Device, system and method for cleaning an element

Abstract

A downhole tool includes a body having a longitudinal axis and a fluid passage extending through the body. The downhole tool includes at least one blade having one or more engagement surfaces thereon. At least one junk slot extends adjacent to the at least one blade. The downhole tool includes a cleaning element at the longitudinal axis of the body. The cleaning element has a base aperture in fluid communication with the fluid passage. The cleaning element includes at least one opening for fluid to flow from the base aperture out of the downhole tool through the at least one junk slot. A flow direction of the at least one opening is offset from the longitudinal axis.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. non-provisional application No. 18 / 408,869, filed January 10, 2024, entitled “DEVICES, SYSTEMS, AND METHODS FORA CLEANING ELEMENT,” the disclosure of which is incorporated herein by reference in its entirety. Background Technology

[0003] Wellbores can be drilled into surface locations or the seabed for various exploration or extraction purposes. For example, wellbores can be drilled to access fluids stored in underground formations, such as liquid and gaseous hydrocarbons, and to extract the fluids from the formation. Wellbores used to produce or extract fluids can be formed in soil formations using drilling tools, such as drill bits for drilling the wellbore and reamers for enlarging the wellbore diameter. Drilling tools may include one or more cutting elements attached to blades attached to the tool. Typically, the tool includes one or more injectors or nozzles for circulating drilling fluid through features of the tool, such as blades and cutting elements. In some cases, typical downhole tools may not adequately circulate drilling fluid to the central region of the drill bit. Additionally, typical downhole tools may not circulate drilling fluid, resulting in drilling fluid originating from the central region of the drill bit. Summary of the Invention

[0004] In some embodiments, the downhole tool includes a body having a longitudinal axis and a fluid passage extending through the body. The downhole tool includes at least one blade having one or more mating surfaces thereon. At least one waste container extends adjacent to the at least one blade. The downhole tool includes a cleaning element at the longitudinal axis of the body. The cleaning element has a base orifice in fluid communication with the fluid passage. The cleaning element includes at least one opening for allowing fluid to flow from the base orifice through the at least one waste container out of the downhole tool. The flow direction of the at least one opening is offset from the longitudinal axis.

[0005] In some embodiments, a downhole tool cleaning element includes a body configured to be connected to the downhole tool at its central axis. The cleaning element includes a base orifice within the body and configured to be in fluid communication with a fluid passage of the downhole tool when the body is connected to the downhole tool. The cleaning element includes at least one opening in the body for allowing fluid to flow from the base orifice out of the at least one opening and to at least one feature of the downhole tool, wherein the flow direction of the at least one opening is offset from the central axis.

[0006] In some embodiments, the downhole tool includes a body having a longitudinal axis and a fluid channel extending through the body. The downhole tool includes at least one blade having one or more mating surfaces thereon. At least one waste container extends adjacent to the at least one blade. The downhole tool includes a cleaning element at the longitudinal axis of the body. The cleaning element has a matrix orifice in fluid communication with the fluid channel. The cleaning element includes at least one opening for allowing fluid to flow from the matrix orifice through the at least one waste container out of the downhole tool. The flow direction of the at least one opening is offset from the longitudinal axis. The cleaning element includes an ultrahard layer bonded to the upper surface of the cleaning element.

[0007] This summary is provided to introduce the selection of concepts further described in specific embodiments. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help limit the scope of the claimed subject matter. Additional features and aspects of embodiments of this disclosure will be set forth herein and will be apparent in part from the description, or may be learned by practicing these embodiments. Attached Figure Description

[0008] To describe how the above and other features of this disclosure can be obtained, a more specific description will be given by reference to specific embodiments shown in the accompanying drawings. For better understanding, in the various drawings, the same elements are denoted by the same reference numerals. While some drawings may be schematic or exaggerated representations of concepts, at least some drawings are drawn to scale. It should be understood that the drawings depict some exemplary embodiments, and the embodiments will be described and explained with additional features and details using the drawings, in which: Figure 1 An example of a drilling system 100 for drilling formations to form a wellbore according to at least one embodiment of the present disclosure is shown; Figure 2-1 This is a perspective view of a drill bit including a cleaning and cutting element according to at least one embodiment of the present disclosure; Figure 2-2 yes Figure 2-1 A top view of the drill bit; Figure 2-3 yes Figure 2-1 A cross-sectional view of the drill bit; Figure 2-4 yes Figure 2-1 Longitudinal cross-sectional view of the drill bit; Figure 3-1 This is a side view of a cleaning cutting element according to at least one embodiment of the present disclosure; Figure 3-2 yes Figure 3-1 A side cross-sectional view of the clean cutting element; Figure 4This is a cross-sectional view representing a cleaning cutting element according to at least one embodiment of the present disclosure; Figure 5 This is a cross-sectional view representing a cleaning cutting element according to at least one embodiment of the present disclosure; Figure 6 This is a cross-sectional view representing a cleaning cutting element according to at least one embodiment of the present disclosure; Figure 7 This is a longitudinal cross-sectional view of a drill bit according to at least one embodiment of the present disclosure, the drill bit having a cleaning and cutting element fixed to its body; Figure 8-1 This is an exploded view of a cleaning and cutting system according to at least one embodiment of the present disclosure; Figure 8-2 yes Figure 8-1 A cross-sectional view of the assembled cleaning and cutting system; Figure 9 This is a flowchart of a method for forming a cutting element according to at least one embodiment of the present disclosure; Figure 10-1 This is a side view representing a cleaning element according to at least one embodiment of the present disclosure; Figure 10-2 This is a side cross-sectional view representing a cleaning element implemented in a downhole tool according to at least one embodiment of the present disclosure; Figure 11-1 This is a side cross-sectional view representing a cleaning element implemented in a downhole tool according to at least one embodiment of the present disclosure; Figure 11-2 This is a top view of a cleaning element implemented in a downhole tool according to at least one embodiment of the present disclosure; Figure 12 This is a side view schematic diagram of a cleaning element implemented in a downhole tool according to at least one embodiment of the present disclosure; Figure 13-1 A representation of a cleaning element implemented in a downhole tool according to at least one embodiment of the present disclosure is shown; Figure 13-2 A representation of a cleaning and cutting element implemented in a downhole tool according to at least one embodiment of the present disclosure is shown; Figure 14 A representation of a cleaning element implemented in a downhole tool according to at least one embodiment of the present disclosure is shown; Figure 15-1 and Figure 15-2 A representation of a cleaning and cutting element implemented in a downhole tool according to at least one embodiment of the present disclosure is shown; Figure 16-1 A representation of a cleaning element according to at least one embodiment of the present disclosure is shown; and Figure 16-2 A representation of a cleaning element according to at least one embodiment of the present disclosure is shown. Detailed Implementation

[0009] This disclosure generally relates to apparatus, systems, and methods for cutting elements and / or cleaning elements having fluid paths to guide drilling fluid from a matrix bore in the matrix to a conduit having an outlet opening in the matrix sidewall. Typically, a drill bit may have limited fluid flow in its central region. The drill bit may include cutting elements and / or cleaning elements extending into its central region to remove material. To remove chips and / or cool the drill bit, the drill bit may typically include one or more nozzles located in a scrap channel between two cutting edges. Nozzles can effectively guide fluid between the cutting edges, but drilling fluid may not circulate around the central region of the drill bit. Alternatively, due to the angle of conventional nozzle orientation, areas of the drill bit (such as the nose and shoulder regions, portions of the cutting edges, mating surfaces, etc.) may not have effective hydraulic energy for cooling and for rapidly removing chips. This can reduce the efficiency of cutting removal and / or cooling of the cutting elements in the center, nose, and / or shoulder regions of the drill bit, as well as other features.

[0010] According to at least one embodiment of this disclosure, a cutting element can be fixed to the central region of the drill bit. Drilling fluid can pass through the body of the drill bit and enter the base bore of the cutting element. The drilling fluid can be guided out of the cutting element through one or more conduits. The conduits can direct the drilling fluid to one or more structures on the drill bit. For example, the drilling fluid can be directed to one or more scrap channels between two blades of the drill bit, and / or along one or more blades and / or engagement surfaces of the drill bit. This can help improve fluid flow in the central and nose regions of the drill bit and / or along the engagement profile of the drill bit. Improving fluid flow in this way can help increase the cutting efficiency of the drill bit and / or reduce the accumulation of chips and other materials in the central and nose regions of the drill bit. In some embodiments, it can be advantageously implemented to guide the drilling fluid in this way to direct the drilling fluid away from one or more locations on the drill bit. For example, in some cases, it may be desirable to reduce hydraulic energy in unwanted areas of the drill bit. This can help reduce and / or minimize wear, erosion, material loss, or other undesirable damage to the drill bit.

[0011] Figure 1 An example of a drilling system 100 for drilling formation 101 to form a wellbore 102 is shown. The drilling system 100 includes a drilling rig 103 for rotating a drilling tool assembly 104 that extends downward into the wellbore 102. The drilling tool assembly 104 may include a drill string 105, a bottom hole assembly (“BHA”) 106, and a drill bit 110 attached to the downhole end of the drill string 105.

[0012] The drill string 105 may include several joints of the drill pipe 108 connected end-to-end via a tool joint 109. The drill string 105 transmits drilling fluid through a central bore and transmits rotational power from the drilling rig 103 to the BHA 106. In some embodiments, the drill string 105 may also include additional components such as sub sections, short joints, etc. The drill pipe 108 provides a hydraulic passage through which drilling fluid is pumped from the surface. The drilling fluid exits through nozzles, orifices, or other orifices of selected size in the drill bit 110 to cool the drill bit 110 and its cutting structures, and to remove cuttings from the wellbore 102 during drilling.

[0013] BHA 106 may include drill bit 110 or other components. An exemplary BHA 106 may include additional or other components (e.g., connected between drill string 105 and drill bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (“MWD”) tools, logging-while-drilling (“LWD”) tools, downhole motors, reamers, slug cutters, hydraulic disconnectors, slappers, vibration or damping tools, other components, or combinations thereof. BHA 106 may also include a rotary steerable system (RSS). The RSS may include an orientation drilling tool that changes the orientation of drill bit 110, thereby altering the wellbore trajectory. At least a portion of the RSS may maintain a geostationary position relative to an absolute reference frame (e.g., gravity, magnetic north, and / or true north). Using measurements obtained from the geostationary position, the RSS can position drill bit 110, change the path of drill bit 110, and guide the orientation drilling tool along its projected trajectory.

[0014] Typically, drilling system 100 may include other drilling components and accessories, such as specialized valves (e.g., kerb plugs, blowout preventers, and safety valves). Additional components included in drilling system 100 may be considered part of drilling tool assembly 104, drill string 105, or BHA 106, depending on their location within drilling system 100.

[0015] Drill bit 110 in BHA 106 can be any type of drill bit suitable for degrading downhole materials. For example, drill bit 110 can be a drill bit suitable for drilling formation 101. Example types of drill bits used for drilling formations are stationary cutter or scraper bits. In other embodiments, drill bit 110 can be a milling cutter for removing downhole metal, composite materials, elastomers, other materials, or combinations thereof. For example, drill bit 110 can be used with a directional drilling tool to grind into the casing 107 that lines the wellbore 102. Drill bit 110 can also be a chip mill for grinding away tools, plugs, cement, other materials, or combinations thereof within the wellbore 102. The chips or other cuttings generated by using the mill can be lifted to the surface or allowed to fall downhole.

[0016] The drill bit 110 may include a cleaning element or a cleaning cutting element fixed to the central region of the drill bit for circulating drilling fluid from the central region of the drill bit. As discussed herein, this can help improve the circulation of drilling fluid in the central region, thereby increasing drilling efficiency and / or reducing or preventing the accumulation of cuttings and / or other materials in the central region.

[0017] Figure 2-1 This is a perspective view of a drill bit 210 according to at least one embodiment of the present disclosure. The drill bit 210 includes a body 212 and a plurality of blades 214 extending from the body 212. The drill bit 210 may also include a plurality of cutting elements 216 fixed to one or more of the blades 214. When the drill bit 210 rotates, the cutting elements 216 may engage the formation and degrade at least a portion of the formation.

[0018] The drill bit 210 may also include one or more nozzles 218. Drilling fluid can pass through fluid channels in the body 212 of the drill bit 210 and can be guided out of the drill bit 210 through the nozzles 218. This helps to cool the drill bit 210, including the cutting element 216, the blades 214, the body 212, and other parts of the drill bit 210. In some cases, drilling fluid guided from one or more nozzles 218 can pass through a scrap groove 220 located between two adjacent blades 214. Cuttings or material removed by the cutting element 216 during drilling can be flushed away from the cutting element 216 through the scrap groove 220 in front of the cutting element 216.

[0019] According to at least one embodiment of this disclosure, the drill bit 210 may include a cleaning and cutting element 222. The cleaning and cutting element 222 may include a superhard layer 223 bonded to a substrate 225. The superhard layer 223 may be formed of a superhard material, such as polycrystalline diamond (PCD) and / or polycrystalline diamond composite (PDC).

[0020] In some embodiments, the cleaning cutting element may include both a substrate and a PCD on the top 251 of the cleaning cutting element 222. For example, the top 251 may include a conical superhard layer 223. The substrate material 225 may extend into the conical top 251 of the cleaning cutting element 222.

[0021] The superhard layer 223 can be shaped and positioned to engage the formation. For example, the superhard layer 223 can have a conical shape. The conical superhard layer 223 can engage the formation to degrade it. In some embodiments, the superhard layer 223 can be configured to engage the formation perpendicularly along the longitudinal axis 228. As the drill bit 210 descends along the longitudinal axis 228 into the formation, the superhard layer 223 can contact the formation and crush it at the tip of the cone. This can help improve formation degradation in the central region 226 of the drill bit 210, where rotation of the drill bit 210 can limit and / or reduce shearing motion of the cutting element 216 in the central region 226.

[0022] In some embodiments, the superhard layer 223 may have any other shape. For example, the superhard layer 223 may have a truncated conical shape, a conical shape with an offset tip of the cone, a ridge shape (e.g., an "axe" shape), a conical shape with two or more tips, any other shape and combination thereof.

[0023] The cleaning cutting element 222 may include a hole through the base 225. Drilling fluid guided through the body 212 may be directed into the base 225 of the cleaning cutting element 222 and exit the base 225 through one or more outlet openings 224.

[0024] The outlet opening 224 on the cleaning cutting element 222 can direct drilling fluid to any structure on the drill bit 210. For example, the outlet opening 224 can direct drilling fluid to one or more of the cutting blades 214. In some examples, the outlet opening 224 can direct drilling fluid to one or more of the cutting elements 216 on the cutting blades 214. In some examples, the outlet opening 224 can direct drilling fluid to the scrap channel 220 between adjacent cutting blades 214.

[0025] In some embodiments, drilling fluid exiting outlet opening 224 can cool the cleaning cutting elements 222, blades 214, body 212, and / or cutting elements 216 on the drill bit 210. In some embodiments, drilling fluid exiting outlet opening 224 can flush cuttings away from the drill bit 210. For example, drilling fluid exiting outlet opening 224 can flush cuttings away from the cutting elements 216 on the blades 214, through and away from the scrap groove 220 between adjacent blades 214, and / or away from the body 212 of the drill bit 210. Drilling fluid exiting outlet opening 224 can help improve cooling and / or cutting removal of the drill bit 210.

[0026] According to at least one embodiment of this disclosure, the cleaning and cutting element 222 may be located in the central region 226 of the drill bit 210. The central region 226 may be the bottom region of the drill bit 210. For example, the cleaning and cutting element 222 may be located at the bottom of the drill bit 210. In some examples, the cleaning and cutting element 222 may be located between the cutting blades 214 of the drill bit 210. In some examples, the cleaning and cutting element 222 may be located at the longitudinal axis 228 of the drill bit 210. In some examples, the cleaning and cutting element 222 may be coaxial with the longitudinal axis 228. In some examples, the cleaning and cutting element 222 may have a conical shape, and the point of the conical shape of the cleaning and cutting element 222 may intersect with the longitudinal axis 228.

[0027] In some embodiments, drill bit 210 may include a cleaning and cutting element 222 in any part of drill bit 210. For example, drill bit 210 may include a cleaning and cutting element 222 on the cutting edge 214 of drill bit 210, offset from the longitudinal axis 228 of drill bit 210 on the body 212 of drill bit 210. Placing the cleaning and cutting element 222 in any part of drill bit 210 can help improve fluid flow throughout drill bit 210.

[0028] In some embodiments, the cleaning cutting element 222 may include an outlet opening 224 for each scrap trough 220 in the drill bit 210. For example, the number of fluid conduits 236 and / or outlet openings 224 may be the same as the number of blades 214. In some embodiments, the cleaning cutting element 222 may include fewer outlet openings 224 than the scrap troughs 220. For example, the number of fluid conduits 236 and / or outlet openings 224 may be less than the number of blades 214. In some examples, the cleaning cutting element 222 may include an outlet opening 224 for each master blade 214. In some examples, the cleaning cutting element 222 may include more outlet openings 224 than the blades 214 and / or scrap troughs 220. For example, the number of fluid conduits 236 and / or outlet openings 224 may be greater than the number of blades 214.

[0029] In some embodiments, the outlet opening 224 may point to a specific feature of the drill bit 210. For example, the outlet opening 224 may point to the center of the scrap chute 220. In some examples, the outlet opening 224 may point to the cutting blade 214. In some examples, the outlet opening 224 may point to a specific cutting element 216 and / or a group of cutting elements 216. In some examples, the outlet opening 224 may point to the leading edge of the cutting blade 214. In some examples, the outlet opening 224 may point to one or more of the nozzles 218 to facilitate and / or improve the flow of drilling fluid from the nozzles 218. In some examples, different outlet openings 224 may point to different features of the drill bit 210. For example, a first outlet opening 224 may point to the scrap chute 220, and a second outlet opening 224 may point to the cutting element 216.

[0030] Figure 2-2 yes Figure 2-1 The diagram shows a top view of drill bit 210. An outlet opening 224 can direct the flow of drilling fluid (collectively referred to as 230) to one or more features of drill bit 210. For example, outlet opening 224 can direct a first flow 230-1 of drilling fluid to a scrap groove 220 between the two blades 214. The first flow 230-1 can be directed to the center of scrap groove 220. This can help increase the fluid flow through drill bit 210, which can help flush cuttings away from the central region 226 of drill bit 210, help flush cuttings away from blades 214, help flush cuttings out of scrap groove 220, increase cooling of one or more structures of drill bit 210, perform any other actions, and combinations thereof.

[0031] In some embodiments, the flow 230 of the drilling fluid may be oriented perpendicular to the cleaning and cutting element 222. A conduit opening at the outlet opening 224 may be oriented toward the outer cylindrical surface of the substrate and may open perpendicular to the outer cylindrical surface of the substrate. This allows the flow 230 of the drilling fluid to exit the outlet opening 224 perpendicular to or substantially perpendicular to the cleaning and cutting element 222. Figure 2-2 In the illustrated embodiment, the cleaning cutting element 222 is rotatably oriented within the body 212 to guide a first flow 230-1 of drilling fluid vertically away from the cleaning cutting element 222 toward the waste trough 220. In some embodiments, the cleaning cutting element 222 may be rotatably oriented at any feature of the drill bit 210, such as one of the blades 214 and / or the cutting element 216.

[0032] In some embodiments, the flow 230 of the drilling fluid may be transverse to, deviate from, or not perpendicular to the orientation of the cleaning cutting element 222. For example, the flow 230 of the drilling fluid may be transverse to or not perpendicular to the outer surface of the substrate and / or the orientation of the superhard layer of the cleaning cutting element 222. For example, the flow direction of the flow 230 may deviate from and / or may not cross or align with the central axis (e.g., longitudinal axis 228) of the cleaning cutting element 222. This can allow the flow 230 to be oriented at specific features of the drill bit 210. For example, in Figure 2-2 In the illustrated embodiment, the second flow 230-2 of drilling fluid is oriented transversely to the cleaning cutting element 222 (e.g., off-center from its central axis) to guide the second flow 230-2 to the illustrated cutting element 216 and / or to guide the second flow 230-2 more closely to the leading face 232 of the blade 214. In some embodiments, the flow direction of the second flow 230-2 is parallel to some or all of the orientation of the blade 214. In some embodiments, the flow direction of the second flow 230-2 is directed toward the blade 214 such that the angle between the flow 230-2 and at least a portion of the blade is not divergent (e.g., parallel or converging). For example, as shown, the flow direction of the first flow 230-1 is directed downward toward the scrap chute 220 such that as the flow travels further down along the drill bit 210, the flow 230-1 diverges from each adjacent blade 214 (e.g., travels away from each adjacent blade 214). This can result in the cleaning and / or cooling effects of flow 230-1 having a smaller impact on the portions of blade 214 and / or cutting element 216 that are positioned further away from the cleaning cutting element 222. The flow direction of the second flow 230-2 can be offset from and / or transverse to the central axis, as described, so that it passes closer to some or all of the blades 214 and / or cutting elements 216 that are positioned further away from the cleaning cutting element 222. In this way, flow 230-2, which is parallel to or converges with some or all of one of the blades 214, can improve the function of the cleaning cutting element 222 relative to the conventional nozzle 218. For example, guiding the second stream 230-2 parallel or converging to the leading face 232 of the cutting element 216 and / or the blade 214 (and / or one or more portions of the blade and / or cutting element 16 located further below the drill bit 210) can help improve the operation of the drill bit by flushing away chips from these locations, providing cooling to these locations, otherwise improving the performance of the drill bit 210, and their combination.

[0033] Figure 2-3 yes Figure 2-1The diagram shows a cross-sectional view of drill bit 210. In the cross-sectional view shown, the cleaning cutting element 222 includes six fluid conduits 236 extending from a base bore 234 in the base 225 of the cleaning cutting element 222. The base bore 234 may extend at least partially through the base 225. The fluid conduits 236 extend through the base 225 to six outlet openings 224 in the outer surface of the cleaning cutting element 222. The six fluid conduits 236 and outlet openings 224 shown are oriented to guide the flow 230 of drilling fluid from the base bore 234 to each scrap groove 220 between the cutting blades 214. As discussed herein, this can help flush cuttings out of the central region 226 of drill bit 210 and / or cool drill bit 210.

[0034] Although Figure 2-3 The illustrated embodiment shows six fluid conduits 236 guiding six streams 230 from the cleaning cutting element 222; however, it should be understood that the cleaning cutting element 222 may include any number of fluid conduits 236 guiding any number of streams 230 from the cleaning cutting element 222. Furthermore, while the illustrated embodiment shows the streams 230 extending perpendicular to the cleaning cutting element 222, it should be understood that the streams 230 may extend from the cleaning cutting element 222 and / or toward any feature of the drill bit 210 in any direction, such as the lateral or offset streams discussed above.

[0035] In some embodiments, the fluid conduit 236 may extend at a radial conduit angle 272 between a conduit axis 268 passing through the fluid conduit 236 and a tangent 274 tangent to the circumferential wall of the base bore 234 and / or the base 225. In some embodiments, the radial conduit angle 272 may have an upper limit, a lower limit, or both of the following values: 90°, 85°, 80°, 75°, 70°, 65°, 60°, 55°, 50°, 45°, or any value in between. For example, the radial conduit angle 272 may be greater than 45°. In another example, the radial conduit angle 272 may be less than 90°. In other examples, the radial conduit angle 272 may be any value within the range of 45° and 90°. In some embodiments, it may be critical that the radial conduit angle 272 is between 60° and 90° for a specific feature of guiding drilling fluid to the drill bit. In some embodiments, each of the fluid conduits 236 may have the same radial conduit angle 272. In some embodiments, different fluid conduits 236 may have different radial conduit angles 272. In some embodiments, adjacent fluid conduits 236 may have the same or different radial conduit angles 272.

[0036] Figure 2-4 yes Figure 2-1The diagram shows a longitudinal cross-sectional view of drill bit 210. It can be seen that the main flow 238 of drilling fluid can flow through the fluid channel 240 in the body 212 of drill bit 210. The fluid channel 240 is in fluid communication with the base hole 234. For example, the main flow 238 of drilling fluid can enter the base hole 234 formed in the base 225 of the cleaning cutting element 222 from the fluid channel 240 in the body 212. The main flow 238 can be diverted to the fluid conduit 236 at the junction 242 in the cleaning cutting element 222. This may cause the main flow 238 to be separated into a flow 230 of drilling fluid, which is guided out of the fluid conduit 236 and flows to various features of drill bit 210.

[0037] In the illustrated embodiment, the joint 242 is located on the upper portion of the cleaning cutting element 222. For example, the joint 242 may be located near the superhard layer 223. In some examples, the joint 242 may be located in the substrate 225 of the cleaning cutting element 222 near the superhard layer 223. In some embodiments, the joint 242 may be located at any portion along the length of the cleaning cutting element 222. The joint 242 may be positioned to help guide and / or divert the main stream 238 of drilling fluid into the fluid conduit 236 and the flow 230 directed to various features of the drill bit 210.

[0038] As discussed in further detail herein, the substrate 225 may include a deflector plate at the junction 242 between the substrate bore 234 and the fluid conduit 236. The deflector plate may be located on the upper surface of the junction 242 to contact the drilling fluid as it enters the junction 242. The deflector plate may help redirect the drilling fluid and reduce wear and / or erosion of the substrate 225 at the junction 242.

[0039] As can be seen, the substrate 225 of the cleaning cutting element 222 can extend above the drill bit sump surface 244 of the body 212. The substrate 225 extending above the drill bit sump surface 244 of the body 212 allows the outlet opening 224 to guide the flow 230 of drilling fluid out of the fluid conduit 236 and into the drill bit 210. In some embodiments, extending the substrate 225 above the drill bit sump surface 244 can cause the superhard layer 223 to extend further above the drill bit sump surface 244, thereby engaging the formation above the drill bit sump surface 244.

[0040] The cleaning cutting element 222 can be secured to the body 212 of the drill bit 210 at the drill slag groove surface 244. For example, the body 212 may include a cutting element recess 245. The cutting element recess 245 can extend from the drill slag groove surface 244 of the body 212 into the body 212. The cleaning cutting element 222 can be brazed to the drill bit 210 in the cutting element recess 245 to secure the cleaning cutting element 222 to the body 212. In some embodiments, the cleaning cutting element 222 can be fastened to the drill bit 210 at the cutting element recess 245 in any manner, such as by welding, brazing, mechanical fasteners, shrink fit, press fit, interference fit, any other manner, and combinations thereof.

[0041] The cleaning cutting element 222 includes a cutting element diameter 247. In some embodiments, the cutting element diameter 247 may be within a range having an upper limit, a lower limit, or both of the following values: 0.5 inches (1.3 cm), 0.6 inches (1.5 cm), 0.7 inches (1.8 cm), 0.8 inches (2.0 cm), 0.9 inches (2.3 cm), 1.0 inch (2.5 cm), 1.1 inch (2.8 cm), 1.2 inches (3.0 cm), 1.3 inches (3.3 cm), 1.4 inches (3.6 cm), 1.5 inches (3.8 cm), and 2.0 inches (5.1 cm). For example, the cutting element diameter 247 may be greater than 0.5 inches (1.3 cm). In another example, the cutting element diameter 247 may be less than 2.0 inches (5.1 cm). In other examples, the cutting element diameter 247 can be any value ranging from 0.5 inches (1.3 cm) to 2.0 inches (5.1 cm). In some embodiments, it may be critical that the cutting element diameter 247 is between 0.5 inches (1.3 cm) and 2.0 inches (5.1 cm) to allow drilling fluid to flow through the substrate 325.

[0042] Drill bit 210 includes a drill bit diameter 249. In some embodiments, the drill bit diameter 249 may be within a range having an upper limit, a lower limit, or both of the following values: 3 inches (7.6 cm), 4 inches (10.2 cm), 5 inches (12.7 cm), 6 inches (15.2 cm), 7 inches (17.8 cm), 8 inches (20.3 cm), 9 inches (22.9 cm), 10 inches (25.4 cm), 11 inches (27.9 cm), 12 inches (30.5 cm), 13 inches (33.0 cm), 14 inches (35.6 cm), 15 inches (38.1 cm), 16 inches (40.6 cm), 17 inches (43.2 cm), 18 inches (45.7 cm), and 26 inches (66.0 cm). For example, the drill bit diameter 249 may be greater than 3 inches (7.6 cm). In another example, the drill diameter 249 can be less than 26 inches (66 cm). In other examples, the drill diameter 249 can be any value in the range between 3 inches (7.6 cm) and 26 inches (66 cm).

[0043] In some embodiments, the cleaning cutting element 222 and drill bit 210 may have a cutting element to drill bit diameter ratio. In some embodiments, the cutting element to drill bit diameter ratio may be within a range having an upper limit, a lower limit, or both of the following values: 1:3, 1:4, 1:5, 1:6, 1:8, 1:9, 1:10, 1:11, 1:12, 1:15, 1:20. For example, the cutting element to drill bit diameter ratio may be greater than 1:3. In another example, the cutting element to drill bit diameter ratio may be less than 1:20. In other examples, the cutting element to drill bit diameter ratio may be any value within the range of 1:3 to 1:20. In some embodiments, it may be critical that the cutting element to drill bit diameter ratio is between 1:5 and 1:12 to provide fluid flow to the central region of the drill bit.

[0044] According to at least one embodiment of this disclosure, the cleaning cutting element 522 may be located at the longitudinal axis 228 of the drill bit 210. For example, the longitudinal axis of the cleaning cutting element 222 (e.g., Figure 5 The longitudinal axis 570 shown may be coaxial with the longitudinal axis 228 of the drill bit. In some embodiments, the longitudinal axis of the cleaning and cutting element 222 may be offset from the longitudinal axis 228 of the drill bit 210. In some embodiments, the longitudinal axis of the cutting element 222 may be parallel to the longitudinal axis 228 of the drill bit. In some embodiments, the cleaning and cutting element 222 may not be parallel to the longitudinal axis 228 of the drill bit, or it may be transverse to the longitudinal axis 228 of the drill bit.

[0045] Figure 3-1This is a side view representing a cleaning and cutting element 322 according to at least one embodiment of the present disclosure. The cleaning and cutting element 322 may include a substrate 325 and an ultra-hard layer 323 bonded to the substrate 325. The substrate 325 includes a plurality of fluid conduits 336 that exit the body of the substrate 325 at outlet openings 324.

[0046] The substrate 325 includes a bottom surface 346 and an upper surface 348 opposite to the bottom surface 346. A circumferential wall 350 may extend between the upper surface 348 and the bottom surface 346. In the illustrated embodiment, the substrate 325 may have a cylindrical shape, wherein the bottom surface 346 has a circular shape, the upper surface 348 has a circular shape, and the circumferential wall 350 forms a cylindrical body between the bottom surface 346 and the upper surface 348. However, it should be understood that the substrate 325 may have other shapes, such as prism volumes with any cross-sectional shape, including oval, circular, triangular, square, rectangular, pentagonal, hexagonal, heptagonal, octagonal, nonagonal, decagonal, any other polygonal shape and combinations thereof.

[0047] As discussed herein, the substrate 325 includes a substrate bore that extends at least partially through it. The substrate bore has an inlet in a bottom surface 346. The substrate bore may extend through the body of the substrate 325 to a junction between the bottom surface 346 and the top surface 348. At the junction, a plurality of fluid conduits 336 may extend toward a circumferential wall 350. The fluid conduits 336 may exit the substrate 325 at an outlet opening 324 in the circumferential wall 350. In this way, drilling fluid can be directed out of the cleaning cutting element 322.

[0048] In some embodiments, the outlet openings 324 may be uniformly distributed circumferentially around the circumferential wall 350, such that the spacing between adjacent outlet openings 324 is the same. In some embodiments, the outlet openings 324 may be non-uniformly distributed circumferentially around the circumferential wall 350, such that the spacing between adjacent outlet openings 324 is different. The circumferential spacing of the outlet openings 324 may be based on the target of the drilling fluid guided from the base 325 through the outlet openings 324.

[0049] In some embodiments, the outlet openings 324 may be uniformly distributed longitudinally along the circumferential wall 350, such that the spacing between the outlet openings 324 and the upper surface 348 (and the bottom surface 346) may be the same. In some embodiments, the outlet openings 324 may be non-uniformly distributed longitudinally along the circumferential wall 350, such that the spacing between the outlet openings 324 and the upper surface 348 (and the bottom surface 346) may be different. The longitudinal spacing of the outlet openings 324 may be based on the target of the drilling fluid guided from the base 325 through the outlet openings 324.

[0050] Figure 3-2 yes Figure 3-1A longitudinal cross-sectional view of the cleaning cutting element 322. The substrate 325 includes a substrate bore 334 passing through it. As discussed herein, drilling fluid can enter the substrate bore 334 from a fluid passage in the drill bit body. The substrate bore 334 has an inlet 352 in a bottom surface 346. Drilling fluid can enter the substrate 325 and the substrate bore 334 at the inlet 352 in the bottom surface 346. The drilling fluid can be diverted to a fluid conduit 336 at or near a junction 342 located on or near the upper surface 348 of the substrate 325. The drilling fluid can exit the substrate 325 through an outlet opening 324 of the fluid conduit 336.

[0051] In the illustrated embodiment, the inlet 352 in the bottom surface 346 has an inlet diameter 354 and an orifice diameter 356 in the body of the substrate 325. The inlet 352 can open such that the inlet diameter 354 is larger than the orifice diameter 356 to help improve the hydraulic flow through the substrate orifice 334 and / or increase the pressure of the drilling fluid through the substrate orifice 334. In some embodiments, the inlet diameter 354 of the inlet 352 may be larger than the outlet diameter 358 of the outlet opening 324. This can help increase the pressure of the drilling fluid as it exits the substrate 325 through the outlet opening 324.

[0052] In some embodiments, the inlet diameter 354 can be within a range having an upper limit, a lower limit, or both of the following values: 0.3 inches (0.8 cm), 0.4 inches (1.0 cm), 0.5 inches (1.3 cm), 0.5 inches (1.3 cm), 0.6 inches (1.5 cm), 0.7 inches (1.8 cm), 0.8 inches (2.0 cm), 0.9 inches (2.3 cm), 1.0 inch (2.5 cm), 1.1 inch (2.8 cm), 1.2 inches (3.0 cm), and 1.3 inches (3.3 cm). For example, the inlet diameter 354 can be greater than 0.3 inches (0.8 cm). In another example, the inlet diameter 354 can be less than 1.3 inches (3.3 cm). In other examples, the inlet diameter 354 can be any value within the range of 0.3 inches (0.8 cm) to 1.3 inches (3.3 cm). In some embodiments, it may be critical that the inlet diameter 354 is between 0.5 inches (1.3 cm) and 1.1 inches (2.8 cm) to maintain a sufficient flow rate of drilling fluid through the matrix orifice 334.

[0053] In some embodiments, the outlet diameter 358 can be within a range having an upper limit, a lower limit, or both of the following values: 0.1 inch (0.3 cm), 0.2 inch (0.5 cm), 0.3 inch (0.8 cm), 0.4 inch (1.0 cm), 0.5 inch (1.3 cm), 0.5 inch (1.3 cm), 0.6 inch (1.5 cm), 0.7 inch (1.8 cm), 0.8 inch (2.0 cm), 0.9 inch (2.3 cm), and 1.0 inch (2.5 cm). For example, the outlet diameter 358 can be greater than 0.1 inch (0.3 cm). In another example, the outlet diameter 358 can be less than 1.0 inch (2.5 cm). In still other examples, the outlet diameter 358 can be any value within the range of 0.1 inch (0.3 cm) to 1.0 inch (2.5 cm). In some embodiments, it may be crucial that the outlet diameter 358 be between 0.3 inches (0.8 cm) and 0.8 inches (2.0 cm) to maintain the flow rate and pressure of the outflow fluid conduit 336.

[0054] The inlet diameter 354 and outlet diameter 358 may have an inlet-to-outlet ratio. In some embodiments, the inlet-to-outlet ratio may be within a range of upper, lower, or both upper and lower limits, including any one of 1:1, 5:4, 4:3, 3:2, 2:1, 3:1, 4:1, 5:1, or any value between them. For example, the inlet-to-outlet ratio may be greater than 1:1. In another example, the inlet-to-outlet ratio may be less than 5:1. In other examples, the inlet-to-outlet ratio may be any value within the range of 1:1 and 5:1. In some embodiments, it may be critical that the inlet-to-outlet ratio is between 4:3 and 2:1 to maintain the desired pressure of the drilling fluid at the outlet opening 324. In some embodiments, each of the outlet openings 324 may have the same inlet-to-outlet ratio. In some embodiments, different outlet openings may have different inlet-to-outlet ratios.

[0055] As discussed herein, the superhard layer 323 can be bonded to the substrate 325 at the upper surface 348 of the substrate 325. In some embodiments, the superhard layer 323 can be formed directly on the substrate 325. For example, the superhard layer 323 can be formed on the substrate 325 when the superhard layer 323 is formed using a high pressure high temperature (HPHT) technique.

[0056] In some embodiments, the superhard layer 323 may be bonded to the upper portion 360 of the substrate 325. The lower portion 362 of the substrate may be formed after the superhard layer 323 is formed on the upper portion 360 of the substrate 325. For example, the lower portion 362 may be additively manufactured on the base of the upper portion 360. Additive manufacturing may include forming the substrate 325 layer by layer on top of the upper portion 360. According to at least one embodiment of the present disclosure, at least a portion of the additively manufactured substrate may allow the formation of substrate holes 334 and fluid conduits 336 in the substrate 325. This may help reduce manufacturing time, including the time spent milling, grinding, and otherwise processing the substrate 325. In some embodiments, at least a portion of the additively manufactured substrate 325 may allow the substrate 325 to include complex geometries of substrate holes 334 and / or fluid conduits 336, which may not be millable and / or grindable. For example, the additively manufactured substrate 325 may allow the substrate hole 334 and / or fluid conduit 336 to include curved portions to guide the fluid conduit 336 and outlet opening 324 to specific features of the drill bit.

[0057] In some embodiments, the substrate 325 may be formed as a single bulk material, for example, through casting, infiltration, sintering, etc. After forming the substrate 325, substrate holes 334 and / or fluid conduits 336 may be formed within the substrate 325. For example, the substrate holes 334 and / or fluid conduits 336 may be drilled, milled, and / or ground into the body of the substrate 325. This can help simplify the manufacture of the cleaning cutting element 322 and / or the substrate 325.

[0058] Figure 4 This is a cross-sectional view representing a cleaning cutting element 422 according to at least one embodiment of the present disclosure. The cleaning cutting element 422 may include a substrate 425 and an ultrahard layer 423 bonded to the substrate 425. The substrate 425 includes a substrate bore 434 at least partially passing through it. As discussed herein, drilling fluid may enter the substrate bore 434 through an inlet 452 in fluid communication with a fluid passage in the drill bit body. The drilling fluid may be diverted to a fluid conduit 436 at or near a junction 442 located on or near the upper surface 448 of the substrate 425. The drilling fluid may exit the substrate 425 through an outlet opening 424 of the fluid conduit 436 exiting a circumferential wall 450 extending between the bottom surface 446 and the upper surface 448.

[0059] According to at least one embodiment of this disclosure, the cleaning cutting element 422 may include a deflector 464. The deflector 464 may be located at the junction 442 between the substrate bore 434 and the fluid conduit 436. The deflector 464 may be positioned to receive the impact of drilling fluid at the junction 442. The drilling fluid may impact the deflector 464 before being redirected to the fluid conduit 436. The deflector 464 may prevent the drilling fluid from engaging or contacting the matrix material of the substrate 425 at the junction 442. This may help reduce or prevent damage to the substrate 425 caused by the drilling fluid engaging the matrix material of the substrate 425 at the junction 442. This may help extend the operational life of the cleaning cutting element 422.

[0060] In some embodiments, the deflector 464 may be formed of a corrosion-resistant and / or abrasion-resistant material. For example, the deflector 464 may be formed of PCD and / or PDC. Forming the deflector 464 with a corrosion-resistant and / or abrasion-resistant material may help reduce wear on the deflector 464 and / or other parts of the cleaning cutting element 422 caused by drilling fluids.

[0061] In the illustrated embodiment, the deflector 464 has a conical shape. The conical shape helps to redirect the flow of drilling fluid into the fluid conduit 436. The deflector 464 can have any shape. For example, the deflector 464 can have a dome shape, a pyramid shape, a truncated cone shape, any other shape, or a combination thereof.

[0062] In some embodiments, the deflector 464 may be formed together with the substrate 425 when the superhard layer 423 is formed on the substrate 425. In some embodiments, the deflector 464 may be formed separately from the substrate 425 and subsequently fixed to the substrate 425 in the upper surface of the joint 442.

[0063] Figure 5 This is a cross-sectional view representing a cleaning cutting element 522 according to at least one embodiment of the present disclosure. The cleaning cutting element 522 may include a substrate 525 and an ultrahard layer 523 bonded to the substrate 525. The substrate 525 includes a substrate bore 534 at least partially passing through it. As described herein, drilling fluid may enter the substrate bore 534 through an inlet 552 in fluid communication with a fluid passage in the drill bit body. The drilling fluid may be diverted to a fluid conduit 536 at or near a junction 542 located on or near the upper surface 548 of the substrate 525. The drilling fluid may exit the substrate 525 through an outlet opening 524 of the fluid conduit 536, thereby exiting a circumferential wall 550 extending between the bottom surface 546 and the upper surface 548.

[0064] In the illustrated embodiment, the fluid conduit 536 may be oriented with a longitudinal conduit angle 566 formed between the conduit axis 568 of the fluid conduit 536 and the longitudinal axis 570 of the cleaning and cutting element 522. The longitudinal conduit angle 566 can be any angle. In some embodiments, the range of the longitudinal conduit angle 566 may have an upper limit, a lower limit, or both of the following values: 145°, 120°, 110°, 100°, 90°, 85°, 80°, 75°, 70°, 65°, 60°, 55°, 50°, 45°. For example, the longitudinal conduit angle 566 may be greater than 45°. In another example, the longitudinal conduit angle 566 may be less than 90°. In other examples, the longitudinal conduit angle 566 may be any value within the range of 45° to 90°. In some embodiments, it may be critical that the longitudinal conduit angle 566 is between 60° and 90° to guide drilling fluid to the drill bit. In some embodiments, each of the fluid conduits 536 may have the same longitudinal conduit angle 566. In some embodiments, different fluid conduits 536 may have different conduit angles 566.

[0065] Figure 6 This is a cross-sectional view representing an exemplary cleaning element 622 according to at least one embodiment of the present disclosure. The cleaning element 622 may exhibit features of a cleaning cutting element (e.g., including a tapered cutting element) or a cleaning element (e.g., without a tapered cutting element) as described herein. For example, the cleaning element 622 may include a substrate 625 and an ultra-hard layer bonded to the substrate 625. The cleaning element 622 may not include an ultra-hard layer bonded to the substrate 625. The substrate 625 includes a substrate bore 634 at least partially passing through it. As discussed herein, drilling fluid may enter the substrate bore 634 through an inlet in fluid communication with a fluid passage in the drill bit body. The drilling fluid may be diverted to the fluid conduit 636 at a junction 642 between the substrate bore 634 and the fluid conduit 636. The drilling fluid may exit the substrate 625 through an outlet opening 624 of the fluid conduit 636, which exits from the circumferential wall 650 of the substrate 625.

[0066] According to at least one embodiment of this disclosure, the cleaning element 622 may include one or more fluid conduits 636 that are not straight. For example, as in Figure 6 As can be seen, the cleaning element 622 may include a fluid conduit 636 that is curved between the base hole 634 and the circumferential wall 650. In other words, the fluid conduit 636 may have a curved profile. The curved fluid conduit 636 may help to orient the drilling fluid leaving the outlet opening 624 into a specific feature that is guided to the drill bit.

[0067] In some embodiments, the curved profile of the fluid conduit 636 can help orient the flow from the fluid conduit 363 such that, as the flow exits the outlet opening 624, it is guided in a direction offset, misaligned, or non-coincident with the central (e.g., longitudinal) axis of the cleaning element 622, as described herein. For example, the flow 630 of drilling fluid may flow out of the outlet opening 624 in a flow direction. The flow direction may be in a direction not aligned with the center or central axis of the cleaning element 622. For example, the flow direction of the flow 630 may be offset by an offset distance 637 such that the flow direction does not coincide with the central axis of the cleaning element 637. Such an offset flow direction can help guide the flow 630 at one or more features of the drill bit, such as in a direction parallel to, converging with, or otherwise non-divergent with one or more blades of the drill bit, as described herein.

[0068] Figure 7 This is a longitudinal cross-sectional view of a drill bit 710 according to at least one embodiment of the present disclosure, the drill bit 710 having a cleaning and cutting element 722 fixed to its body 712. The cleaning and cutting element 722 may include a base hole 734 formed in a base 725 and extending at least partially through it. The base hole 734 may be in fluid communication with a fluid passage 740 through the body 712. The base hole 734 may guide drilling fluid to one or more fluid conduits 736. The fluid conduits 736 may guide drilling fluid to one or more features of the drill bit 710.

[0069] The body 712 may include a cutting element recess 745 formed in the downhole surface 744 of the body 712. According to at least one embodiment of this disclosure, a cleaning cutting element 722 may be secured to the body 712 with a sleeve 776. For example, the cleaning cutting element 722 may be brazed to the sleeve 776. The sleeve 776 may be secured to the body 712 at the cutting element recess 745. For example, the sleeve 776 may be secured to the body 712 by welding, interference fit, press fit, mechanical fasteners, any other connection mechanism, or combinations thereof. In some embodiments, the sleeve 776 may be made of the same material as the base of the cleaning element. In some embodiments, the sleeve 776 may be formed of any other material, such as hardened tool steel. In some embodiments, the sleeve 776 may be formed as a sacrificial component for replacement during servicing of the drill bit 210.

[0070] In some embodiments, the materials of the body 712 and the base 725 of the drill bit 710 may have different coefficients of thermal expansion. This may cause the body 712 and the cutting element recess 745 within the body 712 to expand at a rate different from that of the base 725. When the body 712 and the base 725 cool, the cutting element recess 745 may change shape at a greater or lesser rate than the base 725, thereby preventing the connection between the base 725 and the body 712. For example, if the body 712 has a greater coefficient of thermal expansion than the base 725, the cutting element recess 745 may shrink and damage the base 725 during the brazing and / or cooling process. In some examples, if the body 712 has a smaller coefficient of thermal expansion than the base 725, the connection between the base 725 and the cutting element recess 745 may loosen after the base 725 and the body 712 have cooled.

[0071] To improve the connection between the substrate 725 and the body 712, the substrate 725 can be fixed to the sleeve 776. The sleeve 776 can be independently fixed to the cutting element recess 745 of the body 712. This helps to reduce the mismatch of the coefficient of thermal expansion, thereby improving the connection between the substrate 725 and the body 712.

[0072] Figure 8-1 This is an exploded perspective view of a cleaning and cutting system 886 according to at least one embodiment of the present disclosure. The cleaning and cutting system 886 includes a cleaning base 888 and a cutting superhard layer 890. The cleaning base 888 may include a superhard layer recess 892. The cutting superhard layer 890 may be secured to the cleaning base 888 within the superhard layer recess 892. The cleaning base 888 may also include one or more fluid conduits 836 exiting the cleaning base 888 at an outlet opening 824.

[0073] According to at least one embodiment of this disclosure, the cleaning base 888 can be fixed to a cutting element recess (e.g., in the central region of a drill bit (e.g., drill bit 210)). Figure 2-4 The cutting element recess 245. The cutting superhard layer 890 can be secured to the cleaning base 888 at the superhard layer recess 892. Utilizing separate cutting superhard layers 890 and cleaning bases 888 can help improve the drill bit's flexibility and / or versatility. For example, the cleaning base 888 can be formed separately from the cutting superhard layer 890. This allows the cleaning base 888 to include one or more fluid conduits 836 with internal geometries that may differ and / or be more complex than those in the matrix of the cutting superhard layer 890. In some embodiments, utilizing separate cutting superhard layers 890 and cleaning bases 888 allows drill rig manufacturers to utilize cutting superhard layers 890 that are in stock or otherwise readily available.

[0074] Figure 8-2 It is in the assembly and configuration stage. Figure 8-2A cross-sectional view of the cleaning cutting system 886 is shown. In the illustrated embodiment, the cutting superhard layer 890 is secured to the cleaning base 888 at a superhard layer recess 892. For example, the cutting superhard layer 890 may be brazed, welded, or otherwise attached to the cleaning base 888 at the superhard layer recess 892. In the illustrated embodiment, the cleaning base 888 includes a base bore 894 in fluid communication with the drill bit's fluid passages. Drilling fluid from the drill bit's fluid passages may enter the base bore 894, be diverted to one or more fluid conduits 836, and exit the cleaning base 888 through an outlet opening 824. As discussed herein, the cleaning base 888 can increase the drill bit's flexibility, including flexibility in the placement and / or orientation of one or more fluid conduits 836 and / or outlet opening 824 in the cleaning base 888.

[0075] Figure 9 This is an illustration of a method 978 for forming a cutting element according to at least one embodiment of the present disclosure. The method may include forming a superhard layer on a substrate at 980. As discussed herein, forming a superhard layer on a substrate may include forming the superhard material superhard layer directly on the matrix material forming the substrate.

[0076] At point 982, the operator can form a matrix hole in the matrix. The matrix hole can extend from an inlet at the bottom surface of the matrix to a junction near the superhard layer. At point 984, the operator can form multiple conduits in the matrix. The conduits can extend from the junction to the circumferential wall of the main body of the matrix.

[0077] In some embodiments, forming the matrix aperture and forming the conduit includes additively manufacturing the matrix layer by layer around the matrix aperture and the conduit. In some embodiments, an operator may fix a deflector at the junction between the matrix aperture and the conduit.

[0078] Figure 10-1 This is a side view representing a cleaning element 1022 according to at least one embodiment of the present disclosure. Figure 10-2 This is a side cross-sectional view representing a cleaning element 1022 implemented in downhole tool 1010. The cleaning element 1022 may include any features of one or more embodiments of the cleaning and cutting elements described herein and / or may perform any of their functions. For example, the cleaning element 1022 may be inserted into and / or connected to a downhole tool, such as a drill bit. The cleaning element 1022 may facilitate the supply of one or more drilling fluid flows to the downhole tool 1022 to cool the downhole tool 1022, remove cuttings, etc. The cleaning element 1022 may include a body and may be formed from a substrate 1025.

[0079] In some embodiments, the cleaning element 1022 does not include a superhard layer bonded to or formed on top of the substrate 1025 (e.g., a PDC cutting element), as described above regarding the bonding of cleaning cutting elements. For example, the cleaning element 1022 may not include a superhard layer, such that the cleaning element 1022 may not be configured specifically to degrade formations. In some examples, the upper surface of the cleaning element 1022 may be formed of the same material as the substrate 1025 or the body of the cleaning element 1022. In another example, the cleaning element 1022 may not be configured to bond to formations, and one or more portions of the drill bit may be positioned to hang over the cleaning element, as described in further detail below.

[0080] In some embodiments, the cleaning element 1022 may be configured to at least partially engage the formation and may include one or more coring features for disrupting the formation core. In this way, the cleaning element 1022 may include or exhibit any of the features of the cleaning cutting element described herein, but in some embodiments may not include an ultrahard portion (e.g., a cutting element) for contributing to formation degradation.

[0081] In some embodiments, the base 1025 includes one or more fluid conduits 1036 that exit the body of the base 1025 at an outlet opening 1024. The base 1025 may include a base bore 1033 extending at least partially therethrough. The base bore 1033 may be configured to connect to and be in fluid communication with a fluid passage 1040 of the downhole tool 1010 to receive drilling fluid flowing to the base bore 1033. The fluid conduits 1036 may be connected to the base bore 1033 such that fluid received at the base bore 1033 can flow through the fluid conduits 1036 and exit the base 1025 through the outlet opening 1024. In this way, the cleaning element 1022 may resemble the features and / or geometry of cleaning and cutting elements as discussed herein.

[0082] In some embodiments, the cleaning element 1022 can be assembled within the downhole tool 1010 via the outer surface of the downhole tool 1010. For example, the downhole tool 1010 may include a cleaning element recess 1045 formed within the body 1012 of the downhole tool 1010. The cleaning element 1022 can be assembled within the downhole tool 1010 via, for example, through the top outer surface of the downhole tool 1010 (e.g., as shown in the image). Figure 10-2 The cleaning element 1022 is assembled in the downhole tool 1010 by inserting it into the cleaning element recess 1045 (as shown in the "top," or downhole end of the downhole tool 1010). The cleaning element 1022 can be secured in the cleaning element recess 1045 in any of the ways described herein with respect to the cleaning cutting element. For example, the cleaning element 1022 can be secured by welding, brazing, mechanical fasteners, interference or friction fits, any other connection mechanism, or combinations thereof.

[0083] The cleaning element 1022 can be assembled with the downhole tool 1010 in such a way as to provide drilling fluid flow to or at one or more features of the downhole tool 1010. For example, as shown, an outlet opening 1024 can be positioned above the top and / or outer surface of the downhole tool 1010. The outlet opening 1024 can facilitate the directing of one or more cleaning fluid flows out of the cleaning element 1022 and to one or more features of the downhole tool 1010. For example, the cleaning element 1022 can direct drilling fluid at or relative to one or more blades 1014, the waste chute 1020 between blades 1014, the cutting element 1016, or any other feature and combination thereof. In this way, the cleaning element 1022 may help provide the cooling and / or chip removal features (or any other features) discussed herein with respect to the cleaning cutting element, but may not specifically include the superhard layer and / or cutting element for bonding and / or degrading the formation.

[0084] Figure 11-1 This is a side cross-sectional view representing a cleaning element 1122 implemented in a downhole tool 1110 according to at least one embodiment of the present disclosure. In some embodiments, the cleaning element 1122 may be assembled with the downhole tool 1110 via an inner surface or bore of the downhole tool 1110. For example, a cleaning element recess 1145 may be formed in the downhole tool 1110 from the interior of the downhole tool 1110, and the cleaning element 1122 may be inserted into the cleaning element recess 1145 at or through a fluid passage 1140 of the downhole tool 1110. The cleaning element recess 1145 may include one or more retaining features or retaining mechanisms to retain the cleaning element 1122 within the cleaning element recess 1145. The retaining features prevent the cleaning element 1122 from exiting the cleaning element recess 1145 in any direction. For example, a retaining feature can prevent the cleaning element 1122 from leaving the downhole surface of the downhole tool 1110 (e.g., upward as shown in FIG11), so that the cleaning element 1122 can be retained within the downhole tool 1110. In some examples, the retaining feature can prevent the cleaning element 1122 from leaving the surface of the downhole tool 1110 (e.g., downward as shown in FIG11).

[0085] The cleaning element recess 1145 may extend at least partially through the downhole tool 1110, such that one or more outlet openings 1124 in the cleaning element 1122 extend and / or are exposed above the top or outer surface of the downhole tool 1110. In this manner, the cleaning element 1122 may provide one or more drilling fluid flows to one or more features of the downhole tool 1110, as described herein. In some embodiments, the cleaning element 1122 is partially or completely covered (e.g., at the top) by a bridging member 1169 of the downhole tool 1110. For example, one or more blades, support structures, or substrates of the downhole tool 1110 may contact or engage to form the bridging member 1169. The bridging member 1169 may at least partially (or completely) cover the top of the cleaning element 1122, as shown in FIG11. In this manner, the cleaning element 1122 may be at least partially protected by the bridging member 1169 from the downhole environment, such as by preventing the cleaning element 1122 from contacting or engaging with the formation.

[0086] In some embodiments, the cleaning element 1122 is at least partially (or completely) exposed at its top. For example, while the cleaning element 1122 may be inserted into the cleaning element recess 1245 through the interior of the downhole tool 1110, some or all of the top of the cleaning element 1122 may extend upwards over the exterior or outer surface of the downhole tool 1110. For example, the cleaning element 1122 may not be covered and / or protected, for example, by the blades of the downhole tool 1110. As discussed in further detail below, in some embodiments, some of the downhole tools 1110 (e.g., blades) may be partially suspended above the cleaning element 1122, such that the cleaning element may be partially covered and / or protected, and may be partially exposed (e.g., exposed to the formation). In this way, embodiments of the cleaning element 1122 (e.g., inserted through the interior of the downhole tool 1110) may include a cleaning element 1122 that is partially or substantially covered and partially or substantially exposed to the external environment.

[0087] In some embodiments, the cleaning element 1122 may be secured in the cleaning element recess 1145. The cleaning element 1122 may be secured by a permanent or semi-permanent connection, such as by welding, brazing, press fit or other interference fits, any other connection mechanism, or combinations thereof. In some embodiments, the cleaning element 122 may be mechanically secured in the cleaning element recess 1145. For example, the cleaning element 1122 may be secured by a retaining element 1129. The retaining element 1129 may be a ring, clamp, pin, or any other mechanical device for retaining the cleaning element 1122. The cleaning element 1122 and / or the cleaning element recess 1145 may include one or more associated features or geometries for engaging with the retaining element 1129, such as grooves, slots, glands, etc. As shown in FIG11, the cleaning element 1122 may be secured by a retaining ring that assembles and / or engages with the groove in the cleaning element recess 1145 and / or the cleaning element 1122. In this way, the cleaning element 1122 may be mechanically secured in the downhole tool 1110.

[0088] In some embodiments, the fluid passage 1140 may be sealed to prevent drilling fluid from flowing out of the downhole tool 1110, for example, through the cleaning element recess 1145. For example, a seal 1135 may be positioned between the cleaning element 1122 and the cleaning element recess 1145. The seal 1135 may be an O-ring or gasket, such as a rubber, silicone, plastic, or metal O-ring (or any other suitable material). The seal 1135 may be implemented as a mating sealing surface of the cleaning element 1122 and / or the cleaning element recess 1145. In this way, the seal 1135 prevents unwanted drilling fluid from passing through the cleaning element recess 1145 to the outside of the downhole tool 1110.

[0089] In some embodiments, the cleaning element 1122 may be oriented and / or positioned in a specific direction or orientation. For example, the outlet opening 1124 may be configured to be positioned in a precise direction and / or location so that it can effectively supply drilling fluid to features of the downhole tool 1110 as described herein. In some embodiments, a key 1127 may orient the positioning of the cleaning element 1122. For example, the key 1127 may be a pin that engages with features of the cleaning element 1122 and / or the cleaning element recess 1145 such that the cleaning element 1122 is held in a desired orientation relative to the downhole tool 1110.

[0090] In some embodiments, the mechanical connection can facilitate the removable connection of the cleaning element 1122 to the downhole tool 1110. For example, the cleaning element 1122 may be removable for maintenance or for different configurations of the downhole tool 1110. While the mechanical connection of the cleaning element 1122 has been described primarily with respect to the insertion of the cleaning element 1122 through the interior of the downhole tool 1110, it should be understood that the same or similar mechanical connections may be implemented for cleaning elements that can be inserted through the top or outer surface of the downhole tool 1110.

[0091] Figure 11-2 This is a top view of a cleaning element 1122 implemented in a downhole tool 1110 according to at least one embodiment of the present disclosure. As described above, the cleaning element 122 may include one or more outlet openings 1124 through which drilling fluid can flow to or toward one or more features of the downhole tool 1110. The cleaning element 1122 is substantially centrally located in the downhole tool 1110. For example, the center or longitudinal axis of the cleaning element 1122 and the center or longitudinal axis of the downhole tool 1110 may be coaxial. The cleaning element 1122, centrally located in this manner, can facilitate the flow of drilling fluid substantially from the center or central portion of the downhole tool 1110 and toward one or more features of the downhole tool 1110. This centrally located drilling fluid flow can help increase the fluid flow through the downhole tool 1110, which can help flush cuttings away from the central region of the downhole tool 1110, help flush cuttings out of the scrap trough 1120, increase cooling of one or more features of the downhole tool 1110, perform any other actions, and combinations thereof.

[0092] In some embodiments, the drilling fluid flow may be represented by a first flow 1130-1. An outlet opening 1124 may guide the first flow 1130-1 of the drilling fluid in a first flow direction. The first flow direction may be substantially radial (e.g., perpendicular to the longitudinal axis 1128). For example, the first flow 1130-1 may be a vertical flow that exits from the outlet opening 1124 at an angle substantially perpendicular to the cleaning element 1122. For example, the first flow 1130-1 may flow in a first flow direction that coincides with, intersects with, originates from, is not offset from, or otherwise aligned with the central axis or longitudinal axis 1128 of the downhole tool 1110 and / or the cleaning element 1122, such as... Figure 11-2 As shown in the image.

[0093] In some embodiments, the drilling fluid flow may be represented by a second flow 1130-2. The outlet opening 1124 may guide the second flow 1130-2 of the drilling fluid in a second flow direction that is not a direct radial direction. The second flow 1130-2 may be a transverse flow, flowing from the outlet opening 1124 in a second flow direction transverse to and / or not perpendicular to the cleaning element 1122. For example, the second flow 1130-2 may flow in a second flow direction that is not coincident with, offset from, does not intersect with, or otherwise misaligned with the longitudinal axis 1128. For example, the second flow direction of the second flow 1130-2 may be characterized by an offset distance 1137 from the longitudinal axis 1128.

[0094] The offset nature of the second flow 1130-2 can facilitate guiding the second flow 1130-2 at or toward one or more features of the downhole tool 1110. For example, an offset 1137 of the second flow 1130-2 can facilitate guiding the second flow 1130-2 toward the blade 1114 of the downhole tool 1110. The second flow 1130-2 can be substantially parallel to the blade 1114, or substantially parallel to at least a portion of the blade 1114. For example, the second flow 1130-2 can be substantially parallel to the rotationally positioned inner portion 1114-1 of the downhole tool 1110. In some embodiments, the second flow 1130-2 can be substantially parallel to the engagement (e.g., cutting) surface of the blade 1114, such as one or more cutting elements 1116 disposed thereon (e.g., disposed on the inner portion 1114-1). In some embodiments, the inner portion 1114-1 may be substantially linear, and the outer portion 1114-2 may have a helical or curved shape (e.g., a helix in the direction of rotation of the downhole tool 1110 or opposite to the direction of rotation of the downhole tool 1110). In this way, the second flow 1130-2 may flow substantially parallel to at least the inner portion 1114-1, and in some cases may flow substantially parallel to most or all of the blade 1114. In some embodiments, the second flow 1130-2 may flow in a direction that converges with at least some of the blade 1114 and / or one or more mating surfaces of the blade 1114 (e.g., cutting element 1116). For example, the second flow 1130-2 may be directed at an angle toward some or all of the blade 1114 (e.g., converging with some or all of the blade 1114), such as toward or converging with the inner portion 1114-1 of the blade. The flow 1130-2 can be convergent because as it travels from the outlet opening 1124, it can be closer to some or all of the blades.

[0095] In this way, the second flow 1130-2 can be oriented in a non-divergent second flow direction relative to the blade 1114 (or a portion of the blade 1114), for example, parallel to or converging with the blade 1114. For example, the second flow 1130-2 can be non-divergent because it does not move further away from the blade 1114 as it travels through the downhole tool 1110. This contrasts with the first flow 1130-1, which can diverge from (or move further away from) the blade or at least from the inner portion and / or inner mating surface of the blade as it flows perpendicularly from the cleaning element 1122 through the downhole tool 1110. In this way, the second flow 1130-2 can provide an improved drilling fluid flow to features of the downhole tool (e.g., the blade 1114) positioned radially away from the center of the downhole tool 1110. For example, by not diverging from some or all of the blade 1114, the second flow 1130-2 can provide better cutting removal, cooling, etc., to portions of the blade 1114, the cutting element 1116, and / or features of the blade, which are further rotatably positioned toward the outside of the body of the downhole tool 1110.

[0096] The cleaning element 1122 may include an outlet opening 1124 that is directed to provide one or more drilling fluid flows exhibiting the characteristics and functions of a first flow 1130-1, a second flow 1130-2, or a combination thereof. For example, in some embodiments, all outlet openings 1124 have the same type of flow direction (e.g., vertical or offset). In another example, different outlet openings 1124 have different types of flow directions; for example, some outlet openings 1124 exhibit a vertical flow direction, while some outlet openings 1124 exhibit an offset flow direction.

[0097] Figure 12 This is a side view of a cleaning element 1222 implemented in a downhole tool 1210 according to at least one embodiment of the present disclosure. As discussed herein, the cleaning element 1222 may be implemented together with the downhole tool 1210 at a central axis or longitudinal axis 1228. The cleaning element 1222 may include one or more fluid conduits 1236 and an outlet opening 1224 for providing one or more drilling fluid flows from a central portion of the downhole tool 1210.

[0098] As mentioned above Figure 11-1 and Figure 11-2As discussed, the cleaning element can provide one or more flows of drilling fluid, which may specifically have a directional aspect relative to a horizontal or top-down reference plane of the downhole tool 1210. In some embodiments, the cleaning element may (additionally or alternatively) provide a drilling fluid flow having one or more directional aspects relative to a vertical or lateral reference plane of the downhole tool, such as... Figure 12 As shown.

[0099] The downhole tool 1210 may include one or more blades 1214 having one or more engagement surfaces thereon. The engagement surface may be the engagement surface of one or more cutting elements 1216 disposed on the blades 1214 of the downhole tool 1210. The orientation and positioning of the engagement surface may define the engagement profile 1237 of the blades 1214 and / or the downhole tool 1210.

[0100] In some embodiments, the cleaning element 1222 provides a drilling fluid flow 1230 from the outlet opening 1224. The flow 1230 may have a flow direction more aligned with an engagement profile 1237, which may be a nozzle such as a scrap trough nozzle 1239. For example, the scrap trough nozzle 1239 is shown as an exemplary flow 1231 providing drilling fluid from the downhole tool 1210. In some embodiments, the scrap trough 1239 may be a nozzle, which is typically included in the downhole tool 1210 for providing a drilling fluid flow. The scrap trough nozzle 1239 is shown as an illustrative implementation of the downhole tool 1210 and may not necessarily be implemented in the downhole tool 1210 other than, for example, the cleaning element 1222. Alternatively, the downhole tool 1210 may also include the scrap trough nozzle 1239 in addition to the cleaning element 1222.

[0101] As shown, flow 1230 and exemplary flow 1231 may each intersect the engagement contour 1237. In some embodiments, flow 1230 intersects the engagement contour 1237 at a flow angle 1233, which is smaller than the exemplary flow angle 1235 at which exemplary flow 1231 intersects the engagement contour 1237. In this way, the flow angle 1233 being smaller than the exemplary flow angle 1235 facilitates flow 1230 in a direction that is more aligned (e.g., more parallel) with at least a portion of the engagement contour 1237. In some embodiments, flow 1230 may be substantially parallel to at least a portion of the engagement contour 1237, for example, by rotating the inner portion.

[0102] This aligned or semi-aligned nature of the flow 1231 with the engagement profile 1237 can facilitate the flow 1230 interacting with and / or flowing through more portions of the blade 1214 (e.g., more portions of the cutting element 1216) before the flow 1230 passes through the outer range of the blade 1214 and / or beyond the engagement profile 1237. Conversely, as shown, the exemplary flow 1231 can interact with and / or flow through a relatively small portion of the blade 1214 before exceeding the engagement profile 1237. Compared to the exemplary flow 1231 achieved using the waste chute nozzle 1239, the cleaning element 1222 can in this way facilitate the flow 1230 of drilling fluid to provide cooling, cutting removal, etc., to more blades 1214 (e.g., to more cutting elements 1216). As described herein, this improved flow angle 1233 can be facilitated by the cleaning element 1222 located in a more central region of the downhole tool and the associated outlet opening 1224.

[0103] In some embodiments, the flow angle is an acute angle measured relative to the engagement profile 1237. For example, the flow angle 1233 can be within a range having an upper limit, a lower limit, or both, including any one of 0°, 5°, 10°, 20°, 30°, 45°, 50°, 60°. For example, the flow angle 1233 can be less than 60°. In another example, the flow angle 1233 can be greater than 0°. In yet another example, the flow angle 1233 can be between 0° and 60°. In some embodiments, it is critical that the flow angle 1233 is not greater than 45° in order to achieve the benefits of increased flow through the blade 1214 as described herein. In some embodiments, the flow angle 1233 can be a negative angle. For example, Figure 12 A flow 1230 is shown that originates or emanates from below the engagement contour 1237 and flows upward toward the engagement contour 1237, as defined by a flow angle 1233. In some embodiments, the cleaning element 1222 may be configured and positioned such that the flow 1230 may originate or emanate from above the engagement contour 1237 and flow downward (at least slightly) toward the engagement contour 1237. In this way, the flow angle 1233 may be a negative flow angle. As mentioned above, the flow angle 1233 may be a negative value of any angle and / or angle range of the flow angle 1233. For example, the flow angle 1233 may be any value from 0° to -60°.

[0104] In some embodiments, the cleaning elements and / or cleaning cutting elements described herein may be implemented in a downhole tool, the downhole tool including one or more portions, structures, or features of the downhole tool suspended above the cleaning elements and / or cleaning cutting elements.

[0105] For example, Figure 13-1 A representation of a cleaning element 1322-1 implemented in a downhole tool 1310-1 according to at least one embodiment of the present disclosure is shown. The downhole tool 1310-1 may include one or more blades 1314 having one or more cutting elements 1316 disposed thereon.

[0106] In some embodiments, one or more of the cutting elements 1316 may be disposed on the blade 1314, having a hanger 1341. For example, the blade 1314 may include a support structure 1343 portion of the blade 1314, which may form the overall shape and / or geometry of the blade 1314 and support the cutting element 1316. The support structure 1343 may extend toward the cleaning element 1322-1 such that the support structure 1343 is close to, adjacent to, or even in contact with the cleaning element 1322-1. In some embodiments, the support structure 1343 may not hang over the cleaning element 1322-1. For example, in embodiments where the cleaning element 1322-1 is assembled with the downhole tool 1310-1 from the outer surface of the downhole tool 1310-1, this may facilitate insertion of the cleaning element 1322-1 into the cleaning element recess 1345. The support structure 1343 extending toward and / or adjacent to the cleaning element 1322-1 in this manner may benefit the hanger 1341 of the cutting element 1316. For example, the cutting element 1316 may be positioned on the blade 1314 such that it is at least partially vertically positioned above at least a portion of the cleaning element 1322-1. In this way, the overhang 1341 of the cutting element 1316 may at least partially cover and / or protect the cleaning element 1322-1 from exposure to and / or contact with the formation. For example, as the downhole tool 1310-1 advances through the formation, the cutting element 1316 may remove or degrade the portion of the formation in the downhole path of the cleaning element 1322-1, so that the cleaning element 1322-1 may not engage with that portion of the formation.

[0107] In some embodiments, downhole tool 1310-1 may include two or more cutting elements 1316 suspended above cleaning element 1322-1 in such a manner that (e.g., on the same blade or on two or more blades 1314). The two or more cutting elements 1316 suspended above cleaning element 1322-1 may be suspended to the same or different degrees. For example, multiple cutting elements 1316 may be suspended to different degrees, such that most or all of the cutting element is covered by multiple suspended cutting elements 1316. This suspension of the cutting elements 1316 can facilitate the removal of more formation by downhole tool 1310-1 and advantageously provide a more complete cut at the bottom of the wellbore (e.g., with a smaller core or no core). This can further help protect cleaning element 1322-1 by preventing or minimizing contact between cleaning element 1322-1 and the formation. In some embodiments, at least some of cleaning elements 1322-1 may be uncovered and / or exposed to the formation. For example, the central portion of the formation (relative to downhole tool 1310-1) may not be removed or degraded by cutting element 1316, allowing a formation core to potentially form at its center as downhole tool 1310-1 passes through the formation. Cleaning element 1322-1 may include coring features to remove or destroy the formation core, as described herein.

[0108] Figure 13-2 A representation of a cleaning cutter element 1322-2 implemented in a downhole tool 1310-2 according to at least one embodiment of the present disclosure is shown. The cleaning cutter element 1322-2 may include an ultra-hard layer (e.g., a tapered cutter element) disposed on top of a substrate of the cleaning cutter element 1322-2. The downhole tool 1310-2 may include the elements described above. Figure 13-1Any of the features of the downhole tool 1310-1 discussed. For example, downhole tool 1310-2 may include one or more cutting elements 1316 having a dangle 1341 above the clean cutting element 1322-2. The dangle 1341 of the cutting element 1316 may at least partially cover the clean cutting element 1322-2 to prevent exposure to the formation. In this way, the dangle 1341 of the cutting element 1316 may facilitate the removal of more formation by the downhole tool 1310-2 and advantageously provide a more complete cut to the bottom of the wellbore (e.g., with a smaller core or no core). This may further help protect the clean cutting element 1322-2 by preventing or minimizing contact between the clean cutting element 1322-2 and the formation. For example, the dangle 1341 may advantageously protect one or more portions of the clean cutting element 1322-2 that do not include ultrahard layers. For example, as shown in the figure, an ultrahard layer 1351 may be disposed on top of the cleaning cutting element 1322-2, but may not cover the entire top surface of the cleaning cutting element 1322-2. Exposed portions of the top surface that are not ultrahard may be more susceptible to damage, wear, etc., than ultrahard portions. Overhangs 1341 may extend over at least some of these non-ultrahard portions of the cleaning cutting element 1322-2 such that they do not engage with or contact the formation and are not subject to wear and / or damage.

[0109] As described above, in some embodiments, the cleaning cutting element 1322-2 can be assembled together with the downhole tool 1310-1 in the cutting element recess 1345 by inserting the cleaning cutting element 1322-2 through the outer surface of the downhole tool 1310-2. If the downhole tool 1310-2 is not only suspended from the cleaning cutting element 1322-2 by the cutting element 1316 (e.g., the support structure 1343 is suspended from the cleaning cutting element 1322-2), the insertion of the cleaning cutting element 1322-2 into the cutting element recess 1345 and thus its assembly with the downhole tool 1310-2 can be prevented. Therefore, simply suspending (e.g., one or more) the cutting element 1316 can facilitate the assembly of the downhole tool 1310-2. For example, before one or more overhanging cutting elements 1316 are connected or inserted into the corresponding blade 1314, a cleaning cutting element 1322-2 may be inserted and secured into a cutting element recess 1345, and after the cleaning cutting element 1322-2 is inserted and secured into the cutting element recess 1345, the overhanging cutting element 1316 may then be connected. In this way, one or more overhanging features can also be applied to embodiments of downhole tools having cleaning cutting elements as described herein.

[0110] Figure 14A representation of a cleaning element 1422 implemented in a downhole tool 1410 according to at least one embodiment of the present disclosure is shown. The downhole tool 1410 may include one or more blades 1414 having one or more cutting elements 1416 disposed thereon. In some embodiments, one or more of the blades 1414 may be suspended above the cleaning element 1422. For example, as shown, a support structure 1443 of the blade 1414 may be directed toward and extend above at least a portion of the cleaning element 1422. In some embodiments, one or more cutting elements 1416 disposed on the blade 1414 may also be positioned to be suspended above the cleaning element 1416. Thus, the blade 1414 may at least partially cover the cleaning element 1422 to provide a more complete cut to the bottom of the wellbore and / or protect the cleaning element 1422, as described herein.

[0111] Figure 15-1 and Figure 15-2 A representation of a cleaning element 1522 implemented in a downhole tool 1510 according to at least one embodiment of the present disclosure is shown. The downhole tool 1510 may include one or more blades 1514 having one or more cutting elements 1516 disposed thereon. In some embodiments, two or more (or all) of the blades 1514 may be suspended above the cleaning element 1522. For example, as shown, support structures 1543 of two or more of the blades 1514 may extend toward and above the cleaning element 1522 and may engage or contact above the cleaning element 1522 to form a bridging element 1569. The blades 1514 may engage to form the bridging element 1569 at a central portion of the downhole tool 1510. The bridging element 1569 may help position one or more of the cutting elements 1516 such that they are close to or substantially at the center of the downhole tool 1510, and allow the downhole tool 1510 to cut or remove an increase (or all) of the bottom of the wellbore. The bridging element 1569 can also help protect the cleaning element 1522 by preventing or minimizing the contact between the cleaning element 1522 and the formation.

[0112] In this way, downhole tools can be implemented in various ways, such that one or more features are suspended to varying degrees above cleaning or cleaning cutter elements. This can facilitate the implementation of cleaning / cleaning cutter elements within the downhole tool. For example, the cleaning / cleaning cutter elements described herein can be positioned at the center of the downhole tool. Furthermore, implementing cleaning / cleaning cutter elements with larger dimensions (e.g., diameter) may be advantageous to achieve a greater offset of the aforementioned offset flow features, thereby guiding the flow of drilling fluid at specific locations and / or features within the downhole tool. Therefore, implementing cleaning / cleaning cutter elements within the downhole tool can occupy valuable and large space at the center of the downhole tool, which may prevent other features (e.g., blades and / or cutter elements) from being positioned within that central portion of the downhole tool. This may result in the downhole tool removing less material from the bottom of the well and / or providing a less complete cut to the wellbore, particularly at the center of the downhole tool. Consequently, a large core may form at the center of the downhole tool, which may be undesirable. However, by implementing one or more of the aforementioned suspended features, blades and / or cutter elements can extend closer to the center of the downhole tool for a more complete cut to the bottom of the well. In this way, clean / clean cutting elements (and even those with significantly large diameters) can be achieved without compromising the downhole tool's ability to cut the bottom of the well.

[0113] As described herein, in some embodiments, the cleaning element may be implemented in the downhole tool such that it engages with or contacts at least some of the formation as the downhole tool advances through the formation. For example, implementation of the downhole tool may result in the formation core being formed at the center of the downhole tool. In some embodiments, the formation core may extend gradually toward and contact the cleaning element.

[0114] Figure 16-1A representation of a cleaning element 1622-1 according to at least one embodiment of the present disclosure is shown. In some embodiments, the cleaning element 1622-1 includes a coring feature 1653-1. The coring feature 1653-1 may be positioned at or near the top of the cleaning element 1622-1, wherein a formation core 1655 may extend toward and engage the cleaning element 1622-1. The coring feature 1653-1 may include and / or may represent one or more tilting elements 1657 such that when the formation core 1655 engages the coring feature, the tilting elements 1657 apply a lateral load or lateral force 1661 to the formation core 1655. The lateral force 1661 may cause the formation core 1655 to fracture, crack, or otherwise degrade, such that some or all of the formation core 1655 is removed and carried away with other formation cuttings from the downhole tool. In this way, the formation core 1655 can be removed so that the formation core 1655 does not exert or apply significant axial forces (e.g., caused by drill pressure from downhole tools) on the cleaning element 1622-1, which could damage and / or wear down the cleaning element 1622-1.

[0115] In some embodiments, the coring feature 1653-1 may be implemented with one or more superhard components or layers so that the coring feature 1653-1 can engage the formation core 1655 with increased abrasion resistance. For example, the tilting element 1657 may be covered, layered, or may otherwise have an engagement surface, the engagement surface including a superhard material (such as PCD) bonded thereto. Figure 16-2 A representation of a cleaning element 1622-2 according to at least one embodiment of the present disclosure is shown. The cleaning element 1622-2 may include an ultrahard element 1659. The ultrahard element 1659 may include or exhibit a bevel to apply a lateral load or transverse force 1661 to the formation core 1655 to disrupt the formation core 1655. The ultrahard element 1659 may be offset from the center or central axis of the cleaning element 1622-1, such that the formation core 1655 may engage the beveled side of the ultrahard element 1659 to provide the lateral force 1661. In this way, embodiments of the cleaning element described herein may include coring features to protect the cleaning element from the resulting formation core that may form and contact the cleaning element. The coring features may not be limited to the embodiments shown and described herein, but may include any features for breaking, degrading, or removing the formation core.

[0116] It should be understood that features of various embodiments of the cleaning element, such as the mechanical connection of the cleaning element, the ability of the cleaning element to be inserted from inside the downhole tool, directional offset to provide a non-divergent drilling fluid flow, and the downhole tool being suspended above the cleaning element, are not limited to implementation only with (e.g., without a cutter) cleaning elements, but can be applied, for example, to cleaning cutting elements as described herein. In this way, one or more (or all) of the features and functions of the cleaning elements described herein and / or shown in the illustrative drawings can be applied to cleaning cutting elements having an ultra-hard engagement surface disposed thereon (e.g., a cutting element).

[0117] Furthermore, while the various downhole tools and drill bits described herein are shown and described as having one or more mating surfaces implemented as mating surfaces of associated cutting elements disposed on the blades of the downhole tool, it should be understood that downhole tools may include mating (e.g., cutting) surfaces with or without cutting elements disposed on them. For example, in some embodiments, one or more blades of the downhole tool may include mating surfaces thereon as part of the blade itself, without having cutting elements disposed on the blade. Thus, the features and functions described herein for providing various drilling fluid flows to downhole tools are applicable to blades with mating surfaces implemented relative to cutting elements and those without mating surfaces.

[0118] Embodiments of the clean-cutting element have been described primarily with reference to wellbore drilling operations; the clean-cutting element described herein can be used in applications other than wellbore drilling. In other embodiments, the clean-cutting element according to this disclosure can be used outside of wellbores or other downhole environments used for exploring or producing natural resources. For example, the clean-cutting element of this disclosure can be used in boreholes for placing utility pipelines. Therefore, the terms "wellbore," "borehole," etc., should not be construed as limiting the tools, systems, components, or methods of this disclosure to any particular industry, field, or environment.

[0119] This document describes one or more specific embodiments of the present disclosure. These described embodiments are examples of the technology currently disclosed. Additionally, to provide a concise description of these embodiments, not all features of actual embodiments may be described in the specification. It should be understood that in the development of any such actual implementation, as in any engineering or design project, numerous embodiment-specific decisions will be made to achieve the developer's specific goals, such as complying with system-related and business-related constraints, which may vary from embodiment to embodiment. Furthermore, it should be understood that such development work can be complex and time-consuming, but it remains a routine task of design, fabrication, and manufacturing for those skilled in the art who benefit from this disclosure.

[0120] Furthermore, it should be understood that references to "one embodiment" or "an embodiment" in this disclosure are not intended to be construed as excluding the existence of additional embodiments that also include the described features. For example, any element described with respect to embodiments herein may be combined with any element of any other embodiment described herein. Numbers, percentages, ratios, or other values ​​used herein are intended to include that value, as well as other values ​​that are "about" or "approximate" said values, as will be understood by one of ordinary skill in the art as covered by embodiments of this disclosure. Therefore, the values ​​should be interpreted broadly enough to cover values ​​that are at least sufficiently close to the value to perform the desired function or achieve the desired result. The values ​​include at least the variations expected in a suitable manufacturing or production process and may include values ​​within 5%, 1%, 0.1%, or 0.01% of the stated value.

[0121] In view of this disclosure, those skilled in the art should recognize that equivalent constructions do not depart from the spirit and scope of this disclosure, and various changes, substitutions, and modifications can be made to the embodiments disclosed herein without departing from the spirit and scope of this disclosure. Equivalent constructions including functional “device plus function” clauses are intended to cover structures described herein as performing the stated function, including structural equivalents operating in the same manner and equivalent structures providing the same function. The applicant’s explicit intention is that no claim shall invoke device plus function or other functional claims except those claims that use the term “device for…” in conjunction with the relevant function. Every addition, deletion, and modification to the embodiments falling within the meaning and scope of the claims will be covered by the claims.

[0122] As used herein, the terms “approximately,” “about,” and “substantially” mean quantities close to the stated amount, which are within standard manufacturing or process tolerances, or which still perform the desired function or achieve the desired result. For example, the terms “approximately,” “about,” and “substantially” can refer to quantities less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated amount. Furthermore, it should be understood that any directions or frames of reference described above are only relative directions or movements. For example, any references to “up” and “down,” or “above” or “below”, describe only the relative position or movement of the relevant element.

[0123] This disclosure may be practiced in other specific forms without departing from the spirit or characteristics thereof. The described embodiments are to be considered illustrative rather than restrictive. Therefore, the scope of this disclosure is indicated by the appended claims rather than the foregoing description. Variations within the meaning and scope of equivalents of the claims will be included within their scope.

Claims

1. A downhole tool, comprising: A body having a longitudinal axis and a fluid channel extending through the body; At least one blade, wherein the at least one blade has one or more mating surfaces thereon; At least one waste trough, the at least one waste trough extending adjacent to the at least one blade; and A cleaning element located on the longitudinal axis of a body and having a base hole in fluid communication with a fluid channel, the cleaning element including at least one opening for allowing fluid to flow from the base hole through at least one waste trough out of the downhole tool, wherein at least one blade is at least partially rotatably suspended above the cleaning element.

2. The downhole tool of claim 1, wherein the at least one blade is at least partially rotatably suspended over the cleaning element with at least one of the one or more mating surfaces.

3. The downhole tool of claim 1, wherein the support structure of the at least one blade is not suspended above the cleaning element, and the at least one blade includes an insertable cutting element that is at least partially rotatably suspended above the cutting element upon insertion.

4. The downhole tool of claim 1, wherein the support structure of the at least one blade is at least partially rotatably suspended above the cleaning element.

5. The downhole tool of claim 1, wherein the cleaning element comprises an ultrahard layer on the upper surface.

6. The downhole tool of claim 5, wherein the cleaning element includes a coring feature for applying a lateral load to the formation core during operation of the downhole tool.

7. The downhole tool according to claim 1, wherein the downhole tool is a fixed cutter bit.

8. The downhole tool of claim 1, wherein the at least one blade includes at least one cutting element connected thereto, and the one or more mating surfaces are one or more mating surfaces of the at least one cutting element.

9. The downhole tool of claim 1, wherein the downhole tool comprises a plurality of blades, each blade having one or more mating surfaces thereon, wherein a plurality of waste channels are formed between adjacent blades of the plurality of blades, and wherein the at least one opening comprises a plurality of openings for allowing the fluid to flow from the base hole through the plurality of waste channels out of the downhole tool, wherein at least one of the plurality of blades is at least partially rotatably suspended on the cleaning element.

10. The downhole tool of claim 9, wherein two or more of the plurality of blades are connected to form a bridging member above the cleaning element at the longitudinal axis of the downhole tool.

11. The downhole tool of claim 1, wherein the cleaning element is removably connected to the body.

12. The downhole tool of claim 1, wherein the cleaning element is removably connected to the body at a cleaning element recess in the downhole tool.

13. The downhole tool of claim 12, wherein the cleaning element recess has an insertion direction from the outer surface of the downhole tool.

14. The downhole tool of claim 12, wherein the cleaning element recess has an insertion direction from the inner surface of the downhole tool.

15. The downhole tool of claim 11, wherein the cleaning element is mechanically secured to the body.

16. The downhole tool according to claim 1, wherein, The cleaning element includes a seal between the cleaning element and the body for sealing the fluid to prevent the fluid from flowing out of the fluid channel between the cleaning element and the body.

17. A downhole tool, comprising: A body having a longitudinal axis and a fluid channel extending through the body; At least one blade, wherein the at least one blade has one or more mating surfaces thereon; At least one waste trough, the at least one waste trough extending adjacent to the at least one blade; and A cleaning element, located along the longitudinal axis of the body, comprising: The matrix pores are in fluid communication with the fluid channel; At least one opening for allowing fluid to flow from the base hole through at least one waste chute out of the downhole tool, wherein at least one blade is at least partially rotatably suspended on a cleaning element; and An ultra-hard layer is bonded to the upper surface of the cleaning element.

18. The downhole tool of claim 17, wherein the cleaning element is assembled with the body at a cleaning element recess in the downhole tool, and wherein the cleaning element recess has an insertion direction from the outer surface of the downhole tool.

19. The downhole tool of claim 17, wherein the support structure of the at least one blade does not hang over the cleaning element, and the at least one blade includes an insertable cutting element that, upon insertion, is at least partially rotatably suspended over the cutting element.

20. A downhole tool cleaning element, comprising: A body, configured to be connected to the downhole tool at its central axis; A base hole, which is located within the body and configured to be in fluid communication with the fluid passages of the downhole tool when the body is connected to the downhole tool; and At least one opening in the body allows fluid to flow from the base hole out of the at least one opening and to at least one feature of the downhole tool, wherein the body is assemblable with the downhole tool via a mechanical connection through the inner surface of the downhole tool.

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