Kerf-cutting apparatus and method for improved drilling rates

Claim 2

A drill bit comprising: (a) a bit body having an upper end and a lower end, said lower end forming an annular cutter for cutting an outer annular kerf on rotation of the drill bit; (b) an inner drill member positioned concentrically within said bit body having an upper end connected to said bit body and a lower end forming an annular cutter for cutting an inner annular kerf positioned concentrically within the outer annular kerf on rotation of the drill bit; (c) a first plurality of rotary drilling members attachedly arranged between said bit body and inner drill member for rotation relative to said bit body and inner drill member, having lowermost cutting edges positioned above lowermost cutting edges of the annular cutter of said bit body and inner drill member to remove material between the outer and inner annular kerfs; (d) a second plurality of rotary drilling members attachedly arranged within said inner drill member for rotation relative to said inner drill member, having lowermost cutting edges positioned above lowermost cutting edges of the annular cutter of said inner drill member to remove material surrounded by the inner annular kerf; (e) a drilling fluid conduit disposed within said drill bit for delivering drilling fluid to said annular cutters and said first and second plurality of rotary drilling members, said conduit separately discharging fluid to said first and second plurality of rotary drilling members; and (f) means for connecting the upper ends of said bit body and drilling fluid conduit to a string of drill pipe.

Claim 3

A drill bit in accordance with claim 1 wherein said bit body defines a plurality of spaced apart grooves extending longitudinally from the annular cutter of said bit body toward the upper end of said bit body for removal of drilling fluid and cuttings from below the drill bit.

Claim 4

A drill bit in accordance with claim 1 wherein the annular cutter of said bit body comprises a kerf-cutting skirt having a generally saw-tooth configuration, abrasive resistant means on cutting faces of the skirt and defining outlet passages between adjacent skirt teeth for removal of cuttings from below the bit.

Claim 5

A drill bit in accordance with claim 3 wherein said abrasive resistant means comprises diamonds.

Claim 6

A drill bit in accordance with claim 3 wherein said abrasive resistant means comprises carbides selected from the group consisting of tungsten carbide, boron carbide and silicon carbide.

Claim 7

A drill bit in accordance with claim 3 wherein said abrasive resistant means comprises tungsten carbide.

Claim 8

A drill bit in accordance with claim 3 wherein a plurality of face plates comprising diamonds are attached to cutting faces of the skirt.

Claim 9

A drill bit in accordance with claim 1 wherein the annular cutter of said inner drill member comprises a kerf-cutting skirt having a generally saw-tooth configuration, abrasive resistant means on cutting faces of the skirt and defining outlet passages between adjacent skirt teeth for removal of cuttings from below the bit.

Claim 10

A drill bit in accordance with claim 8 wherein said abrasive resistant means comprises diamonds.

Claim 11

A drill bit in accordance with claim 8 wherein said abrasive resistant means comprises carbides selected from the group consisting of tungsten carbide, boron carbide and silicon carbide.

Claim 12

A drill bit in accordance with claim 8 wherein said abrasive resistant means comprises tungsten carbide.

Claim 13

A drill bit in accordance with claim 8 wherein a plurality of face plates comprising diamonds are attached to cutting faces of the skirt.

Claim 14

A drill bit in accordance with claim 1 wherein the annular cutter of said bit body comprises a plurality of studs protruding from said bit body having abrasive resistant means on cutting faces of the studs.

Claim 15

A drill bit in accordance with claim 13 wherein said abrasive resistant means comprises diamonds.

Claim 16

A drill bit in accordance with claim 13 wherein said abrasive resistant means comprises carbides selected from the group consisting of tungsten carbide, boron carbide and silicon carbide.

Claim 17

A drill bit in accordance with claim 13 wherein said abrasive resistant means comprises tungsten carbide.

Claim 18

A drill bit in accordance with claim 13 wherein a plurality of face plates comprising diamonds are attached to cutting faces of the studs.

Claim 19

A drill bit in accordance with claim 1 wherein the annular cutter of said inner drill member comprises a plurality of studs protruding from said inner drill member having abrasive resistant means on cutting faces of the studs.

Claim 20

A drill bit in accordance with claim 18 wherein said abrasive resistant means comprises diamonds.

Claim 21

A drill bit in accordance with claim 18 wherein said abrasive resistant means comprises carbides selected from the group consisting of tungsten carbide, boron carbide and silicon carbide.

Claim 22

A drill bit in accordance with claim 18 wherein said abrasive resistant means comprises tungsten carbide.

Claim 23

A drill bit in accordance with claim 18 wherein a plurality of face plates comprising diamonds are attached to cutting faces of the studs.

Claim 24

A drill bit in accordance with claim 1 wherein said first plurality of rotary drilling members comprises at least two spaced apart cutting wheels having abrasive resistant teeth.

Claim 25

A drill bit in accordance with claim 23 wherein said abrasive resistant teeth comprise tungsten carbide.

Claim 26

A drill bit in accordance with claim 1 wherein said first plurality of rotary drilling members comprises at least two spaced apart cutting discs.

Claim 27

A drill bit in accordance with claim 1 wherein said second plurality of rotary drilling members comprises at least two spaced apart roller cone cutters.

Claim 28

A drill bit in accordance with claim 26 wherein said roller cone cutters have a plurality of abrasive resistant insert teeth protruding from the surface of said roller cone cutters.

Claim 29

A drill bit in accordance with claim 27 wherein said abrasive resistant insert teeth comprise tungsten carbide.

Claim 30

A drill bit in accordance with claim 26 wherein said roller cone cutters have a plurality of abrasive resistant milled teeth on the surface of said roller cone cutters.

Claim 31

A drill bit in accordance with claim 29 wherein said abrasive resistant teeth are coated with carbide.

Claim 32

A drill bit in accordance with claim 1 wherein said drilling fluid conduit comprises separate passageways discharging separately above and between each of said first and second plurality of rotary drilling members through jet nozzles.

Claim 33

A drill bit comprising: (a) a bit body having an upper end and a lower end, said lower end forming an annular kerf-cutting skirt having a generally saw-tooth configuration and abrasive resistant means on cutting faces of the skirt for cutting an outer annular kerf on rotation of the drill bit; (b) an inner drill member positioned concentrically within said bit body having an upper end connected to said bit body and a lower end forming an annular kerf-cutting skirt having a generally saw-tooth configuration and abrasive resistant means on cutting faces of the skirt for cutting an inner annular kerf positioned concentrically within the outer annular kerf on rotation of the drill bit; (c) at least two spaced apart cutting wheels attachedly arranged between said bit body and inner drill member for rotation relative to said bit body and inner drill member, said cutting wheels having lowermost cutting edges positioned above lowermost cutting edges of the saw-tooth skirt of said bit body and inner drill member to remove material between the outer and inner annular kerfs; (d) at least two spaced apart roller cone cutters attachedly arranged within said inner drill member for rotation relative to said inner drill member, said roller cone cutters having a plurality of abrasive resistant teeth protruding from the surface of the roller cone cutters with lowermost cutting teeth positioned above lowermost cutting edges of the saw-tooth skirt of said inner drill member to remove material surrounded by the inner annular kerf; (e) a drilling fluid conduit disposed within said drill bit for delivering drilling fluid to said cutting wheels, roller cone cutters, and annular kerf-cutting skirts, said conduit comprising separate passageways discharging separately above and between each of said spaced apart cutting wheels and roller cone cutters; (f) means for connecting said drilling fluid conduit and the upper end of said bit body to a string of drill pipe.

Claim 34

A drill bit comprising: (a) a bit body having an upper end and a lower end, said lower end forming an annular kerf-cutting skirt having a generally saw-tooth configuration and abrasive resistant means on cutting faces of the skirt for cutting an outer annular kerf on rotation of the drill bit; (b) an inner drill member positioned concentrically within said bit body having an upper end connected to said bit body and a lower end forming an annular kerf-cutting skirt having a generally saw-tooth configuration and abrasive resistant means on cutting faces of the skirt for cutting an inner annular kerf positioned concentrically within the outer annular kerf on rotation of the drill bit; (c) at least two spaced apart cutting wheels attachedly arranged between said bit body and inner drill member for rotation relative to said bit body and inner drill member, said cutting wheels having lowermost cutting edges positioned above lowermost cutting edges of the saw-tooth skirt of said bit body and inner drill member to remove material between the outer and inner annular kerfs; (d) at least two spaced apart roller cone cutters attachedly arranged within said inner drill member for rotation relative to said inner drill member, said roller cone cutters having a plurality of abrasive resistant teeth protruding from the surface of the roller cone cutters with lowermost cutting teeth positioned above lowermost cutting edges of the saw-tooth skirt of said inner drill member to remove material surrounded by the inner annular kerf; (e) a drilling fluid conduit disposed within said drill bit for delivering drilling fluid to said cutting wheels, roller cone cutters, and annular kerf-cutting skirts, said conduit comprising separate passageways discharging separately above and between each of said spaced apart cutting wheels and roller cone cutters; (f) means for connecting said drilling fluid conduit and the upper end of said bit body to a string of drill pipe.

Claim 35

A drill bit comprising: (a) a bit body having an upper end and a lower end, said lower end forming an annular kerf-cutting skirt for cutting an outer annular kerf on rotation of the drill bit, said skirt having a generally saw-tooth configuration, a plurality of face plates comprising diamonds attached to cutting faces of the skirt, and defining outlet passages between adjacent skirt teeth for removal of cuttings from below the bit, said bit body defining spaced apart grooves extending longitudinally from the annular kerf-cutting skirt toward the upper end of said bit body for removal of cuttings and drilling fluid from below the drill bit; (b) an inner drill member positioned concentrically within said bit body having an upper end connected to said bit body and a lower end forming an annular kerf-cutting skirt for cutting an inner annular kerf positioned concentrically within the outer annular kerf on rotation of the drill bit, said skirt having a generally saw-tooth configuration, a plurality of face plates comprising diamonds attached to cutting faces of the skirt and defining outlet passages between adjacent skirt teeth for removal of cuttings from below the bit; (c) three spaced apart cutting wheels attachedly arranged between said bit body and inner drill member for rotation relative to said bit body and inner drill member to remove material between the outer and inner annular kerfs, said cutting wheels having cutting teeth comprising tungsten carbide with lowermost cutting teeth positioned above lowermost cutting edges of the skirt teeth and below uppermost edges of the outlet passages of said bit body; (d) three spaced apart roller cone cutters attachedly arranged within said inner drill member for rotation relative to said inner drill member to remove material surrounded by the inner annular kerf, said roller cone cutters having a plurality of cutting carbide teeth protruding from the surface of said roller cone cutters with lowermost cutting teeth positioned above lowermost cutting edges of the skirt teeth of said inner drill member and below the uppermost edges of the outlet passages of said inner drill member; (e) a drilling fluid conduit disposed within said drill bit for delivering drilling fluid to said cutting wheels, roller cone cutters, and annular kerf-cutting skirts, said conduit comprising separate passageways discharging separately above and between each of said spaced apart cutting wheels and roller cone cutters; (f) means for connecting said drilling fluid conduit and the upper end of said bit body to a string of drill pipe.

Claim 36

A drill bit comprising: (a) a bit body having an upper end and a lower end, said lower end forming an annular kerf-cutting skirt for cutting an outer annular kerf on rotation of the drill bit, said skirt having a generally saw-tooth configuration, a plurality of face plates comprising diamonds attached to cutting faces of the skirt, and defining outlet passages between adjacent skirt teeth for removal of cuttings from below the bit, said bit body defining spaced apart grooves extending longitudinally from the annular kerf-cutting skirt toward the upper end of said bit body for removal of cuttings and drilling fluid from below the drill bit; (b) an inner drill member positioned concentrically within said bit body having an upper end connected to said bit body and a lower end forming an annular kerf-cutting skirt for cutting an inner annular kerf positioned concentrically within the outer annular kerf on rotation of the drill bit, said skirt having a generally saw-tooth configuration, a plurality of face plates comprising diamonds attached to cutting faces of the skirt and defining outlet passages between adjacent skirt teeth for removal of cuttings from below the bit; (c) three spaced apart cutting wheels attachedly arranged between said bit body and inner drill member for rotation relative to said bit body and inner drill member to remove material between the outer and inner annular kerfs, said cutting wheels having cutting teeth comprising tungsten carbide with lowermost cutting teeth positioned above lowermost cutting edges of the skirt teeth and below uppermost edges of the outlet passages of said bit body; (d) three spaced apart roller cone cutters attachedly arranged within said inner drill member for rotation relative to said inner drill member to remove material surrounded by the inner annular kerf, said roller cone cutters having a plurality of cutting carbide teeth protruding from the surface of said roller cone cutters with lowermost cutting teeth positioned above lowermost cutting edges of the skirt teeth of said inner drill member and below the uppermost edges of the outlet passages of said inner drill member; (e) a drilling fluid conduit disposed within said drill bit for delivering drilling fluid to said cutting wheels, roller cone cutters, and annular kerf-cutting skirts, said conduit comprising separate passageways discharging separately above and between each of said spaced apart cutting wheels and roller cone cutters; (f) means for connecting said drilling fluid conduit and the upper end of said bit body to a string of drill pipe.

Claim 37

A drill bit comprising: (a) a bit body having an upper end and a lower end, said lower end forming an annular cutter for cutting an outer annular kerf on rotation of the drill bit; (b) a plurality of inner drill members positioned concentrically one within the other and within said bit body, each of said inner drill members having upper ends connected to said bit body and lower ends forming annular cutters for cutting concentric annular kerfs on rotation of the drill bit; (c) at least two spaced apart rotary drilling attachedly arranged between said bit body and the outermost of said inner drill members and between each of the plurality of said inner drill members for rotation relative to said bit body and inner drill members, said rotary drilling members having lowermost cutting edges positioned above lowermost cutting edges of the annular cutter of said bit body and inner drill members to remove material between the concentric annular kerfs; (d) at least two spaced apart roller cone cutters attachedly arranged within the innermost of said inner drill members for rotation relative to said inner drill member, said roller cone cutters having lowermost cutting edges positioned above lowermost cutting edges of the annular cutter of the innermost of said inner drill members to remove material surrounded by the innermost concentric annular kerf; (e) a drilling fluid conduit disposed within said drill bit for delivering drilling fluid to said rotary drilling members, roller cone cutters and annular cutters, said conduit comprising separate passageways discharging separately above and between said rotary drilling members and roller cone cutters; (f) means for connecting said drilling fluid conduit and the upper ends of said bit body to a string of drill pipe.

Claim 38

A drill bit comprising: (a) a bit body having an upper end and a lower end, said lower end forming an annular cutter for cutting an outer annular kerf on rotation of the drill bit; (b) a plurality of inner drill members positioned concentrically one within the other and within said bit body, each of said inner drill members having upper ends connected to said bit body and lower ends forming annular cutters for cutting concentric annular kerfs on rotation of the drill bit; (c) at least two spaced apart rotary drilling attachedly arranged between said bit body and the outermost of said inner drill members and between each of the plurality of said inner drill members for rotation relative to said bit body and inner drill members, said rotary drilling members having lowermost cutting edges positioned above lowermost cutting edges of the annular cutter of said bit body and inner drill members to remove material between the concentric annular kerfs; (d) at least two spaced apart roller cone cutters attachedly arranged within the innermost of said inner drill members for rotation relative to said inner drill member, said roller cone cutters having lowermost cutting edges positioned above lowermost cutting edges of the annular cutter of the innermost of said inner drill members to remove material surrounded by the innermost concentric annular kerf; (e) a drilling fluid conduit disposed within said drill bit for delivering drilling fluid to said rotary drilling members, roller cone cutters and annular cutters, said conduit comprising separate passageways discharging separately above and between said rotary drilling members and roller cone cutters; (f) means for connecting said drilling fluid conduit and the upper ends of said bit body to a string of drill pipe.