Cutting element for active cooling and methods thereof

Abstract

A cutting element including a base. The base including a cylindrical body having a body axis, and where the cylindrical body defines a fluid bore extending at least partially therethrough along to the body axis. A fluid conduit in fluid communication with the fluid bore and oriented transverse to the body axis. A cutting support extending from the cylindrical body and a ultrahard layer joined to the cutting support such that a cutting surface of the ultrahard layer is oriented transverse to the body axis.

Description

FILED ELECTRONICALLY Docket No. IS24.0250-US-PSPCUTTING ELEMENT FOR ACTIVE COOLING AND METHODS THEREOFCROSS-REFERENCED TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application63 / 682,100 filed on August 12, 2024, the disclosure of which is incorporated herein by reference in its entirety.BACKGROUND OF THE DISCLOSURE

[0002] Wellbores may be drilled into a surface location or seabed for a variety of exploratory or extraction purposes. For example, a wellbore may be drilled to access fluids, such as liquid and gaseous hydrocarbons, stored in subterranean formations and to extract the fluids from the formations. Wellbores used to produce or extract fluids may be formed in earthen formations using earth-boring tools such as drill bits for drilling wellbores and reamers for enlarging the diameters of wellbores. An earth-boring tool may include one or more cutting elements secured to a blade of the tool. Typically, the tool includes one or more cutter pockets on an outer surface of the tool body, and the cutting elements are secured within the pockets by brazing.SUMMARY

[0003] In some aspects, the techniques described herein relate to a cutting element. The cutting element includes a base. The base includes a cylindrical body having a body axis and where the cylindrical body defines a fluid bore extending at least partially therethrough along to the body axis. The cylindrical body further defines a fluid conduit in fluid communication with the fluid bore and oriented transverse to the body axis, the fluid conduit extending to an exit opening in the cylindrical body. The cutting element further including a cutting support extending from the cylindrical body, and an ultrahard layer joined to the cutting support such that a cutting surface of the ultrahard layer is oriented transverse to the body axis.

[0004] In some aspects, the techniques described herein relate to a bit. The bit includes a bit body having a longitudinal axis and a fluid passage extending through the bit body. The bit further including a blade extending from the bit body and where the blade includes a first row of cutting elements and a second row of cutting elements. The second row ofFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP cutting elements is positioned rotationally behind the first row of cutting elements based on a direction of rotation of the bit. The bit further includes a cutting element located on the blade in the first row of cutting elements. The cutting element including a body having a body axis, the body defining a fluid bore extending therethrough to a first exit opening in the body. The fluid bore in fluid communication with the fluid passage, the cutting element further including a cutting support extending from the body and an ultrahard layer joined to the cutting support. The cutting surface of the ultrahard layer is oriented in the direction of rotation of the bit. The first exit opening in the body is positioned rotationally behind the ultrahard layer.

[0005] In some aspects, the techniques described here relate to a method of manufacturing a bit. The method includes providing a cylindrical body, the cylindrical body defining a fluid bore extending at least partially therethrough along to a body axis of the cylindrical body, and an exit opening at a first lateral surface of the cylindrical body, the cylindrical body including a second lateral surface, an ultrahard layer joined to the cylindrical body at the second lateral surface. The method further includes positioning the cylindrical body in a cutting element pocket located on a blade of the bit, the blade including a first row of cutting elements and a second row of cutting elements rotationally behind the first row of cutting elements based on a direction of rotation, the cylindrical body positioned on the first row of cutting elements such that the exit opening is oriented to direct fluid laterally between the first row of cutting elements and the second row of cutting elements. The method further including brazing the cylindrical body to the blade at the cutting element pocket.

[0006] This summary is provided to introduce a selection of concepts that are further described in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Additional features and aspects of embodiments of the disclosure will be set forth herein, and in part will be obvious from the description, or may be learned by the practice of such embodiments.FILED ELECTRONICALLY Docket No. IS24.0250-US-PSPBRIEF DESCRIPTION OF THE DRAWINGS

[0007] In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0008] FIG. 1 shows one example of a drilling system for drilling an earth formation to form a wellbore, according to at least one embodiment of the present disclosure;

[0009] FIGS. 2-1 and 2-2 are a cross sectional view of a cutting element, in accordance with at least one or more embodiments.

[0010] FIGS. 2-3 and 2-4 are a perspective view of the cutting element, in accordance with at least one or more embodiments.

[0011] FIG. 3 is a cross sectional view of a cutting element, in accordance with at least one or more embodiments.

[0012] FIGS. 4-1 and 4-2 are a perspective view of a cutting element, in accordance with at least one or more embodiments.

[0013] FIG. 5-1 is a perspective view of a base including a cylindrical body, in accordance with at least one or more embodiments.

[0014] FIG. 5-2 is a perspective view of a cutting element, in accordance with at least one or more embodiments.

[0015] FIG. 6-1 illustrates a perspective view of a bit, in accordance with at least one or more embodiments.

[0016] FIG. 6-2 illustrates a cross sectional view of a bit, in accordance with at least one or more embodiments.

[0017] FIG. 6-3 is a close-up perspective view of a blade of a bit, in accordance with at least one or more embodiments.FILED ELECTRONICALLY Docket No. IS24.0250-US-PSP

[0018] FIG. 7-1 and 7-2 illustrate a close-up perspective view of a blade of a bit, in accordance with at least one or more embodiments.

[0019] FIG. 8 illustrates a series of acts for manufacturing a bit, in accordance with one or more embodiments.DETAILED DESCRIPTION

[0020] This disclosure generally relates to devices, systems, and methods for cooling cutting elements on a drill bit of a downhole drilling system. A cutting element can include a substrate with an ultrahard layer bonded to a side surface of a base surface. The ultrahard layer is typically formed into a shape based on the function of the cutting element. For example, a scraping cutting element typically includes a flat cutting surface that is parallel or approximately parallel to the substrate and / or the base of the cutting element. In some examples, the ultrahard layer can have a conical, frustoconical, or domed surface. This may help to facilitate crushing of the rock and / or as depth-of-cut control to reduce blade wear.

[0021] A bit is formed from a plurality of blades extending from a body. A blade refers to a cutting edge that removes material when a drill is operated. A typical blade includes a first row of cutting elements (e.g., a primary row of cutters) and a second row of cutting elements (e.g., backup row of cutters) located rotationally behind the first row based on the rotation direction of the bit. The first row of cutting elements are typically provided with cooling via nozzles located on the bit body in front of the first row of cutting elements. However, in some situations, there may be limited space to provide a cooling for the second row of cutting elements. This may result in increased wear based on an increase in temperature during operation and / or a buildup of cuttings based on reduced flushing of the cuttings from the second row of cutting elements.

[0022] In accordance with at least one embodiment of the present disclosure, a cutting element includes a base having a cylindrical body. A fluid bore extends at least partially through the cylindrical body along a body axis of the cylindrical body. A fluid conduit extends from the fluid bore to an exit opening on a side-surface of the cylindrical body. In some embodiments, a nozzle is secured to the body at the exit opening, and the nozzle is oriented to direct fluid laterally between a first row or cutting element and a second row of cutting elements. One possible advantage of providing cooling and removing cuttingFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP material away from the second row of cutting elements will increase the lifespan of the drill bit.

[0023] In some embodiments, the exit opening is positioned rotationally behind the cutting surface of the cutting element. This may place the exit opening rotationally behind the first row of cutting elements and rotationally ahead of the second row of cutting elements. One possible advantage of placing the exit openings for a fluid on the cutting element of first row of cutting elements is to provide efficient cooling and / or improve the removal of cuttings for the second row of cutting elements.

[0024] FIG. 1 shows one example of a drilling system 100 for drilling an earth formation 101 to form a wellbore 102. The drilling system 100 includes a drill rig 103 used to turn a drilling tool assembly 104 which extends downward into the wellbore 102. The drilling tool assembly 104 may include a drill string 105, a bottomhole assembly (“BHA”) 106, and a bit 110, attached to the downhole end of the drill string 105.

[0025] The drill string 105 may include several joints of drill pipe 108 connected end- to-end through tool joints 109. The drill string 105 transmits drilling fluid through a central bore and transmits rotational power from the drill rig 103 to the BHA 106. In some embodiments, the drill string 105 may further include additional components such as subs, pup joints, etc. The drill pipe 108 provides a hydraulic passage through which drilling fluid is pumped from the surface. The drilling fluid discharges through selected-size nozzles, jets, or other orifices in the bit 110 for the purposes of cooling the bit 110 and cutting structures thereon, and for lifting cuttings out of the wellbore 102 as it is being drilled.

[0026] The BHA 106 may include the bit 110 or other components. An example BHA 106 may include additional or other components (e.g., coupled between to the drill string 105 and the bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (“MWD”) tools, logging-while-drilling (“LWD”) tools, downhole motors, underreamers, section mills, hydraulic disconnects, jars, vibration or dampening tools, other components, or combinations of the foregoing. The BHA 106 may further include a rotary steerable system (RSS). The RSS may include directional drilling tools that change a direction of the bit 110, and thereby the trajectory of the wellbore. At least a portion of the RSS may maintain a geostationary position relative to an absolute reference frame, such as gravity, magnetic north, and / or true north. UsingFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP measurements obtained with the geostationary position, the RSS may locate the bit 110, change the course of the bit 110, and direct the directional drilling tools on a projected trajectory.

[0027] In general, the drilling system 100 may include other drilling components and accessories, such as special valves (e.g., kelly cocks, blowout preventers, and safety valves). Additional components included in the drilling system 100 may be considered a part of the drilling tool assembly 104, the drill string 105, or a part of the BHA 106 depending on their locations in the drilling system 100.

[0028] The bit 110 in the BHA 106 may be any type of bit suitable for degrading downhole materials. For instance, the bit 110 may be a drill bit suitable for drilling the earth formation 101. Example types of drill bits used for drilling earth formations are fixed cutter or drag bits. In other embodiments, the bit 110 may be a mill used for removing metal, composite, elastomer, other materials downhole, or combinations thereof. For instance, the bit 110 may be used with a whipstock to mill into casing 107 lining the wellbore 102. The bit 110 may also be a junk mill used to mill away tools, plugs, cement, other materials within the wellbore 102, or combinations thereof. Swarf or other cuttings formed by use of a mill may be lifted to surface or may be allowed to fall downhole. In accordance with at least one embodiment of the present disclosure, the bit 110 may include a fluid passage extending through the bit body plurality of blades with plurality of cutting elements, as further discussed down below.

[0029] In accordance with numerous embodiments, blades of a bit 110 may have numerous insert cavities that are configured to receive or engage with cutting elements. In various embodiments, one or more cutting elements may be oriented so that one of the cutting surfaces faces a direction of rotation of the bit 110. In this manner, the cutting element may engage the formation as the bit 110 is rotated. In some embodiments, the cutting element may be an active cutting element configured to engage with the formation rather than a passive cutting element configured to provide depth of cut control or to reduce wear of the surrounding bit material. In some embodiments, the cutting element may be a passive cutting element configured to provide depth of cut control or to reduce wear of the surrounding bit material.FILED ELECTRONICALLY Docket No. IS24.0250-US-PSP

[0030] FIGS. 2-1 and 2-2 are a cross sectional view of a cutting element 212, in accordance with at least one or more embodiments. FIGS. 2-3 and 2-4 are a perspective view of the cutting element 212, in accordance with at least one or more embodiments. The cutting element 212 includes a base 214 and a ultrahard layer 228.

[0031] In some embodiments, the base 214 is a substrate of the ultrahard layer 228. In some embodiments, the base 214 is formed from a carbide material. The base 214 includes a cylindrical body 216 (e.g., a circular cross-sectional top-down shape). The cylindrical body 216 can have a body axis 218 in the middle of the cylindrical body 216 of the cutting element 212.

[0032] The cylindrical body 216 defines a fluid bore 220 extending at least partially therethrough in parallel to and / or along the body axis 218. The fluid bore 220 includes an inlet 234 at the bottom surface 280 of the cylindrical body 216. In some embodiments, the fluid bore 220 may be casted and / or molded during the manufacturing process of the base 214. In some embodiments, the fluid bore 220 may be added to the cylindrical body after manufacturing the body. For example, the fluid bore 220 may be milled, drilled, laser cut, or otherwise installed in the base 214.

[0033] The cylindrical body 216 further includes a fluid conduit 222 in fluid communication with the fluid bore 220, the fluid conduit oriented with a conduit axis 240 that is transverse to the body axis 218. In some or more embodiments, the cutting element 212 may include one fluid conduit 222. In some embodiments, as shown in FIG. 2-2, the cutting element 212 may include two fluid conduits 222. In some embodiments, the first and the second fluid conduits 222 may be oriented at an opening angle 282 within respect to each other. For example, the opening angle 282 between the first and the second fluid conduits 222 may be less than 240 degrees. In some embodiments, the opening angle 282 may be in a range having an upper value, a lower value, or upper and lower values including any of 50-240 degrees, or any value therebetween. For example, the opening angle 282 may be greater than 50 degrees. In another example, the opening angle 282 may be less than 240 degrees. In yet other examples, the opening angle 282 may be any value in a range between 50 and 240 degrees. In some embodiments, it may be critical that the opening angle 282 is greater than 50 degrees to orient the fluid to effectively clean and cool the cutting elements located rotationally behind the cutting element 212 (e.g., the cuttingFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP elements on a second row of cutting elements) based on a direction of rotation 254. In some embodiments, the opening angle 282 depends on the profile of the cutting element so as to provide efficient cooling for the cutting elements on the second row of cutting elements.

[0034] In some embodiments, the fluid conduit 222 and the body axis 218 may be oriented at an exit angle 284 with each other. In some embodiments, the exit angle 284 may be in a range having an upper value, a lower value, or upper and lower values including any of 60-160 degrees, or any value therebetween. For example, the exit angle 284 may be greater than 60 degrees. In another example, the exit angle 284 may be less than 160 degrees. In yet other examples, the exit angle 284 may be any value in a range between 60 and 160 degrees. In some embodiments, it may be critical that the exit angle 284 is less than 160 degrees to orient the fluid to effectively clean and cool the cutting elements located rotationally behind the cutting element 212 (e.g., the cutting elements on a second row of cutting elements) based on a direction of rotation 254. In some embodiments, the exit angle 284 depends on the profile of the cutting element so as to provide efficient cooling for the cutting elements on the second row of cutting elements.

[0035] While embodiments of the present disclosure illustrate two fluid conduits 222, it should be understood that the cutting element 212 may include any number of fluid conduits 222 (and their associated exit openings), including 1, 2, 3, 4, or more fluid conduits. The fluid bore 220 and the one or more fluid conduits 222 are configured to provide fluid to one or more cutting elements adjacent to the cutting element 212. For example, the fluid conduit 222 includes an exit opening 232 at the lateral surface of the base 214. The exit opening 232 may be oriented to direct drilling fluid to the sides of the cutting element 212, thereby cooling and / or cleaning the adjacent cutting elements.

[0036] As discussed herein, drilling fluid may pass into the fluid bore 220 through an inlet 234 in fluid communication with a fluid passage in a bit body, as further discussed in connection to FIG. 6-2. The drilling fluid may pass out of the cutting element 212 through the exit opening 232 of the body. In particular, the exit opening 232 is located rotationally behind the ultrahard layer 228 (e.g., on a first lateral side of the body) with respect to a direction of rotation 254. One possible advantage of including the exit opening 232 positioned rotationally behind the ultrahard layer 228 is that the fluid may be used to keep a cutting surface of the second row of cutting elements clean and / or aid in cooling at leastFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP a portion of a ultrahard layer. The fluid may aid in cooling and / or cleaning the cutting elements located rotationally behind the cutting element 212. One possible advantage is that this may allow the second row of cutting elements to cut formation material more efficiently and / or increase the use life of the cutting elements in the second row of cutting elements.

[0037] In some embodiments, the cutting element 212 includes a nozzle, a jet, or other orifices secured to the body at the exit opening to direct the fluid along a fluid path 238, as shown in connection to FIG. 2-4. In other words, the nozzle may direct fluid laterally along a fluid path 238 between a first row of cutting elements 212 and a second row of cutting elements 212, as further discussed in connection to FIGS. 6-3, 7-1 and 7-2. Directing the fluid laterally along the fluid path 238 will provide the fluid in front of a second row of cutters for cooling and / or cleaning.

[0038] The base 214 further includes a cutting support 224 extending laterally from the cylindrical body 216. In some embodiments, the cylindrical body 216 is integrally formed with the cutting support 224. In this manner, the cylindrical body 216 and the cutting support 224 may form a substrate of the ultrahard layer 228. The ultrahard layer 228 is joined to the cutting support 224 such that a cutting surface 226 of the ultrahard layer 228 is oriented transverse to the body axis 218 (e.g., on a second lateral surface of the body). As shown in FIG. 2-1, the cutting support 224 includes a lateral side surface 230 or a lateral surface on the cylindrical body 216 to which the ultrahard layer 228 is joined to. In some embodiments, the lateral side surface 230 is a non-flat surface. In some embodiments, the lateral side surface 230 and / or the cutting surface 226 are transverse to the body axis 218. As shown in FIG. 2-1, the cutting surface 226 is oriented in a cutting angle 286 with respect to the body axis 218. In some embodiments, the cutting angle 286 may be in a range having an upper value, a lower value, or upper and lower values including any of 5-85 degrees, or any value therebetween. For example, the cutting angle 286 may be greater than 5 degrees. In another example, the cutting angle 286 may be less than 85 degrees. In yet other examples, the cutting angle 286 may be any value in a range between 5 and 85 degrees. In some embodiments, it may be critical that the cutting angle 286 is less than 85 degrees to orient the cutting surface 226 towards the movement of rotation 254. In some embodiments, the cylindrical body 316 may include a cutting support pocket, such as aFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP cutting support pocket 342 of FIG. 3 or cutting support pocket 442 of FIGS. 4-1 and 4-2, to which the ultrahard layer 228 may be attached to via an insert substrate, such as the insert substrate 344 of FIG. 3 or insert substrate 444 of FIG. 4.

[0039] The ultrahard layer 228 may be formed from an ultrahard material. For example, the ultrahard material may be Poly crystalline diamond (PCD), Poly crystalline diamond compact (PDC), sapphire, moissantite, hexagonal diamond (Lonsdaleite), tungsten carbide, cubic boron nitride (cBN), polycrystalline cBN (PcBN), Q-carbon, binderless PcBN, diamond-like carbon, boron suboxide, aluminum manganese boride, metal borides, boron carbon nitride, PCD (including, e.g., leached metal catalyst PCD, non- metal catalyst PCD, and binderless PCD or nanopoly crystalline diamond (NPD)), any other ultrahard material, and combinations thereof.

[0040] In some embodiments, as further discussed in connection to FIGS. 3, 4-1, and 5-2 the ultrahard layer 228 is joined to an insert substrate and the insert substrate is secured to the cutting support 224. For example, the insert substrate may be brazed to the cutting support 224. In some embodiments, the ultrahard layer 228 and the insert substrate may be connected via a high temperature and high-pressure sintering process. For example, the insert substrate could be made of tungsten carbide material and when assembled with the ultrahard layer, the insert substrate, and the ultrahard layer 228 may be integrally formed using the high pressure and temperature sintering process.

[0041] In some embodiments, the cutting element 212 may be secured to a blade, such as the blade 652 of FIGS. 6-1 and 6-3 or the blade 752 of FIGS. 7-1 and 7-2. For example, the cutting element 212 may be secured to the blade by brazing, welding, mechanical fastener, shrink fit, press-fit, interference fit, any other manner, and combinations thereof. In some embodiments, the cutting element 212 may be casted directly to the blade.

[0042] FIG. 3 is a cross sectional view of a cutting element 312, in accordance with at least one or more embodiments. The cutting element 312 includes a base 314 and a ultrahard layer 328. In some embodiments, the base 314 is formed from a carbide material. The base 314 includes a cylindrical body 316 having a body axis 318. The cylindrical body 316 defines a fluid bore 320 extending at least partially therethrough along to the body axis 318. The fluid bore 320 includes an inlet 334 at the bottom surface 380 of the cylindrical body 316. In some embodiments, the fluid bore 320 may be casted and / or molded duringFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP the manufacturing process of the base 314. In some embodiments, the fluid bore 320 may be laser cut to the base 314.

[0043] The cylindrical body 316 further includes a fluid conduit 322 in fluid communication with the fluid bore 320 and oriented with a conduit axis 340 that is transverse to the body axis 318. In some or more embodiments, the cutting element 312 may include one fluid conduit 322. In some embodiments, the cutting element 312 may include two fluid conduits 322. In some embodiment, the cutting element 312 may include more than two fluid conduits 322. The fluid bore 320 and the one or more fluid conduits 322 are configured to provide fluid to one or more cutting elements. In some embodiments, the fluid conduit 322 includes an exit opening at the lateral surface of the base 314. In some embodiments, the cutting element includes a nozzle secured to the body at the exit opening. For example, the nozzle, the jet, or the other orifice may direct the fluid perpendicular to the direction of movement, as shown in connection to FIG. 6-3. In other words, the nozzle may direct fluid laterally between a first row of cutting elements 656 and a second row of cutting elements 658, as further discussed in connection to FIG. 6-3. By directing the fluid this way will provide the fluid in front of a second row of cutters.

[0044] The base 314 further includes a cutting support pocket 342 extending from the cylindrical body 316. For example, as shown in FIG. 3, the cutting support pocket 342 may include an indentation or cavity extending into the cylindrical body 316.

[0045] In some embodiments, the ultrahard layer 328 is joined to an insert substrate 344 and the insert substrate 344 is secured to the cutting support pocket 342. The ultrahard layer 328 and the insert substrate 344 may be connected via a high temperature and high- pressure sintering process. For example, the insert substrate 344 could be made of tungsten carbide material and when assembled with the ultrahard layer, the insert substrate 344 and the ultrahard layer 328 may be integrally formed using the high pressure and temperature sintering process. Separately connecting the insert substrate 344 to the base 314 may facilitate replacement of the ultrahard layer 328 and the insert substrate 344, such as to replace worn elements and / or to install an ultrahard layer 328 having a different geometry.

[0046] The ultrahard layer 328 may be formed from an ultrahard material. For example, the ultrahard material may be Polycrystalline diamond (PCD), Poly crystalline diamond compact (PDC), sapphire, moissantite, hexagonal diamond (Lonsdaleite),FILED ELECTRONICALLY Docket No. IS24.0250-US-PSP tungsten carbide, cubic boron nitride (cBN), polycrystalline cBN (PcBN), Q-carbon, binderless PcBN, diamond-like carbon, boron suboxide, aluminum manganese boride, metal borides, boron carbon nitride, PCD (including, e.g., leached metal catalyst PCD, non- metal catalyst PCD, and binderless PCD or nanopoly crystalline diamond (NPD)), any other ultrahard material, and combinations thereof.

[0047] In some embodiments, the cutting element 312 may be secured to a blade, such as the blade 652 of FIG. 6 or the blade 752 of FIGS. 7-1, and 7-2. For example, the cutting element 312 may be secured to the blade by brazing, welding, mechanical fastener, shrink fit, press-fit, interference fit, any other manner, and combinations thereof. In some embodiments, the cutting element 312 may be casted directly to the blade.

[0048] FIGS. 4-1 and 4-2 are a perspective view of a cutting element 412, in accordance with at least one or more embodiments. The cutting element 412 includes a base 414 and a ultrahard layer 428. In some embodiments, the base 414 is a substrate of the ultrahard layer 428. In some embodiments, the base 414 is formed from a carbide material. The base 414 includes a cylindrical body 416 having a body axis 418. The cylindrical body 416 defines a fluid bore extending at least partially therethrough along to the body axis 418. The fluid bore includes an inlet at the bottom surface 480 of the cylindrical body 416. In some embodiments, the fluid bore may be casted and / or molded during the manufacturing process of the base 414. In some embodiments, the fluid bore may be laser cut to the base 414.

[0049] The cylindrical body 416 further includes a fluid conduit in fluid communication with the fluid bore and oriented transverse to the body axis 418. In one or more embodiments, the cutting element 412 may include one fluid conduit. In some embodiments, the cutting element 412 may include two fluid conduits. In some embodiment, the cutting element 412 may include more than two fluid conduits. The fluid bore and the one or more fluid conduits are configured to provide fluid to one or more cutting elements. In some embodiments, the fluid conduit includes an exit opening 432 at the lateral surface of the base 414. In some embodiments, the cutting element includes a nozzle, a jet, or other orifices secured to the body at the exit opening 432. For example, the nozzle, the jet, or the other orifice may direct 738 the fluid perpendicular to the direction of rotation 754, as shown in connection to FIG. 7-1. In other words, the nozzle may directFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP738 fluid laterally between a first row of cutting elements 756 and a second row of cutting elements 758, as further discussed in connection to FIGS. 6-3 and 7-1. By directing the fluid this way will provide the fluid in front of a second row of cutters.

[0050] The base 414 further includes a cutting support pocket 442 extending from the cylindrical body 416. For example, as shown in FIG. 4, the cutting support pocket 442 may include one extension from the cylindrical body 416.

[0051] In some embodiments, the ultrahard layer 428 is joined to an insert substrate 444 and the insert substrate 444 is secured to the cutting support pocket 442. The ultrahard layer 428 and the insert substrate 444 may be connected via a high temperature and high- pressure sintering process. For example, the insert substrate 444 could be made of tungsten carbide material and when assembled with the ultrahard layer 428, the insert substrate 444 and the ultrahard layer 428 may be integrally formed using the high pressure and temperature sintering process.

[0052] The ultrahard layer 428 may be formed from an ultrahard material. For example, the ultrahard material may be Poly crystalline diamond (PCD), Polycrystalline diamond compact (PDC), sapphire, moissantite, hexagonal diamond (Lonsdaleite), tungsten carbide, cubic boron nitride (cBN), polycrystalline cBN (PcBN), Q-carbon, binderless PcBN, diamond-like carbon, boron suboxide, aluminum manganese boride, metal borides, boron carbon nitride, PCD (including, e.g., leached metal catalyst PCD, non- metal catalyst PCD, and binderless PCD or nanopolycrystalline diamond (NPD)), any other ultrahard material, and combinations thereof.

[0053] In some embodiments, the cutting element 412 may be secured to a blade, such as the blade 652 of FIG. 6 or the blade 752 of FIGS. 7-1 and 7-2. For example, the cutting element 412 may be secured to the blade by brazing, welding, mechanical fastener, shrink fit, press-fit, interference fit, any other manner, and combinations thereof. In some embodiments, the cutting element 412 may be casted directly to the blade.

[0054] FIG. 5-1 is a perspective view of a base 514 including a cylindrical body 516, in accordance with at least one or more embodiments.

[0055] In some embodiments, the cylindrical body 516 is configured to be positioned in a cutting element pocket located on a blade of a bit. For example, the cylindrical body 516 may be positioned in a first row of cutting elements based on a direction of rotation ofFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP the bit, as further shown in FIG. 6-1 . In another example, the cylindrical body 516 may be positioned between the first row of cutting elements and a second row of cutting elements on a direction of rotation of the bit.

[0056] The cylindrical body 516 has a body axis 518. The cylindrical body 516 defines a fluid bore extending at least partially therethrough along to the body axis 518. The fluid bore includes an inlet at the bottom surface 580 of the cylindrical body 516. In some embodiments, the fluid bore may be casted and / or molded during the manufacturing process of the base 514. In some embodiments, the fluid bore may be laser cut to the base 514. In some embodiments, the bit includes a bit body having a longitudinal axis and a fluid passage extending through the bit body and the fluid bore is in fluid communication with the fluid passage.

[0057] The cylindrical body 516 further includes a fluid conduit in fluid communication with the fluid bore and oriented transverse to the body axis 518. In some or more embodiments, the cutting element 512 may include one fluid conduit. In some embodiments, the cutting element 512 may include two fluid conduits. In some embodiment, the cutting element 512 may include more than two fluid conduits. The fluid bore and the one or more fluid conduits are configured to provide fluid to one or more cutting elements. In some embodiments, the fluid conduit includes an exit opening 532 at the lateral surface of the base 514, such that the exit opening 532 is oriented to direct fluid laterally between the first row of cutting elements and the second row of cutting elements. In some embodiments, the cutting element includes a nozzle, a jet, or other orifice secured to the body at the exit opening 532.

[0058]

[0059] FIG. 5-2 is a perspective view of a cutting element 512, in accordance with at least one or more embodiments. The cutting element 512 includes a base 514 and a ultrahard layer 528. In some embodiments, the base 514 is a substrate of the ultrahard layer 528. In some embodiments, the base 514 is formed from a carbide material. The base 514 includes a cylindrical body 516 having a body axis 518. The cylindrical body 516 defines a fluid bore extending at least partially therethrough along to the body axis 518. The fluid bore includes an inlet at the bottom surface 580 of the cylindrical body 516. In some embodiments, the fluid bore may be casted and / or molded during the manufacturingFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP process of the base 14. In some embodiments, the fluid bore may be laser cut to the base 514.

[0060] The cylindrical body 516 further includes a fluid conduit in fluid communication with the fluid bore and oriented transverse to the body axis 518. In some or more embodiments, the cutting element 512 may include one fluid conduit. In some embodiments, the cutting element 512 may include two fluid conduits. In some embodiment, the cutting element 512 may include more than two fluid conduits. The fluid bore and the one or more fluid conduits are configured to provide fluid to one or more cutting elements. In some embodiments, the fluid conduit includes an exit opening 532 at the lateral surface of the base 514. In some embodiments, the cutting element includes a nozzle, a jet, or other orifice secured to the body at the exit opening 532. For example, the nozzle, the jet, or the other orifice may direct the fluid perpendicular to the direction of movement, as shown in connection to FIG. 7-1 In other words, the nozzle may direct fluid laterally between a first row of cutting elements and a second row of cutting elements, as further discussed in connection to FIGS. 6-3 and 7-1. By directing the fluid this way will provide the fluid in front of a second row of cutters.

[0061] The base 514 further includes a cutting support 524 extending from the cylindrical body 516. In some embodiments, the ultrahard layer 528 is joined to the insert substrate 544 then attached to the cutting support 524 such that a cutting surface 526 of the ultrahard layer 528 is oriented transverse to the body axis 518. As shown in FIG. 5-1, the cutting support 524 includes a side surface 530 to which the insert substrate 544 is joined to. As shown in FIG. 5-1, the side surface 530 and the bottom surface 580 are not parallel, nor opposite sides of the cutting element 512. Instead, the bottom surface 580 and the side surface 530 are transverse to each other.

[0062] In some embodiments, as shown in FIG 5-2, the ultrahard layer 528 is joined to an insert substrate 544 and the insert substrate 544 is secured to the cutting support 524. The ultrahard layer 528 and the insert substrate 544 may be connected via a high temperature and high-pressure sintering process. For example, the insert substrate 544 could be made of tungsten carbide material and when assembled with the ultrahard layer 528, the insert substrate 544 and the ultrahard layer 528 may be integrally formed using the high pressure and temperature sintering process.FILED ELECTRONICALLY Docket No. IS24.0250-US-PSP

[0063] The ultrahard layer 528 may be formed from an ultrahard material. For example, the ultrahard material may be Poly crystalline diamond (PCD), Polycrystalline diamond compact (PDC), sapphire, moissantite, hexagonal diamond (Lonsdaleite), tungsten carbide, cubic boron nitride (cBN), polycrystalline cBN (PcBN), Q-carbon, binderless PcBN, diamond-like carbon, boron suboxide, aluminum manganese boride, metal borides, boron carbon nitride, PCD (including, e.g., leached metal catalyst PCD, non- metal catalyst PCD, and binderless PCD or nanopoly crystalline diamond (NPD)), any other ultrahard material, and combinations thereof.

[0064] In some embodiments, the cutting element 512 may be secured to a blade, such as the blade 652 of FIG. 6 or the blade 752 of FIG. 7-1. For example, the cutting element 512 may be secured to the blade by brazing, welding, mechanical fastener, shrink fit, press- fit, interference fit, any other manner, and combinations thereof. In some embodiments, the cutting element 512 may be casted directly to the blade.

[0065] FIG. 6-1 illustrates a perspective view of a bit 610, in accordance with at least one or more embodiments. The bit 610 may include a bit body 650 from which a plurality of blades 652 may protrude. At least one of the blades 652 may have a plurality of cutting elements 612 connected thereto. In some embodiments, at least one of the cutting elements 612 may be a planar cutting element, such as a shear cutting element. In other embodiments, at least one of the cutting elements 612 may be a non -planar cutting element, such as a conical cutting element or a ridged cutting element. The blade 652 includes a first row of cutting elements 656 and a second row of cutting elements 658. The second row of cutting elements 658 is positioned rotationally behind the first row of cutting elements 656 based on a direction of rotation 654 of the bit 610. As the bit 610 rotates in a direction of rotation 654, the first row of cutting elements 656 may encounter and / or pass by features of the formation before the second row of cutting elements 658.

[0066] The cutting element 612 may be a cutting or crushing element that is configured to engage the formation with a cutting or crushing functionality. In some embodiments, the blade 652 may include an insert cavity configured to receive a cutting elements 612. The insert cavity may penetrate into the blade 652. For example, a cylindrical blade pocket may be formed into the outer surface of the blade 652, in other words the outer surface of the blade 652 may have one or more cylindrical blade pockets locatedFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP therein. The cutting element 612 may have a cylindrical shape that is complementary to the cylindrical blade pocket of the insert cavity. The cutting element 612 may be secured to the blade 652 at the outer surface in one of the insert cavities. The cutting element 612 may be secured to the insert cavity in any manner. For example, the cutting element 612 may be secured to the insert cavity by braze, weld, press fit, mechanical fastener, any other connection mechanism, and combinations thereof. In some embodiments, the cutting element 612 may be secured to the blade 652 at any portion of the bit 610.

[0067] FIG. 6-2 illustrates a cross sectional view of a bit 610, in accordance with at least one or more embodiments. The bit 610 includes a bit body 650 having a longitudinal axis 660 and a fluid passage 662 extending through the bit body 650. The blade 652 includes a first row of cutting elements and a second row of cutting elements. The second row of cutting elements is positioned rotationally behind the first row of cutting elements based on a direction of rotation 654 of the bit 610. In some embodiments, a cutting element 612 is located on the blade 652 in the first row of cutting elements. The cutting element 612 includes a body having a body axis 618. The body further including a fluid bore 620 extending at least partially therethrough. The fluid bore 620 is in fluid communication with the fluid passage 662.

[0068] FIG. 6-3 is a close-up perspective view of a blade 652 of a bit, in accordance with at least one or more embodiments. The blade 652 includes a first row of cutting elements 656 and a second row of cutting elements 658. The second row of cutting elements 658 is positioned rotationally behind the first row of cutting elements 656 based on a direction of rotation 654 of the bit. As shown in FIG. 6-3 one of the cutting elements 612 in the first row of cutting elements 656 includes a body 616 having a first lateral side of the body 666 that is configured to receive a ultrahard layer 628. The first side of the body 666 (and the ultrahard layer 628) is oriented towards the direction of rotation 654 of the bit. The cutting element 612 further includes an exit opening 632 positioned rotationally behind the first side of the body 666 based on the direction of rotation 654 of the bit. In one or more embodiments, as shown in FIG. 6-3, the cutting element 612 includes two exit openings 632. The one or more exit openings 632 are oriented to direct 638 fluid perpendicular to the direction of rotation 654 of the bit. In one or more embodiments, the exit openings 632 have an opening angle 682 of less than 180 degrees. One possible benefitFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP of having an opening angle 682 between the two exit openings 632 is to direct 638 the fluid laterally between the first row of cutting elements 656 and the second row of cutting elements 658, as shown in FIG. 6-3.

[0069] FIG. 7-1 and 7-2 illustrate a close-up perspective view of a blade 752 of a bit, in accordance with at least one or more embodiments. The blade 752 includes a first row of cutting elements 756 and a second row of cutting elements 758. The second row of cutting elements 758 is positioned rotationally behind the first row of cutting elements 756 based on a direction of rotation 754 of the bit. As the bit rotates in a direction of rotation 754, the first row of cutting elements 756 may encounter and / or pass by features of the formation before the second row of cutting elements 758.

[0070] The first row of cutting elements 756 includes a cutting element 712 that is configured to engage the formation with a cutting or crushing functionality. In some embodiments, the blade 752 may include an insert cavity configured to receive a cutting elements 712. The insert cavity may penetrate into the blade 752. For example, a cylindrical blade pocket may be formed into the outer surface of the blade 752, in other words the outer surface of the blade 752 may have one or more cylindrical blade pockets located therein. The cutting element 712 may have a cylindrical shape that is complementary to the cylindrical blade pocket of the insert cavity. The cutting element 712 may be secured to the blade 752 at the outer surface in one of the insert cavities. The cutting element 712 may be secured to the insert cavity in any manner. For example, the cutting element 712 may be secured to the insert cavity by braze, weld, press fit, mechanical fastener, any other connection mechanism, and combinations thereof. In some embodiments, the cutting element 712 may be secured to the blade 752 at any portion of the bit.

[0071] As shown in FIG. 7-1 one of the cutting elements 712 in the first row of cutting elements 756 includes a body 750 having a first side of the body 766 that is configured to receive a ultrahard layer 728. The first side of the body 766 (and the ultrahard layer 728) is oriented towards the direction of rotation 754 of the bit. The cutting element 712 further includes an exit opening 732 positioned rotationally behind the first side of the body 766 based on the direction of rotation 754 of the bit. In one or more embodiments, as shown in FIG. 7-1, the cutting element 712 includes two exit openings 732. The one or more exit openings 732 are oriented to direct fluid in a fluid path 738 that is perpendicular to theFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP direction of rotation 754 of the bit. In one or more embodiments, the exit openings 732 have an opening angle 782 of less than 180 degrees. One possible benefit of having an opening angle 782 between the two exit openings 732 is to direct the fluid path 738 laterally between the first row of cutting elements 756 and the second row of cutting elements 758.

[0072] FIG. 8 illustrates a series of acts 850 for manufacturing a bit, in accordance with one or more embodiments. While FIG. 8 illustrates acts according to one or more embodiments, alternative embodiments may omit, add to, reorder, and / or modify any of the acts shown in FIG. 8. The acts of FIG. 8 can be performed as part of a method. Alternatively, a system or a device can perform the acts of the FIG. 8.

[0073] As shown in FIG. 8, the series of acts 850 may include an act 852 of providing a cylindrical body. In one or more embodiments, the cylindrical body defining a fluid bore extending at least partially therethrough along to a body axis of the cylindrical body, and an exit opening at a first lateral surface of the cylindrical body, the cylindrical body including a second lateral surface, an ultrahard layer joined to the cylindrical body at the second lateral surface.

[0074] The series of acts 850 may further include an act 854 of positioning the cylindrical body in a cutting element pocket located on a blade of the bit. In one or more embodiments, the blade including a first row of cutting elements and a second row of cutting elements rotationally behind the first row of cutting elements, the cylindrical body positioned on the first row of cutting elements such that the exit opening is oriented to direct fluid laterally between the first row of cutting elements and the second row of cutting elements.

[0075] The series of acts 850 may further include an act 856 of brazing the cylindrical body to the blade at the cutting element pocket.

[0076] One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, not all features of an actual embodiment may be described in the specification. It should be appreciated 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 developers’ specific goals, such as compliance with system -related andFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP business-related constraints, which may vary from one embodiment to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0077] Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. For example, any element described in relation to an embodiment herein may be combinable with any element of any other embodiment described herein. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.

[0078] A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.

[0079] The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that is within standard manufacturing orFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP process tolerances, or which still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements.

[0080] The present disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. Changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

FILED ELECTRONICALLY Docket No. IS24.0250-US-PSPCLAIMSWhat is claimed is:

1. A base, comprising: a cylindrical body configured to be inserted in a cutting element pocket of a bit and the cylindrical body having a body axis, wherein the cylindrical body defines a fluid bore extending at least partially therethrough along the body axis, the cylindrical body further defining a fluid conduit in fluid communication with the fluid bore and oriented transverse to the body axis, the fluid conduit extending to an exit opening in the cylindrical body; and a cutting support extending from the cylindrical body.

2. The base of claim 1, further including an ultrahard layer joined to the cutting support such that a cutting surface of the ultrahard layer is oriented transverse to the body axis.

3. The base of claim 1, further comprising a nozzle secured to the exit opening, wherein the nozzle is oriented to direct fluid laterally between a first row of cutting elements and a second row of cutting elements.

4. The base of claim 1, wherein the exit opening is on a lateral surface of the cylindrical body.

5. The base of claim 2, wherein the base is integrally formed with the cutting support, the base and the cutting support forming a substrate of the ultrahard layer.

6. The base of claim 5, wherein the ultrahard layer is brazed to the substrate.FILED ELECTRONICALLY Docket No. IS24.0250-US-PSP7. The base of claim 2, wherein the ultrahard layer is joined to an insert substrate, the insert substrate brazed to the cutting support.

8. The base of claim 7, wherein the cutting support includes a cutting support pocket and wherein the ultrahard layer is brazed to the base at the cutting support pocket.

9. A bit, comprising: a bit body having a longitudinal axis; a fluid passage extending through the bit body; a blade extending from the bit body, the blade including a first row of cutting elements and a second row of cutting elements, wherein the second row of cutting elements is positioned rotationally behind the first row of cutting elements based on a direction of rotation of the bit; and a cutting element located on the blade in the first row of cutting elements including: a body having a body axis, the body defining a fluid bore extending therethrough to a first exit opening in the body, the fluid bore in fluid communication with the fluid passage; a cutting support extending from the body; and an ultrahard layer joined to the cutting support, wherein a cutting surface of the ultrahard layer is oriented in the direction of rotation of the bit; and wherein the first exit opening in the body is positioned rotationally behind the ultrahard layer.

10. The bit of claim 9, wherein the first exit opening is oriented to direct fluid perpendicular to the direction of rotation of the bit.

11. The bit of claim 9, wherein the body defines a second exit opening, the fluid bore in fluid communication with the second exit opening.FILED ELECTRONICALLY Docket No. IS24.0250-US-PSP12. The bit of claim 11, wherein the first exit opening and the second exit opening define an opening angle of less than 240 degrees.

13. The bit of claim 9, wherein the cutting element includes a nozzle secured to the body at the first exit opening.

14. The bit of claim 13, wherein the nozzle is oriented to direct fluid laterally between the first row of cutting elements and the second row of cutting elements.

15. The bit of claim 9, wherein the first exit opening opens at a lateral surface of the body.

16. The bit of claim 9, wherein the body is integrally formed with the cutting support, the body and the cutting support forming a substrate of the ultrahard layer.

17. The bit of claim 9, wherein the ultrahard layer is joined to the cutting support via a substrate.

18. The bit of claim 9, wherein the cutting element includes the cutting support extending from the body.

19. The bit of claim 18, wherein the cutting support includes a cutting support pocket and wherein the ultrahard layer is configured to be placed in the cutting support pocket.

20. A method of manufacturing a bit, comprising: providing a cylindrical body, the cylindrical body defining a fluid bore extending at least partially therethrough along to a body axis of the cylindrical body, and an exit opening at a first lateral surface of the cylindrical body, theFILED ELECTRONICALLY Docket No. IS24.0250-US-PSP cylindrical body including a second lateral surface, an ultrahard layer joined to the cylindrical body at the second lateral surface; positioning the cylindrical body in a cutting element pocket located on a blade of the bit, the blade including a first row of cutting elements and a second row of cutting elements rotationally behind the first row of cutting elements, the cylindrical body positioned on the first row of cutting elements such that the exit opening is oriented to direct fluid laterally between the first row of cutting elements and the second row of cutting elements; and brazing the cylindrical body to the blade at the cutting element pocket.

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