distance 202 may be in a range from about 0.5 inches (12.7 mm) to about 0.25 inches (6.35 mm), such as from about 0.4 inches (10.16 mm) to about 0.3 inches (7.62 mm), or about 0.375 inches (9.53 mm).

The nozzle 106 may be secured to the earth-boring tool 100 through an interface 206. The interface 206 may include interlocking threads that may facilitate removal, replacement, and/or changing the nozzle 106. Drilling operations in different types of formations may be benefited by different sizes of outlets 116 on the nozzles 106. For example, a smaller outlet 116 may increase a velocity of the fluid leaving the nozzle 106, which may improve the penetration into formation materials having less permeable rock properties, such as granite or marble. Alternatively, a larger outlet 116 may increase the volume of fluid while reducing the velocity of the fluid, which may facilitate penetration of a larger amount of fluid into a more permeable formation material, such as sandstone.

The nozzle 106 includes an inlet 208 on an opposite end of the nozzle 106 from the outlet 116. The inlet 208 is coupled to fluid paths through the earth-boring tool 100, which may direct fluid from the drill string to the nozzles 106. The nozzle 106 may include a neck 210 positioned between the inlet 208 and the outlet 116. The neck 210 may reduce a cross-sectional major dimension (e.g., a diameter, a width, an apothem, etc.) of the fluid path through the nozzle 106 from the size of the inlet 208 to at least the size of the outlet 116. The neck 210 may have a convergence angle in a range from about 5° to about 25°, such as from about 10° to about 15°. The neck 210 may be positioned a distance from the outlet 116 of at least about three times a major dimension (e.g., diameter, width, apothem, etc.) of the outlet 116. In some embodiments, the neck 210 may extend the entire length of the extension 118, such that the fluid path may slowly converge to the major dimension of the outlet 116 along the entire length of the extension 118. In other embodiments, the neck 210 may have a larger convergence angle, such as a convergence angle greater than about 15° that may be positioned close to the outlet 116 to increase an exit velocity of the fluid. Reducing the cross-sectional major dimension of the fluid path through the nozzle 106 may provide a jetting effect accelerating the fluid passing through the nozzle 106, such that the fluid leaving the nozzle 106 through the outlet 116 is traveling at a higher rate of speed than the fluid entering the nozzle 106 through the inlet 208. The speed of the fluid leaving the nozzle 106 through the outlet 116 may be determined by several factors, such as the number of nozzles 106 on the earth-boring tool 100, the size of the outlet 116 of the nozzle 106, and the difference in size from the inlet 208 to the outlet 116 of the nozzle 106. The distance between the neck 210 and the outlet 116 may facilitate a stabilization of the speed of the fluid, such that the fluid exiting the outlet 116 may flow at a substantially uniform velocity greater than the velocity of the fluid entering the nozzle 106 through the inlet 208.

FIGS. 3A and 3B illustrate embodiments of a nozzle 106. The nozzle 106 may include an extension 118 configured to extend the outlet 116 to a position closer to the formation from the mounting location of the nozzle 106 on an associated earth-boring tool 100 (FIGS. 1 and 2). The outlet 116 includes an orifice 302 coupled to the fluid path defined in the nozzle 106. As described above, different nozzles 106 may have different orifice 302 sizes, as illustrated in FIGS. 3A and 3B. The different orifice 302 sizes may alter flow properties of the fluid passing out of the outlet 116 of the respective nozzles 106. As described above, a larger orifice 302, as illustrated in FIG. 3A, may provide a larger volume of fluid at a lower velocity, whereas a smaller orifice 302, as illustrated in FIG. 3B may provide a smaller volume of fluid at a higher velocity.

The nozzles 106 may include tool interfaces 304 on the extension 118 of the nozzle 106. The tool interfaces 304 may facilitate the installation and removal of the nozzle 106. For example, the interfaces 206 on the nozzles 106 may be threads and the tool interfaces 304 on the respective nozzles 106 may facilitate coupling a wrench, socket or other tool to the extension 118 of the nozzle 106 to turn the nozzle 106 engaging the threads of the interface 206 to install or remove the nozzle 106.

In some embodiments, nozzles 106 having different orifice 302 sizes may be positioned in different positions about the earth-boring tool 100, such that the earth-boring tool 100 may have different pressure zones. For example, a nozzle 106 having a smaller orifice 302 may be positioned ahead of a first blade and a second nozzle 106 having a larger orifice 302 may be positioned ahead of a second blade. The first nozzle 106 may provide a fluid stream with a higher velocity than the second nozzle 106. As the earth-boring tool 100 rotates the different nozzles 106 may generate an oscillating pressure on the formation. In another embodiment, the nozzles 106 may be configured to have adjustable geometry, such that the nozzles 106 may change the exit velocity of the fluid during operation. The adjustable nozzles 106 may then cause the exit velocity of the fluid to oscillate during operation.

In some embodiments, the major dimension of the orifice 302 may be in a range from about 0.04 inches (1.016 mm) to about 0.75 in (19.05mm), such as from about 0.25 in (6.35 mm) to about 0.5 in (12.7 mm). As discussed above, orifice 302 sizes may determine a exit velocity of the fluid stream exiting the associated nozzle 106 through the orifice 302. The major dimension of the orifice 302 may also facilitate clearing clogs or debris from the associated nozzle 106. For example, an increase in the major dimension of the orifice 302 may reduce the likelihood of debris becoming lodged in the orifice 302 and blocking flow through the nozzle 106. In some embodiments, filtering may be used to reduce the debris flowing through the nozzle 106 and facilitate reducing the major dimension of the orifice 302 to increase the exit velocity of the fluid stream.

FIG. 4, illustrates a schematic view of a nozzle 106 positioned ahead of a cutting element 108. As cutting elements 108 wear a distance between the outlet 116 of the nozzle 106 and the formation 406 may be reduced. As the distance between the outlet 116 of the nozzle 106 and the formation 406 reduces, the likelihood of damage to the nozzle 106 or the nozzle 106 becoming clogged with cutting debris may increase. In some embodiments, the nozzle 106 may be configured to automatically adjust the distance between the nozzle 106 and the formation 406. For example, the nozzle 106 may be supported by a compressible element 402, such as a spring, hydraulic ram, pneumatic ram, etc. The compressible element 402 may be configured to facilitate the nozzle 106 moving into the associated earth-boring tool 100. As the distance between the outlet 116 and the formation 406 decreases a pressure of the fluid in a high-pressure zone 404 between the outlet 116 and the formation 406 may increase. The increased pressure in the high-pressure zone 404 may apply a greater pressure to the compressible element 402 through the nozzle 106. The greater pressure applied to the compressible element 402 may cause the compressible element 402 to compress such that the nozzle 106 may move a greater distance into the earth-boring tool 100 to maintain a constant pressure in the high-pressure zone 404. Maintaining the pressure in the high-pressure zone 404 at a constant pressure may result in the outlet 116 of the nozzle 106 being maintained at a substantially constant distance from the formation 406.

In other embodiments, the compressible element 402 is a controllable element, that may be controlled through a controller or through operator inputs. The operator or controller may then control the distance between the outlet 116 and the nozzle 106 directly by controlling the compressible element 402. In other embodiments, the operator or controller may control the response of the compressible element 402, such as by raising a pressure or spring rate of the compressible element 402 to reduce the response to pressure changes in the high-pressure zone or by reducing the pressure or spring rate of the compressible element 402 to increase the response to pressure changes in the high-pressure zone.

FIGS. 5-8B illustrate schematic view of different nozzle configurations that may direct the flow of the fluid in different directions relative to an associated cutting element 108. Splitting the near nozzle fluid flow in different directions may improve cutting efficiency of the associated cutting elements 108 and earth-boring tool 100. The extension 118 of the nozzles 106 may facilitate greater flow control proximate a formation 406 by increasing a distance traveled by the fluid in the fluid passage of the nozzle 106. The increased distance within the nozzle 106 may also result in the fluid traveling a smaller distance from the outlet 116 of the nozzle 106 to the formation 406 or cutting face 112. In some embodiments, as illustrated in FIG. 5, the fluid flow may be split so a first outlet 506 of a first nozzle 502 is directed toward a surface of the formation 406 and configured to weaken the material of the formation 406. A second outlet 508 of a second nozzle 504 may be directed toward the cutting face 112 of the cutting element 108 for cutting removal and cooling.

In another embodiment, the fluid flow may be split in a plane perpendicular to the cutting direction of the cutting elements 108 as illustrated in FIG. 6. For example, the cutting face 112 of the cutting element 108 may travel in the Y direction and the nozzles 602 may be positioned in a plane defined by the X and Y axes. Each of the outlets 604 of the nozzles 602 may be directed toward the formation 406 and configured to cause the fluid ejected from the nozzles 602 to impinge on the formation 406 to loosen the materials of the formation 406 ahead of the cutting element 108. Splitting the fluid flow in this manner may increase and/or balance a flow impact area of the formation 406. Splitting the fluid flow between two nozzles 602 or 502, 504, may increase an area covered by the fluid while reducing a velocity of the fluid exiting the respective nozzles 602, 502, 504.

In another embodiment, the fluid flow from multiple nozzles 702, 704 may converge in an area ahead of the cutting face 112 of the cutting element 108. The first nozzle 702 and the second nozzle 704 may have separate inlets. The first outlet 706 and the second outlet 708 may be directed toward a similar area of the formation 406. When merged, the two nozzles 702, 704 deliver greater hydraulic power to the location than one of nozzles 702, 704 alone. An arrangement with converging nozzles may increase fluid penetration into a material of the formation 406 that may have smaller pores. For example, multiple nozzles 702, 704 directed at a similar area of the formation may result in a higher volume of fluid while maintaining an increased velocity, which may improve penetration of the fluid into the formation 406.

In some embodiments, an angle 802 of the fluid flow may be adjustable as illustrated in FIGS. 8A and 8B. The angle 802 between an extension 804 and a fluid inlet 208 may be adjusted to change the direction of the fluid flow toward the formation 406. Different angles 802 may provide different benefits for the associated cutting elements 108. For example, a cutting element 108 having a larger back rake angle may be more likely to have cutting debris lodged between the cutting face 112 and the formation 406. Thus, adjusting the angle 802 of the extension 804 toward the cutting face 112 may facilitate improved cleaning of the cutting face 112 which may substantially prevent cutting debris from becoming lodged between the cutting face 112 and the formation 406. In another example, a cutting element 108 having a relatively small cutting face 112, such as a conical cutting element or chisel shaped cutting element, the angle 802 of the extension 804 may be directed toward the formation 406 to weaken the formation because the smaller cutting face 112 may be less likely to have material lodged between the cutting face 112 and the formation 406.

In some embodiments, the angle 802 of the extension 804 is configured to be adjusted through a manual adjustment by an operator while the associated earth-boring tool 100 is not downhole. This may facilitate the installation of the same extension 804 in multiple earth-boring tools 100 and the operator may then adjust the angle of the extension 804 as desired to facilitate different configurations of the earth-boring tool, such as different cutting elements, different types of formations, different back-rake angles, etc.

In other embodiments, the angle 802 of the extension 804 is configured to be adjusted through a controlled input while the associated earth-boring tool 100 is downhole (e.g., during operation). This may facilitate changing the angle 802 of the extension 804 to adjust to different formation materials addressing changes in the formation 406 as the earth-boring tool 100 advanced into the borehole. In other cases, sensor readings may indicate different issues downhole that may be addressed by changing the angle 802 of the extension 804. For example, excessive heat in the cutting element 108 may be resolved by changing the angle 802 of the extension 804 to direct the fluid toward the cutting face 112 of the cutting element 108. In another example, a reduction in the depth of cut or rate of penetration may be resolved by changing the angle 802 of the extension 804 to direct the fluid toward the formation 406.

FIG. 9 illustrates a mold 900 for an earth-boring tool, such as the earth-boring tool 100 described above. The mold 900 may include features configured to define fluid passages 902, nozzle cavities 904, and cutter pockets 906. As illustrated, the fluid passages 902 may branch from a common inlet 908 positioned near a center of the earth-boring tool. The fluid passages 902 may each be coupled between the inlet 908 and a nozzle cavity 904. The nozzle cavities 904 may each be configured to receive a nozzle, such as the nozzles 106, 602, 804 described above. In some embodiments, additional machining may be performed in the nozzle cavities 904 after they are formed in the molding process, such as to add threads or other interfacing features.

FIG. 10, illustrates an earth-boring tool 1010 with features that may be included in the earth-boring tool 100 described above. The earth-boring tool 1010 may include a pressure chamber 1006 disposed inside the earth-boring tool 1010. The chamber 1006 may be shaped to conform to the inner geometry. The chamber 1006 may be positioned between a fluid inlet 1008 and the fluid passages 1002 directed to the nozzles, such as nozzles 106, 602, 804. The chamber 1006 may be configured to accumulate hydraulic pressure and then release fluid into the fluid passage 1002 to an outlet 1004 to the nozzles once the pressure threshold is reached.

The fluid from the drill string flows into the chamber 1006 through the inlet 1008. The inlet 1008 may include a check valve 1012, as illustrated in FIG. 10. The check valve 1012 is configured to prevent fluid from flowing out of the chamber 1006 through the check valve 1012, while facilitating fluid flowing into the chamber 1006 through the check valve 1012. In some embodiments, the chamber 1006 may include an accumulator configured to slow the pressure change in the chamber 1006 by increasing a volume of the chamber 1006 as the pressure in the chamber 1006 increases and reducing a volume of the chamber 1006 as the pressure in the chamber 1006 decreases.

The chamber 1006 may include one or more pressure actuated valves on an outlet side of the chamber 1006 coupled to the fluid passages 1002. The pressure actuated valves may be configured to open when the pressure in the chamber 1006 reaches a predetermined pressure to release the pressurized fluid to the nozzles through the outlet 1004. The one or more pressure actuated valves may close when the pressure in the chamber 1006 falls below a second predetermined pressure, such that the pressure in the chamber may increase.

In some embodiments, some nozzles of the earth-boring tool 100 may be operatively coupled to the chamber 1006 and other nozzles of the earth-boring tool 100 may be coupled directly to the fluid passages in the drill string bypassing the chamber 1006. For example, the nozzles bypassing the chamber may be configured to provide a constant flow of fluid, such as for clearing debris and cooling cutting elements while the nozzles operatively coupled to the chamber 1006 are configured to provide high-pressure fluid, that may not be constant, to impinge on the formation and weaken the material of the formation. In other embodiments, the chamber 1006 may be operatively coupled to nozzles 106 that utilize a controlled pressure, such as the nozzle 106 illustrated in FIG. 4 where the pressure to the nozzle may define a distance between the nozzle 106 and the formation 406 (FIG. 4).

FIG. 11 illustrates a schematic view of a blade 102 of an earth-boring tool 100. The earth-boring tool 100 may include a nozzle 1104 positioned and shaped to be complementary to a face 1112 of the blade 102. The nozzle 1104 may be positioned and shaped, such that an outlet 1102 of the nozzle 1104 is positioned under the cutting elements 108 and is directed toward the cutting elements 108. The nozzle 1104 may be tapered to form a chisel or duckbill-like shape with the outlet 1102 having a substantially smaller cross-sectional area than the inlet 1110. The outlet 1102 may define a long thin opening configured to generate blade-like fluid flow ahead of the cutting element 108. The tapered nozzle 1104 may be positioned after the neck 1106, which may be configured to accelerate the fluid flow by changing a cross-sectional dimension of the fluid passage 1108 in a similar manner to that described above with respect to the neck 210.

Additive manufacturing processes may facilitate forming nozzles 1104 with intricate internal geometric features, such as a grate outlet, corrugated nozzle, varying inner diameters, flow splitters inside the nozzle to direct flow, auger-like inner structure in the center-line or fins on the inner walls to generate a pointed vortex, etc. These intricate internal geometric features may facilitate the directional flows, split flow directions, etc., described above, with respect to FIGS. 5-8 and 11.

FIGS. 12A and 12B illustrate a schematic view of a blade 102 of an earth-boring tool 100. A nozzle 1206 may be positioned in the junk slot 104 immediately ahead of the blade 102. The blade 102 and associated junk slot 104 may include one or more fins 1204, 1208 that may direct the flow of the fluid exiting the outlet 1202 of the nozzle 1206 to the cutting elements 108 of the blade 102. For example, the junk slot 104 may include large fins 1204 formed from an abrasion resistant material that may direct the fluid flow toward the blade 102. A face of the blade 102 may include additional smaller fins 1208 extending from the face of the blade 102 configured to direct fluid flow to the individual cutting elements 108 on the blade 102. The fins 1204, 1208 may be formed from abrasion resistant material, such as tungsten carbide. As described above, additive manufacturing processes may facilitate forming the fins 1204, 1208 with complex geometries.

Cutting elements 108 may also be formed through additive manufacturing processes, which may facilitate forming the cutting elements 108 with complex internal geometries and fluid passages, such as micro channels. FIGS. 13A-13H illustrate different embodiments of cutting elements 108 with different fluid passages passing through the cutting element 108 and exiting through the cutting face 112 or through the sides of the cutting element 108. The fluid passages in the cutter substrate may cool the cutter during drilling. Fluid exiting the cutting elements 108 may clean the cutting elements 108 and/or weaken the formation material.

The cutting elements 108 may include a single fluid passage 1302 passing through the cutting element 108 and exiting the cutting face 112 through a single outlet 1304 as illustrated in FIG. 13A. In some embodiments, the outlet 1304 may be positioned proximate an edge of the cutting face 112 as illustrated in FIG. 13A. In other embodiments, the outlet 1304 may be positioned near a center of the cutting face 112.

Other cutting elements 108 may include multiple fluid passages 1302 passing through the cutting element 108 and exiting the cutting face 112 through multiple outlets 1304 as illustrated in FIG. 13B. In some embodiments, the cutting element 108 may include a single fluid passage 1302 configured to split and exit the cutting element 108 through multiple outlets 1304 through the cutting face 112. The multiple outlets 1304 may be positioned about the cutting face 112. In some embodiments, the multiple outlets 1304 may be circular as illustrated in FIG. 13B. In other embodiments, the multiple outlets 1304 may have other shapes, such as rectangular shapes, as illustrated in FIG. 13C, or triangular shapes, oval shapes, etc. In some embodiments, the multiple fluid passages 1302 may intersect in a common passage 1306 within the cutting element 108 as illustrated in FIG. 13D.

Some cutting elements 108 may be non-planar cutting elements (e.g., cutting elements with a non-planar cutting face), such as the cutting elements 108 illustrated in FIGS. 13D-13G. In some embodiments, the outlets 1304 may be positioned in a planar portion of the cutting face 112 as illustrated in FIG. 13D. In other embodiments, the outlets 1304 may be positioned in non-planar portions of the cutting face 112 as illustrated in FIGS. 13E and 13F. For example, the outlets 1304 may be positioned around a perimeter of a concave cutting face 112 as illustrated in FIG. 13E or on the tapered sides of the cutting face 112 of a chisel shaped cutting element 108 as illustrated in FIG. 13F.

In some embodiments, the outlets 1304 may be formed to direct fluid flow in a specific direction as illustrated in FIG. 13G. For example, the fluid passage 1302 may be arranged at an angle relative to the cutting face 112 of the cutting element 108, such that the fluid may exit the outlets 1304 at substantially the same angle as the fluid passage 1302. The outlets 1304 may also be configured to maintain the same angle of flow as the fluid passage 1302. For example, the outlets 1304 may have an oblong shape or other shape configured to maintain the angle of the fluid passage 1302 through the respective outlet 1304. In some embodiments, the flow is directed toward the formation engaging portion 1308 of the associated cutting element 108 as illustrated in FIG. 13G.

In some embodiments, the outlets 1304 are positioned on a side surface 1310 of the cutting element 108 rather than in the cutting face 112, as illustrated in FIG. 13H. Positioning the outlets 1304 in the side surface 1310 of the cutting element 108 may facilitate directing the fluid flow directly into the formation to weaken the formation materials or cleaning around the cutting element 108, such as cleaning adjacent cutting elements or clearing debris surrounding the cutting element 108.

Embodiments of the present disclosure may cause the pore pressure in a formation to be artificially increased in a controlled area. Increasing the pore pressure of the formation may reduce the forces required to shear the formation and remove the material from the formation. This may reduce the power required to remove the material, reducing the power used in a drilling operation and/or increasing the speed with which the drilling may be performed. Controlling the area where the pore pressure of the formation is artificially increased may enable a drilling operation to maintain the integrity of the wellbore through overbalanced drilling in the majority of the wellbore, while weakening the wall of the wellbore in a localized area to increase the efficiency of the material removal process. Increasing the efficiency of the material removal process may reduce the cost of drilling a wellbore. Increasing the efficiency of the material removal process may further reduce the amount of time before a wellbore may begin production and become a profitable wellbore.

Non-limiting example embodiments include:

Embodiment 1: A nozzle for use in an earth-boring tool, the nozzle comprising: an inlet; an interface complementary to a nozzle receiving cavity of an earth-boring tool; an outlet; and an extension extending from the interface to the outlet, the extension configured to position the outlet a distance away from a mounting surface of the earth-boring tool.

Embodiment 2: The nozzle of embodiment 1, further comprising a fluid passage defined in the nozzle from the inlet to the outlet, the fluid passage including a neck reducing a major dimension of the fluid passage.

Embodiment 3: The nozzle of embodiment 2, wherein the neck has a convergence angle in a range from about 5° to about 25°.

Embodiment 4: The nozzle of embodiment 2 or embodiment 3, wherein the neck is positioned a distance from the outlet and the distance is at least three times a major dimension of the outlet.

Embodiment 5: The nozzle of any one of embodiments 1 through 4, wherein the inlet has a first major dimension and the outlet has a second major dimension and the first major dimension is greater than the second major dimension.

Embodiment 6: The nozzle of any one of embodiments 1 through 5, further comprising a second outlet and a second extension extending from the interface to the second outlet.

Embodiment 7: The nozzle of embodiment 6, wherein the extension and the second extension define an angle between the extension and the second extension, such that the second outlet is configured to direct a fluid in a different direction from fluid directed through the outlet.

Embodiment 8: The nozzle of any one of embodiments 1 through 7, wherein the extension defines an angle between the extension and the inlet.

Embodiment 9: The nozzle of embodiment 8, wherein the nozzle is configured to be adjustable, such that the angle between the extension and the inlet is adjustable.

Embodiment 10: An earth-boring tool comprising: at least one blade including at least one cutting element; at least one junk slot positioned adjacent the at least one blade; and a nozzle positioned in a recess in the at least one junk slot, the nozzle comprising: an outlet; and an extension extending from a surface of the at least one junk slot to the outlet, the extension elevating the outlet to a position within a circumference of the at least one cutting element.

Embodiment 11: The earth-boring tool of embodiment 10, wherein the nozzle is complementary to a face of the at least one blade.

Embodiment 12: The earth-boring tool of embodiment 10 or embodiment 11, wherein the at least one junk slot includes a fin configured to direct fluid flow from the nozzle to the at least one blade.

Embodiment 13: The earth-boring tool of any one of embodiments 10 through 12, further comprising a pressure chamber defined within the earth-boring tool, the pressure chamber coupled between a fluid inlet and the nozzle.

Embodiment 14: The earth-boring tool of any one of embodiments 10 through 13, further comprising a second nozzle positioned in the at least one junk slot.

Embodiment 15: The earth-boring tool of embodiment 14, wherein the nozzle and the second nozzle are configured and positioned to direct a first fluid stream directed from the nozzle and a second fluid stream directed from the second nozzle toward substantially a same location ahead of the at least one blade.

Embodiment 16: The earth-boring tool of any one of embodiments 10 through 15, further comprising a compressible element positioned between the nozzle and the recess in the at least one junk slot.

Embodiment 17: A cutting element comprising: one or more fluid passages defined within the cutting element; and one or more fluid outlets through a surface of the cutting element, the one or more fluid outlets operatively coupled to the one or more fluid passages; wherein the one or more fluid passages include a path formed through additive manufacturing.

Embodiment 18: The cutting element of embodiment 17, wherein the one or more fluid passages comprise at least two fluid passages extending from a common fluid passage.

Embodiment 19: The cutting element of embodiment 18, wherein the at least two fluid passages extend from the common fluid passage to at least two outlets.

Embodiment 20: The cutting element of any one of embodiments 17 through 19, wherein the one or more fluid passages extend at an angle relative to a cutting face of the cutting element, wherein the angle is configured to direct flow toward a formation engaging portion of the cutting element.

The embodiments of the disclosure described above and illustrated in the accompanying drawing figures do not limit the scope of the invention, since these embodiments are merely examples of embodiments of the invention, which is defined by the appended claims and their legal equivalents. Any equivalent embodiments are intended to be within the scope of this disclosure. Indeed, various modifications of the present disclosure, in addition to those shown and described herein, such as alternative useful combinations of the elements described, may become apparent to those skilled in the art from the description. Such modifications and embodiments are also intended to fall within the scope of the appended claims and their legal equivalents.

Claims

1. A nozzle for use in an earth-boring tool, the nozzle comprising:

an inlet;

an interface complementary to a nozzle receiving cavity of an earth-boring tool;

an outlet; and

an extension extending from the interface to the outlet, the extension configured to position the outlet a distance away from a mounting surface of the earth-boring tool.

2. The nozzle of claim 1, further comprising a fluid passage defined in the nozzle from the inlet to the outlet, the fluid passage including a neck reducing a major dimension of the fluid passage.

3. The nozzle of claim 2, wherein the neck has a convergence angle in a range from about 5° to about 25°.

4. The nozzle of claim 2, wherein the neck is positioned a distance from the outlet and the distance is at least three times a major dimension of the outlet.

5. The nozzle of claim 1, wherein the inlet has a first major dimension and the outlet has a second major dimension and the first major dimension is greater than the second major dimension.

6. The nozzle of claim 1, further comprising a second outlet and a second extension extending from the interface to the second outlet.

7. The nozzle of claim 6, wherein the extension and the second extension define an angle between the extension and the second extension, such that the second outlet is configured to direct a fluid in a different direction from fluid directed through the outlet.

8. The nozzle of claim 1, wherein the extension defines an angle between the extension and the inlet.

9. The nozzle of claim 8, wherein the nozzle is configured to be adjustable, such that the angle between the extension and the inlet is adjustable.

10. An earth-boring tool comprising:

at least one blade including at least one cutting element;

at least one junk slot positioned adjacent the at least one blade; and

a nozzle positioned in a recess in the at least one junk slot, the nozzle comprising: an outlet; and an extension extending from a surface of the at least one junk slot to the outlet, the extension elevating the outlet to a position within a circumference of the at least one cutting element.

11. The earth-boring tool of claim 10, wherein the nozzle is complementary to a face of the at least one blade.

12. The earth-boring tool of claim 10, wherein the at least one junk slot includes a fin configured to direct fluid flow from the nozzle to the at least one blade.

13. The earth-boring tool of claim 10, further comprising a pressure chamber defined within the earth-boring tool, the pressure chamber coupled between a fluid inlet and the nozzle.

14. The earth-boring tool of claim 10, further comprising a second nozzle positioned in the at least one junk slot.

15. The earth-boring tool of claim 14, wherein the nozzle and the second nozzle are configured and positioned to direct a first fluid stream directed from the nozzle and a second fluid stream directed from the second nozzle toward substantially a same location ahead of the at least one blade.

16. The earth-boring tool of claim 10, further comprising a compressible element positioned between the nozzle and the recess in the at least one junk slot.

17. A cutting element comprising:

one or more fluid passages defined within the cutting element; and

one or more fluid outlets through a surface of the cutting element, the one or more fluid outlets operatively coupled to the one or more fluid passages;

wherein the one or more fluid passages include a path formed through additive manufacturing.

18. The cutting element of claim 17, wherein the one or more fluid passages comprise at least two fluid passages extending from a common fluid passage.

19. The cutting element of claim 18, wherein the at least two fluid passages extend from the common fluid passage to at least two outlets.

20. The cutting element of claim 17, wherein the one or more fluid passages extend at an angle relative to a cutting face of the cutting element, wherein the angle is configured to direct flow toward a formation engaging portion of the cutting element.