Cutting Element Internal Fluid Flow Pathways for Thermal Management

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Solution Overview

Problem

Conventional cutting elements in earth-boring tools suffer from thermal damage due to high temperatures during drilling, leading to decreased efficiency and operational life.

Innovation Solution

Incorporating internal fluid flow pathways within cutting elements, which direct coolant fluid through the supporting substrate and cutting table to cool internal regions, enhancing thermal management and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If conventional cutting elements are used during drilling operations, then cutting efficiency is maintained initially, but thermal damage occurs leading to decreased cutting efficiency and shortened operational life

Engineering Contradiction:

Improveoperational life of cutting elementsVSAvoidthermal damage to cutting tables

Core Design Contradiction:

Duration of action of moving objectVSTemperature

Solution Approach 1:

The cutting element is segmented into functional zones with internal fluid flow pathways distributed throughout the supporting substrate and cutting table. This segmentation allows coolant to reach multiple internal regions simultaneously, distributing thermal management across the entire structure rather than relying on surface cooling alone.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A fluid intermediary (coolant) is introduced into the cutting element through internal flow pathways. This fluid acts as a thermal mediator, absorbing heat generated during drilling operations and transporting it away from critical regions, thereby preventing thermal damage to the cutting tables and supporting substrate.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If internal fluid flow pathways are incorporated in cutting elements, then thermal management is enhanced, but device complexity increases

Engineering Contradiction:

Improvethermal management of cutting elementsVSAvoidstructural complexity of cutting elements

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The fluid flow pathways are merged into the existing structure of the supporting substrate and cutting table during the sintering process. Rather than adding separate cooling components, the cooling function is integrated directly into the structural elements, eliminating the need for additional parts and reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The physical and chemical parameters of the supporting substrate and cutting table are modified during sintering to create internal fluid flow pathways. By changing the structural parameters of these components during manufacturing, the cooling function is built-in without requiring complex assembly of separate parts.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If internal fluid flow pathways are created through sintering with acid-dissolvable structures, then cooling efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvedrilling efficiencyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

Acid-dissolvable structures are incorporated into the green compact before sintering as preliminary placeholders for the fluid flow pathways. During the sintering process, these structures dissolve, automatically creating the desired internal channels. This preliminary action simplifies the manufacturing process by eliminating the need for post-sintering drilling or machining operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical process of creating fluid flow pathways (such as drilling or machining after sintering) is replaced with a chemical process. Acid-dissolvable structures are used as sacrificial elements that chemically dissolve during sintering, leaving behind the desired fluid flow pathways without requiring mechanical removal operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution significantly improves drilling efficiency and extends the operational life of cutting elements by effectively managing heat and reducing thermal damage.

Implementation Method 1

a fluid flow pathway extending through the supporting substrate and the cutting table. The fluid flow pathway is configured to direct fluid delivered to an outermost boundary of the supporting substrate through internal regions of the supporting substrate and the cutting table

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11732532B2Methods of forming cutting elements

Publication Date: 2023.08.22 BAKER HUGHES CO

AI summary

A cutting element comprises a supporting substrate, a cutting table comprising a hard material attached to the supporting substrate, and a fluid flow pathway extending through the supporting substrate and the cutting table. The fluid flow pathway is configured to direct fluid delivered to an outermost boundary of the supporting substrate through internal regions of the supporting substrate and the cutting table. A method of forming a cutting element and an earth-boring tool are also described.