Drill bit connector for mitigating torsional vibrations

Abstract

The present invention relates to a connector for connecting a drill string to a drill bit and a method of manufacturing the same. In particular, the present invention discloses a connector comprising a housing comprising a first connection portion at a first end for connecting to a drill string, a base connected to the housing and comprising a second connection portion at a second end for connecting to a drill bit, and an intermediate component disposed between the base and the housing; wherein the connector is configured for rotation about an axis during use, wherein the intermediate component allows for limited relative rotation between the housing and the base about the axis.

Description

[0001] priority

[0002] This application claims priority to U.S. non-provisional application No. 17 / 097,333, filed November 13, 2020, and U.S. provisional application No. 63 / 020,406, filed May 5, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention generally relates to connectors for connecting components to drill strings, drill bit assemblies including such connectors, and methods of manufacturing such connectors. The connectors of this invention advantageously transmit torque while suppressing system vibrations and accommodating (e.g., limiting, reducing, or preventing) misalignment. Background Technology

[0004] There are various drilling techniques known for creating holes underground, penetrating rock, etc. Each technique is often suited to a specific application or substrate type, and each technique may also have specialized equipment, particularly equipment related to the drill bit.

[0005] Drilling techniques for oil and gas wells typically involve a drill string consisting of many interconnected components. For example, a drill string usually includes a drill bit attached to a drill pipe, which is advanced underground by rotating the drill pipe, causing the drill bit to cut into the rock. Various types of drill bits are known for this purpose, including stationary cutter bits and roller cone bits. Significant differences also exist in the design of these categories of drill bits, depending on factors such as the hardness, type, and structure of the ground being drilled.

[0006] In contrast, drilling through overburden (e.g., blast hole patterns) would require different techniques and equipment. Different types of drill bits might be needed to withstand significant and continuous variations in rock type and hardness, as there may be different types or mixtures of rock and soil, or various unpredictable cracks and discontinuities that could damage the aforementioned types of equipment. Furthermore, drilling could utilize rotation and hammering or impact to advance the drill bit into the ground, rather than pure rotation.

[0007] However, these alternative technologies and equipment may require various trade-offs. Different equipment designs may be more complex, or the drill bits used may not be able to penetrate the surface as quickly as possible due to the need to modify their design to withstand harsher drilling environments.

[0008] Any prior publications (or information obtained from them) or any known matters referenced in this specification shall not be construed as an admission or endorsement or recommendation of any kind that such prior publications (or information obtained from them) or known matters constitute part of the general knowledge of the field of work covered by this specification. Summary of the Invention

[0009] In one aspect, the present invention provides a connector for connecting a first drill string assembly to a second drill string assembly, the connector comprising: a housing including a first connecting portion at a first end for connecting to the first drill string assembly; a base connected to the housing and including a second connecting portion at a second end for connecting to the second drill string assembly; and an intermediate member disposed between the base and the housing; wherein the connector is configured for rotation about an axis during use, and wherein the intermediate member is configured to allow limited relative rotation between the housing and the base about the axis. In some cases, the first drill string assembly is selected from the group consisting of components of a drill bit, drill collar, drill pipe section, stabilizer, mud motor, mud motor assembly, and bottom hole tool assembly. In some cases, the second drill string assembly is selected from the group consisting of components of a drill bit, drill collar, drill pipe section, stabilizer, mud motor, mud motor assembly, and bottom hole tool assembly. In some cases, the first drill string assembly includes a mud motor, drill collar, rotary steering tool, or tubular metal component, and wherein the second drill string assembly includes a drill bit. In some cases, the intermediate member is made of an elastically deformable material. In some cases, the first drill string is connected to the housing by thread or weld, or the first drill string component is abutted against the housing. In some cases, the second drill string component is connected to the base by thread or weld, or the second drill string component is abutted against the base. In some cases, the connector includes a center hole for fluid communication between the first and second drill string components via the connector. In some cases, relative rotation between the housing and the base is limited to an angle of less than 30° from the nominal position. In some cases, the maximum nominal thickness of the intermediate component is less than 30 mm. In some cases, the base is at least partially located within the housing, and the intermediate component is a sleeve assembled between the base and the housing and substantially located within the housing.

[0010] In some cases, the base includes: an elongated cylinder having a flange extending from a lower end perpendicular to its axis, the flange being configured for attachment to a second drill string component; and a plurality of racks extending radially from the outer surface of the elongated cylinder. In some cases, the housing includes a cylindrical body having a plurality of grooves on its inner surface configured to receive the racks of the base. In some cases, the intermediate component is a sleeve that fills the space between the racks of the base and the grooves of the housing. In some cases, the elongated cylinder of the base is substantially fitted within the housing, and a locking ring is secured to the flange-opposite end of the elongated cylinder, such that the locking ring prevents the base from being removed from the housing. In some cases, the flange includes one or more through-holes, through which a curable compound is injected or poured to form the intermediate component.

[0011] In another aspect, the present invention describes a method for manufacturing a connector for connecting a first drill string component to a second drill string component, the connector comprising a shell, a base, and an intermediate component disposed therebetween, the method comprising the steps of: forming the shell and the base; inserting the base at least partially into the shell and securing it to each other; and forming the intermediate component by injecting or pouring a curable compound into the space between the shell and the base.

[0012] In another aspect, the present invention describes a method for manufacturing a connector for connecting a first drill string component to a second drill string component, the connector comprising a housing, a base, and an intermediate component disposed therebetween, the method comprising the steps of: forming the housing, the base, and the intermediate component; inserting the base at least partially into the housing, the intermediate component being disposed therebetween; and securing the base and the housing to each other.

[0013] In another aspect, the present invention describes a drilling method comprising the steps of: securing a drill bit to a drill string assembly using a connector according to claim 1 to form an assembled drill bit; and drilling using the assembled drill string and a drilling rig. In some cases, the drill bit is a polycrystalline diamond composite (PDC) drill bit or a claw-shaped drill bit.

[0014] It should be understood that the generalized forms of the embodiments and their respective features can be used in combination and / or independently, and reference to individual generalized forms is not intended to be limiting. Furthermore, it should be understood that the features of the method can be performed using the system or apparatus, and the features of the system or apparatus can be implemented using the method. Attached Figure Description

[0015] Various examples and embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

[0016] Figure 1 This is a low-angle isometric view of a drill bit connector according to an embodiment of the present invention;

[0017] Figure 2 yes Figure 1 Exploded isometric view of the drill bit connector;

[0018] Figure 3 yes Figure 1 Isometric view of the lower part of the drill bit connector housing;

[0019] Figure 4 yes Figure 1 Isometric view of the lower part of the base of the drill bit connector;

[0020] Figure 5 yes Figure 1 An isometric view of the upper part of the middle component of the drill bit connector;

[0021] Figure 6 yes Figure 1 A front cross-sectional view of the drill bit connector, shown as it is connected to the drill bit;

[0022] Figure 7 This is an exploded isometric view of a drill bit connector according to an embodiment of the present invention;

[0023] Figure 8 This is an exploded isometric view of a drill bit connector according to an embodiment of the present invention. Detailed Implementation

[0024] Exemplary embodiments of connectors, which are typically used to connect components of drill strings according to embodiments, will now be described.

[0025] The term "drill string" as used throughout this specification is broadly interpreted to include any string, tubing, or machinery used to transmit drilling fluid and / or torque for downhole drilling. A drill string comprises numerous components, including, for example, drill bits, drill collars, one or more sections of drill pipe (e.g., transition tubing and / or heavy-duty drill pipe), drill stabilizers, downhole motors (e.g., mud motors and / or mud motor assemblies), and other bottom-hole drill string assemblies. Typically, a bottom-hole drill string assembly can be any component or tool located at the bottom of the drill string, such as a rotary steerable system, measurement-while-drilling (MWD) tools, and / or logging-while-drilling (LOD) tools.

[0026] Drill pipe can be any pipe, rod, or other similar component, or any series of pipes or such components, used or applicable to drilling processes. Drilling processes can include any wide range of drilling applications, such as, but not limited to, exploration drilling, oil and gas well drilling, blasting hole drilling, and various other types of rock or soil drilling.

[0027] The drill bit can be selected from a wide range of equipment. For example, it can be any known or new drill bit used for any of the drilling processes described above or other drilling processes. Examples may include, but are not limited to, various types of roller cone drill bits, fixed bits, polycrystalline diamond composite (PDC) drill bits, and claw drill bits.

[0028] As already noted, this invention describes a connector, a drill string component for connecting parts of a drill string. Connectors are generally suitable for connecting any part of a drill string. In one embodiment, for example, the connector connects the drill bit and a drill pipe section. Those skilled in the art will understand that although the detailed embodiments of this invention primarily describe connecting a drill bit to a drill pipe, the connector described herein is suitable for connecting and transmitting torque between other parts of the drill string.

[0029] The connector includes a housing, a base, and an intermediate component. The housing has a first component (e.g., a tube) connection portion located at a first (e.g., upper) end for connection to a drill pipe or other drill string component. This connection portion can be connected to the drill string component using any suitable method, such as welding, a locking mechanism, or a threaded connection, wherein the housing can have any suitable type of external or internal thread.

[0030] The base is connected to the shell and has a second component (e.g., drill bit) connection portion located at a second (e.g., lower) end for connection to the drill bit. This connection portion can be connected to the drill bit using any suitable method, such as welding, a locking mechanism, or a threaded connection, wherein the base can have any suitable type of external or internal thread.

[0031] An intermediate component is disposed between the base and the housing. The connector is configured to rotate about an axis during use, and the intermediate component allows for limited relative rotation between the housing and the base about the axis. In this way, the connector transmits torque between the housing (e.g., including the first component) and the base (e.g., including the second component).

[0032] As already noted, the connector includes a housing for connecting a first component at a first end and a base for connecting a second component at a second end. In some embodiments, the first end is an upper end and the second end is a lower end. In other words, the housing may be oriented towards the top end of the connector, while the base may be oriented towards the bottom end of the connector. In some embodiments, the first end is a lower end and the second end is an upper end. In other words, the housing may be oriented towards the bottom end of the connector, while the base may be oriented towards the top end of the connector.

[0033] The relative rotation between the shell and the base is advantageous because it allows for the cushioning or absorption of sudden, strong forces, thereby protecting the drill bit, drill pipe, and / or other drilling components.

[0034] For example, some areas of the ground being drilled may be uneven, which could cause the drill bit to rotate relatively freely for a short period before contacting harder rock or other features. This can generate sudden forces on the drill bit, causing shock to the drilling equipment and potentially damaging various components, especially the drill bit itself. The drill bit and drill rod together can have a large mass and momentum, so the assembly cannot easily decelerate when contacting harder rock, resulting in enormous forces. However, connectors allow the drill bit to decelerate temporarily more quickly, helping to distribute forces and prevent damage.

[0035] Further features of embodiments of the connector will now be described with reference to the accompanying drawings.

[0036] In some embodiments, the intermediate component is made of an elastically deformable material. For example, the intermediate component may be made of a material such as, but not limited to, rubber, a highly elastic metal such as high-carbon spring steel, or a plastic. In these embodiments, the intermediate component may deform as the base and shell rotate relative to each other before the component moves back to its original position and the intermediate component returns to its original shape.

[0037] In these or other embodiments, the relative rotation between the housing and the base can be limited. That is, there may be a maximum degree of rotation from the nominal position through which the component cannot move. In one embodiment, for example, the relative rotation between the housing and the base is limited to 0° to 30°, such as 1° to 28°, 2° to 26°, 3° to 24°, 4° to 22°, or 5° to 20°. With respect to the lower limit, the relative rotation can be limited to greater than 1°, such as greater than 2°, greater than 3°, greater than 4°, or greater than 5°. With respect to the upper limit, the relative rotation can be limited to less than 30°, less than 28°, less than 26°, less than 24°, less than 22°, or less than 20°.

[0038] In some embodiments, the connector may have a central bore for fluid communication between the drill pipe and the drill bit via the connector. This allows any desired drilling fluid (such as air or drilling mud) to be pumped down the center of the drill pipe, through the connector, and into the drill bit, where the drilling fluid can exit to bring cuttings back to the surface.

[0039] In some embodiments, the base may be at least partially located inside the shell. The intermediate component may be a sleeve fitted between the base and the shell and substantially inside the shell. That is, during assembly, there may be a space between at least a portion of the base and the shell, which allows the intermediate component to be shaped to fill that space.

[0040] In some specific exemplary embodiments, the base may be formed as an elongated cylinder having a flange extending from a lower end perpendicular to the axis. This flange may be configured to attach to a drill bit. Multiple racks may also extend radially from the outer surface of the cylinder. Similarly, in some specific exemplary embodiments, the shell may be formed as a cylindrical body having multiple grooves on its inner surface. These grooves may be configured to receive the racks of the base.

[0041] Optionally, in some embodiments, the shell may be formed with a cylindrical body having a plurality of teeth extending radially from an inner surface, and the outer surface of the cylinder may be formed with a plurality of grooves. These grooves may be configured to receive the teeth of the base.

[0042] Such an embodiment may be advantageous because the rack and groove can interact to limit rotation of the base relative to the shell. The intermediate component can also be formed as a sleeve that fills the space between the rack of the base and the groove of the shell, thereby suppressing relative rotation before reaching a limit and preventing any movement between the base and the shell without significant force.

[0043] As already noted, in some embodiments, the intermediate component is formed as a sleeve. The structure of the sleeve is not particularly limited, and the sleeve may or may not include a number of individual sub-components. In some cases, for example, the intermediate component may be a single continuous sleeve. In other cases, the intermediate component may be a sleeve formed by multiple sub-components, for example, these multiple sub-components may be linked or otherwise connected or adjacent to form the intermediate component.

[0044] The nominal thickness of the intermediate component is crucial to the effective performance of the drill bit connector of this invention. That is, the intermediate component must be appropriately thick to support the necessary functions of the drill bit connector. In particular, if the intermediate component is too thin, it will not be able to adequately suppress vibrations of the drill string components. Furthermore, if the intermediate component is too thin, it may be overly sensitive to damage, degradation, deterioration, or failure.

[0045] In some embodiments, the intermediate components have a substantially consistent nominal thickness. This nominal thickness can be any suitable amount and can vary depending on the connector size and various other factors. In one embodiment, for example, the nominal thickness is 0.5 mm to 30 mm, such as 1 mm to 25 mm, 2 mm to 20 mm, or 5 mm to 15 mm. At the upper limit, the nominal thickness can be less than 30 mm, such as less than 25 mm, less than 20 mm, or less than 15 mm. At the lower limit, the nominal thickness can be greater than 0.5 mm, such as greater than 1 mm, greater than 2 mm, or greater than 5 mm.

[0046] In some embodiments, the nominal thickness of the intermediate component varies. For example, the nominal thickness of the intermediate component may increase or decrease periodically around its circumference. In some cases, the intermediate component may be thicker with respect to counterclockwise rotation. Exemplary intermediate components with different nominal thicknesses include... Figure 5 As shown in the figure, the nominal thickness varies periodically. Furthermore, in... Figure 5 In the embodiment shown, the intermediate component is fabricated such that the base rotates against the thickest part during drilling.

[0047] In embodiments of drill connectors with varying nominal thicknesses for intermediate components, the thickness can be measured at its thickest point. In other words, the intermediate component can be described by its maximum nominal thickness. For example, in one embodiment, the maximum nominal thickness is 0.5 mm to 30 mm, such as 1 mm to 25 mm, 2 mm to 20 mm, or 5 mm to 15 mm. At the upper limit, the maximum nominal thickness can be less than 30 mm, such as less than 25 mm, less than 20 mm, or less than 15 mm. At the lower limit, the maximum nominal thickness can be greater than 0.5 mm, such as greater than 1 mm, greater than 2 mm, or greater than 5 mm.

[0048] In some embodiments, the elongated cylinder of the base is substantially fitted within the housing. A locking ring can be secured to the end of the elongated cylinder opposite the flange, such that the locking ring prevents the base from moving out of the housing. That is, the base flange prevents movement in one direction, while the locking ring prevents movement in another direction. In this way, even if an intermediate component exists in one part, the base and the housing are directly secured to each other.

[0049] In some exemplary embodiments, the flange may have one or more through-holes. An intermediate part can then be formed by injecting or pouring a curable compound through these through-holes. Alternatively, during manufacturing, the base and shell may first be fixed together, and then a curable compound may be injected through the through-holes to form the intermediate part.

[0050] In some embodiments, a drill bit assembly may be provided, including a connector such as [example connector name], wherein the drill bit is secured to a base. For example, the drill bit may be welded directly to the base during manufacturing, or secured in some other suitable manner.

[0051] In some specific embodiments, the drill bit may be a polycrystalline diamond composite (PDC) drill bit. This type of drill bit is well-known for use in oil and gas drilling where the surface composition being drilled is relatively uniform. This drill bit design is known to be very effective in such situations, but is generally considered unsuitable for conditions where the surface is less uniform, such as in boreholes in areas with faults, volcanic intrusions, and other inconsistencies that could damage the drill bit. However, a connector is advantageous because it can provide sufficient damping to allow the use of this type of drill bit in such situations without causing excessive damage to the drill bit or other components.

[0052] Exemplary embodiments of methods for manufacturing or assembling connectors for connecting drill bits to drill pipes will now be described. The connector may be similar to the connectors previously described, comprising a housing, a base, and an intermediate component disposed therebetween. Methods of manufacturing such a connector may include forming the housing and base before at least partially inserting the base into the housing and securing them to each other. The intermediate component can then be formed by injecting or pouring a curable compound into the space between the housing and the base.

[0053] Once the curable compound is allowed to harden, the connector is complete, and it has the advantage that the intermediate components will be shaped to fit very closely to the base and shell. Therefore, any tolerances in the manufacturing of the base and intermediate components will not cause problems when assembling the connector.

[0054] It should be understood that different methods of manufacturing the connector can be used in alternative embodiments. In such instances, the connector can still be similar to that described previously, comprising a housing, a base, and an intermediate component disposed therebetween. Methods of manufacturing such a connector may include forming the housing, the base, and the intermediate component, and inserting the base at least partially into the housing, with the intermediate component disposed therebetween. The base and the housing can then be secured to each other.

[0055] An exemplary embodiment of the blast hole drilling method will now be described. In this method, a connector is used to secure the drill bit to the drill rod. Advantageously, the connector can be similar to the connector previously described. The assembled drill bit, connector, and drill rod can then be used with a drilling rig to drill a blast hole.

[0056] In one specific exemplary embodiment, the drill bit is a polycrystalline diamond composite (PDC) drill bit. As previously stated, such drill bits are generally unsuitable for drilling blast holes because the ground quality (especially if blasting has previously occurred) is too inconsistent and often leads to drill bit damage. Since drill bits are very expensive, frequent replacement or even repair of them in these situations is not cost-effective. However, by using the described connector, this method allows the drill bit to operate for a longer period, making its use feasible under these conditions.

[0057] Several exemplary embodiments of the connector of the present invention will now be described with reference to the accompanying drawings.

[0058] First refer to Figure 1-5 ,in particular Figure 2 One embodiment of the connector shown is... Figure 2 The internal components of the assembled connector 100 are shown most clearly. The connector 100 includes a housing 200, a base 300, and an intermediate component 400.

[0059] Figure 2 and 3The housing 200 of this embodiment is shown in more detail. In the illustrated embodiment, the housing 200 has a cylindrical body 202 with a connecting portion 203 at its upper end. The connecting portion 203 is configured to connect to a drill string component (e.g., a drill rod) and has tapered threads 204 on its outer surface.

[0060] The shell 200 has a hollow core 210 that widens at the end near the connecting portion 203 to form a step 211. At the opposite end, the hollow core 210 includes a series of grooves 212 that give the hollow core 210 of this embodiment a cross-sectional shape resembling an asterisk or star.

[0061] Figure 2 and 4 The base 300 of this embodiment is shown in more detail. In the illustrated embodiment, the base 300 has an elongated cylinder 302 having a flange 303 extending from its lower end perpendicular to the longitudinal axis of the cylinder 302. The flange 303 may be configured to attach to a drill string component 600 (e.g., a drill bit), such as by means of... Figure 6 The weld shown is 601. It should be understood that... Figure 6 The drill bit shown is for illustrative purposes only, and the drill string assembly 600 can be any other component assembled in this manner.

[0062] A series of racks 305 extend radially from the outer surface of the cylinder 302. The racks 305 make this portion of the base 300's cross-sectional appearance generally similar to, only smaller than, the cross-sectional appearance of the shell 200 in the recess 212 region. This allows the base 300 and the shell 200 to be assembled to each other, as follows. The end of the cylinder 302 opposite the flange 303 includes threads 308, which are also used to connect the base 300 to the shell 200, and will also be described below.

[0063] Figure 2 and 5 The intermediate component 400 of this embodiment is shown in more detail. In the illustrated embodiment, the intermediate component 400 has an outer surface 402 that substantially matches the shape of the hollow core 210 and the groove 212 of the shell 200. It also has an inner surface 403 that substantially matches the cylinder 302 and the rack 305 of the base 300. Thus, the intermediate component 400 is a sleeve fitted onto the base 300 and inside the shell 200, filling the space between the rack 305 of the base 300 and the groove 212 of the shell 200.

[0064] As before, when assembling connector 100, intermediate component 400 can be disposed between base 300 and housing 200. Figure 5In the illustrated embodiment, the intermediate component 400 has a varying thickness, with a maximum nominal thickness 405 of approximately 10 mm in this embodiment. It should be understood, of course, that this may vary in alternative embodiments.

[0065] When assembling the connector 100 of this embodiment, the base 300 is inserted into the housing 200, such that the flange 303 abuts the lower end of the housing 200. In this embodiment, a rib 215 is provided at the lower end of the housing 200, and the rib 215 is fitted into a slot 315 in the flange 303 of the base 300 for alignment.

[0066] The base 300 is secured in place within the housing 200 using a locking ring 500 with an internal thread 501, which is mounted on the thread 308 of the base 300. The locking ring 500 can be threaded onto the base 300 up to the step 211 at the upper end of the housing 200. In this way, the base 300 is secured within the housing 200 because the locking ring 500 prevents removal.

[0067] In some cases, a slot may be used to tighten the locking ring 500 into place. In other cases, the locking ring may include, for example, a hole for securing a screw to prevent the locking ring 500 from loosening over time. Other tools may be used to secure the locking ring, such as ball bearings and locking pins. Advantageously, the components are locked together to prevent the base 300 from being removed from the housing 200, while still allowing some degree of relative rotation between these components. In the illustrated embodiment, a washer 505 is disposed between the locking ring 500 and the step 211 of the housing 200 to reduce friction and / or prevent wear caused by relative rotation.

[0068] During the use of connector 100, it rotates about the longitudinal axis of cylinder 302, which will align with the intended axis of rotation of the drill pipe and drill bit. Under the condition of an unusually strong rotational force applied between the drill pipe and drill bit, intermediate component 400 deforms, thereby allowing limited relative rotation between housing 200 and base 300 about the axis.

[0069] While such relative rotation is possible, the extent of the possible relative rotation is limited because the rack 305 is partially located within the groove 212. In this embodiment, it is approximately 4-6° from the neutral position, but it should be understood that this can vary in alternative embodiments.

[0070] The intermediate component 400, which allows this relative rotation, will be made of an elastically deformable material so that it will substantially return to its original shape once the force is removed. In the described embodiment, this will be plastic, but it is understood that many other materials may be used alternatively.

[0071] To form the intermediate component 400, the base 300 can first be inserted into and secured to the shell 200. A curable compound can then be injected into the space between the base 300 and the shell 200 through the through-hole 317. The compound can completely fill the space and then cure, thereby forming the intermediate component 400. Therefore, excess material retained in the through-hole 317 forms spikes 407 extending from the ends of the intermediate component 400.

[0072] While this embodiment relates to forming the intermediate component 400 by injection or casting as described above, it should be understood that in other embodiments the intermediate component may also be formed separately prior to subsequent assembly with the base 300 and the shell 200.

[0073] The base 300 has a central bore 318 that extends through the length of the cylinder 302 and through the flange 303. Since the base 300 extends fully through the housing 200 when the connector 100 is assembled, this means that the central bore 318 effectively extends through the entire length of the connector 100. Therefore, the bore 318 allows fluid communication between the drill pipe and the drill bit 600 via the connector. Thus, drilling fluids such as air or drilling mud that may be required can still be supplied to the drill bit 600.

[0074] As already noted, the connectors described herein can vary. In particular, the drill string components to be connected and the means for connecting the connectors to each drill string component can vary in various embodiments. To further illustrate this, refer to... Figure 7 and 8 The additional embodiments shown are illustrated.

[0075] Figure 7 Another embodiment of the connector is shown, including a housing 200 (which includes a non-adjacent sub-component cylinder 200B), a base 300, and an intermediate component 400. Figure 1-6 Similar to the illustrated embodiment, the base of this embodiment includes a base 300 having an elongated cylinder 302 with a flange 303 extending from a lower end perpendicular to the longitudinal axis of the cylinder 302. A series of racks 305 extend radially from the outer surface of the cylinder 302. The end of the cylinder 302 opposite to the flange 303 includes a slot 308X, which also serves to connect the base 300 to the housing 200. The connector also includes a locking ring 500 for attaching the base 300 to the housing 200.

[0076] exist Figure 7 In one embodiment, the housing 200 has a connecting portion at its upper end, and this connecting portion can be configured to connect to the drill string component via a tapered thread (not shown) on its inner surface. Simultaneously, the base 300 can be configured to connect to the drill string component via a tapered thread on its outer surface.

[0077] Figure 8 Another embodiment of the connector is shown, comprising a housing 200 (which includes non-adjacent sub-component cylinders 200B), a base 300, and an intermediate component 400. Figure 1-6 Similar to the illustrated embodiment, the base of this embodiment includes a base 300 having an elongated cylinder 302 with a flange 303 extending from a lower end perpendicular to the longitudinal axis of the cylinder 302. A series of racks 305 extend radially from the outer surface of the cylinder 302. The end of the cylinder 302 opposite to the flange 303 includes a slot 308X, which also serves to connect the base 300 to the housing 200. The sub-component cylinder 200B has a hollow core that widens to form a step 21IB and includes a series of grooves 212B. The connector of this embodiment also includes a locking ring 500 for attaching the base 300 to the housing 200.

[0078] exist Figure 8 In one embodiment, the housing 200 has a connecting portion at its upper end, which can be configured to be connected to the drill string component by welding or a tapered thread (not shown). Meanwhile, the base 300 can be configured to be connected to the drill string component by welding.

[0079] In the foregoing description of the preferred embodiments, specific terms have been used for clarity. However, the invention is not intended to be limited and should be understood to include all technical equivalents that operate in a similar manner to achieve similar technical purposes.

[0080] In this specification and the claims thereafter, unless the context otherwise requires, the word “comprising” and variations thereof, such as “comprising” or “including”, shall be understood to include integers or groups of integers or steps, but not to exclude any other integers or groups of integers.

[0081] Those skilled in the art will understand that many variations and modifications will become apparent. All such variations and modifications that become apparent to those skilled in the art should be considered to fall within the spirit and scope of the invention as described above.

[0082] Example

[0083] As used below, any reference to a series of embodiments should be understood as referring to each of those embodiments individually (e.g., "Embodiments 1-4" should be understood as "Embodiments 1, 2, 3, or 4").

[0084] Example 1 is a connector for connecting a first drill string component to a second drill string component. The connector includes: a housing having a first connecting portion at a first end for connecting to the first drill string component; a base connected to the housing and having a second connecting portion at a second end for connecting to the second drill string component; and an intermediate component disposed between the base and the housing. The connector is configured to rotate about an axis during use, and the intermediate component is configured to allow limited relative rotation between the housing and the base about the axis.

[0085] Example 2 is the connector of Example 1, wherein the first drill string component is selected from the group consisting of the drill bit, drill collar, drill pipe section, stabilizer, mud motor, mud motor assembly and bottom hole drilling tool assembly.

[0086] Example 3 is the connector of Examples 1-2, wherein the second drill string component is selected from the group consisting of the drill bit, drill collar, drill pipe section, stabilizer, mud motor, mud motor assembly and bottom hole drilling tool assembly.

[0087] Example 4 is a connector of Examples 1-3, wherein the first drill string component includes a mud motor, drill collar, rotary guide tool or metal tubular component, and wherein the second drill string component includes a drill bit.

[0088] Example 5 is a connector of Examples 1-4, wherein the intermediate component is made of an elastically deformable material.

[0089] Example 6 is a connector of Examples 1-5, wherein the first drill bit is connected to the housing by thread or welding, or wherein the first drill bit component is adjacent to the housing.

[0090] Example 7 is the connector of Examples 1-6, wherein the second drill string component is connected to the base by thread or welding, or wherein the second drill string component is adjacent to the base.

[0091] Example 8 is a connector of Examples 1-7, wherein the connector includes a central hole for fluid communication between a first drill string component and a second drill string component via the connector.

[0092] Example 9 is a connector of Examples 1-8, wherein the relative rotation between the shell and the base is restricted to an angle of less than 30° from the nominal position.

[0093] Example 10 is a connector of Examples 1-9, wherein the intermediate component has a maximum nominal thickness of less than 30 mm.

[0094] Example 11 is a connector of Examples 1-10, wherein the base is at least partially located inside the housing, and the intermediate component is a sleeve assembled between the base and the housing and substantially located inside the housing.

[0095] Example 12 is a connector of Examples 1-11, wherein the base includes: an elongated cylinder having a flange extending from a lower end perpendicular to the axis, the flange being configured for attachment to a second drill string component; and a plurality of racks extending radially from the outer surface of the elongated cylinder.

[0096] Example 13 is a connector of Example 12, wherein the shell includes a cylindrical body having a plurality of grooves on its inner surface configured to receive a rack of the base.

[0097] Example 14 is the connector of Example 13, wherein the intermediate component is a sleeve that fills the space between the rack of the base and the groove of the shell.

[0098] Example 15 is a connector of Examples 12-14, wherein the elongated cylinder of the base is substantially fitted inside the housing, and a locking ring is fixed to the end of the elongated cylinder opposite the flange, such that the locking ring prevents the base from being removed from the housing.

[0099] Example 16 is a connector of Examples 12-15, wherein the flange includes one or more through holes, and a curable compound is injected or poured through one or more through holes to form an intermediate component.

[0100] Example 17 is a method of manufacturing a connector for connecting a first drill string component to a second drill string component, the connector including a shell, a base, and an intermediate component disposed therebetween, the method comprising the steps of: forming the shell and the base; inserting the base at least partially into the shell and securing it to each other; and forming the intermediate component by injecting or pouring a curable compound into the space between the shell and the base.

[0101] Example 18 is a method of manufacturing a connector for connecting a first drill string component to a second drill string component, the connector including a housing, a base and an intermediate component disposed therebetween, the method comprising the steps of: forming the housing, the base and the intermediate component; inserting the base at least partially into the housing, the intermediate component being disposed therebetween; and securing the base and the housing to each other.

[0102] Example 19 is a drilling method comprising the steps of: securing a drill bit to a drill string assembly using a connector according to claim 1 to form an assembled drill bit; and using the assembled drill string with a drilling rig to perform drilling.

[0103] Example 20 is a drilling method of Example 19, wherein the drill bit is a polycrystalline diamond composite (PDC) drill bit or a claw drill bit.

Claims

1. A connector for connecting a first drill string assembly to a second drill string assembly, the connector comprising: The housing includes a first connecting portion located at a first end for connection to a first drill string component; The base is connected to the shell and includes a second connecting portion located at the second end for connecting to the second drill string component; An intermediate component is disposed between the base and the shell; as well as A locking ring, which is removably connected to the base and connects the base to the housing to restrict axial movement between the base and the housing; The connector is configured to rotate about an axis during use, and the intermediate component is configured to allow limited relative rotation between the housing and the base about the axis.

2. The connector according to claim 1, wherein, The first drill string component is selected from the group consisting of drill bit, drill collar, drill pipe section, stabilizer, mud motor, mud motor assembly, and bottom hole drilling tool assembly.

3. The connector according to claim 1, wherein the second drill string component is selected from the group consisting of a drill bit, drill collar, drill pipe section, stabilizer, mud motor, mud motor assembly, and bottom hole drilling tool assembly.

4. The connector according to claim 1, wherein, The first drill string component includes a mud motor, drill collar, rotary guide tool, or metal tubular component; and the second drill string component includes a drill bit.

5. The connector according to claim 1, wherein, The intermediate component is made of an elastic, deformable material.

6. The connector according to claim 1, wherein, The first drill string is connected to the housing by threads or welding, or the first drill string component is adjacent to the housing.

7. The connector according to claim 1, wherein, The second drill string component is connected to the base by threads or welding, or the second drill string component is adjacent to the base.

8. The connector according to claim 1, wherein, The connector includes a central hole for fluid communication between the first drill string component and the second drill string component.

9. The connector according to claim 1, wherein, The relative rotation between the shell and the base is restricted to an angle of less than 30° from the nominal position.

10. The connector according to claim 1, wherein, The intermediate component has a maximum nominal thickness of less than 30 mm.

11. The connector according to claim 1, wherein, The base is located at least partially inside the shell, and the intermediate component is a sleeve assembled between the base and the shell and located substantially inside the shell.

12. The connector according to claim 1, wherein, The base includes: An elongated cylinder having a flange that projects from the lower end of the axis and is perpendicular to the axis; the flange is configured for attachment to the second drill string component; and Multiple racks extend radially from the outer surface of the elongated cylinder.

13. The connector according to claim 12, wherein, The shell includes a cylindrical body with a plurality of grooves on its inner surface, the grooves being configured to receive a rack of teeth on the base.

14. The connector according to claim 13, wherein, The intermediate component is a sleeve that fills the space between the rack of the base and the groove of the shell.

15. The connector according to claim 12, wherein, The elongated cylinder of the base is substantially fitted inside the housing, and the locking ring is fixed to the end of the elongated cylinder opposite the flange, such that the locking ring prevents the base from being removed from the housing.

16. The connector according to claim 12, wherein, The flange includes one or more through holes, and the intermediate component is formed by injecting or pouring a curable compound into the one or more through holes.

17. A method of manufacturing a connector for connecting a first drill string assembly to a second drill string assembly, the connector comprising a housing, a base, an intermediate component disposed between the housing and the base, and a locking ring, the locking ring being connected to the base and connecting the base to the housing to prevent the housing from being removed from the base, the method comprising the steps of: Forming the shell and base; The base is at least partially inserted into the shell and fixed to each other; as well as The intermediate component is formed by injecting or pouring a curable compound into the space between the shell and the base.

18. A method of manufacturing a connector for connecting a first drill string assembly to a second drill string assembly, the connector comprising a housing, a base, an intermediate component disposed therebetween, and a locking ring, the locking ring being connected to the base and connecting the base to the housing to prevent the housing from being removed from the base, the method comprising the steps of: Forming the shell, base, and intermediate components; The base is at least partially inserted into the shell, and the intermediate component is disposed between the base and the shell; as well as The base and the shell are fixed together.

19. A drilling method, the method comprising the following steps: The drill bit is secured to the drill string assembly using the connector as described in claim 1 to form an assembled drill bit; and Drilling is performed using the drill string of the assembly, which includes a drilling rig.

20. The method according to claim 19, wherein the drill bit is a polycrystalline diamond composite (PDC) drill bit or a claw-shaped drill bit.

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