Abstract
The present invention relates to a drilling system with a multi-function drill head used in, among other applications, oil and gas drilling. The system is used to enhance the effective permeability of an oil and/or gas reservoir by drilling or cutting new structures into the reservoir. The system is capable of cutting straight bores, radius bores, or side panels, by water jets alone or in combination with lasers. In various embodiments, a device for remotely controlling the mode of the system by variations in the pressure of a drilling fluid is also provided, allowing an operator to switch between various modes (straight drilling, radius bore drilling, panel cutting, etc.) without withdrawing the drill string from the well bore.
Claims
1. A drilling system comprising: a drill string; a drilling fluid for drilling into a geological formation, wherein the drilling fluid flows through the drill string; a drill head interconnected to the drill string, the drill head having at least two operating modes, wherein a first operating mode of the at least two operating modes is selected from a group consisting of a straight drilling mode, a radius bore drilling mode, a side panel cutting mode, a propulsion mode, and a non-operational mode, and wherein the drill head comprises a valve assembly comprising: a housing comprising: a bore; a first end; a first hole; a second hole; a first body groove interconnected to the first hole, wherein the first body groove corresponds to the first operating mode; and a second body groove interconnected to the second hole, wherein the second body groove corresponds to a second operating mode of the at least two operating modes; and a spool having an axial bore, a first end, and a second end, wherein the spool is moveable between a first position and a second position, wherein the first end of the spool receives the drilling fluid, and wherein the first position corresponds to a first pressure of the drilling fluid and the second position corresponds to a second pressure of the drilling fluid; wherein the first operating mode corresponds to the first pressure of the drilling fluid and the second operating mode corresponds to the second pressure of the drilling fluid, wherein the first pressure of the drilling fluid is between about 40 kpsi and about 50 kpsi and the second pressure of the drilling fluid is between about 30 kpsi and about 40 kpsi; a drill head body having a leading surface and a circumferential surface; and a swivel head interconnected to the leading surface of the drill head body, wherein the swivel head is angularly articulable relative to a longitudinal axis of the drill head body, and wherein the swivel head comprises: a first fluid jet cutter; a second fluid jet cutter; a first laser cutter; and a second laser cutter.
2. The drilling system of claim 1, further comprising a side panel cutting head positioned on the circumferential surface of the drill head body.
3. The drilling system of claim 1, wherein the housing further comprises: a third hole; a fourth hole; a third body groove interconnected to the third hole, wherein the third body groove corresponds to a third operating mode; and a fourth body groove interconnected to the fourth hole, wherein the fourth body groove corresponds to a fourth operating mode.
4. The drilling system of claim 3, wherein: the third operating mode corresponds to a third pressure of the drilling fluid, and wherein the third pressure is between about 20 kpsi and about 30 kpsi; and the fourth operating mode corresponds to a fourth pressure of the drilling fluid, and wherein the fourth pressure is less than about 20 kpsi.
5. The drilling system of claim 1, wherein the first hole of the housing is positioned on a downstream surface of the housing.
6. The drilling system of claim 1, wherein the first hole of the housing is positioned on a lateral surface of the housing.
7. The drilling system of claim 1, wherein the first hole of the housing is positioned on an upstream face of the housing.
8. The drilling system of claim 1, further comprising a detent assembly for locking the spool in the first position and in the second position, wherein the detent comprises a spring biased against a locking pin, wherein the locking pin is biased against a first notch of the spool when the spool is in the first position and the locking pin is biased against a second notch of the spool when the spool is in the second position, and wherein the locking pin of the detent assembly is selected from a group consisting of a ball, a pin, a sphere, a wheel, and a block.
9. The drilling system of claim 1, further comprising a percussive fluid jet.
10. The drilling system of claim 1, wherein the drill head comprises a laser distributor swivel.
11. The drilling system of claim 1, wherein the drill head body is displaced about fifteen degrees relative to the longitudinal axis of the drill head body.
12. The drilling system of claim 1, wherein the first hole of the housing is positioned on an upstream face of the housing.
13. A drilling system comprising: a drill string; a drilling fluid for drilling into a geological formation, wherein the drilling fluid flows through the drill string; a drill head interconnected to the drill string, the drill head having at least four operating modes, wherein a first operating mode of the at least four operating modes is selected from a group consisting of a straight drilling mode, a radius bore drilling mode, a side panel cutting mode, a propulsion mode, and a non-operational mode, and wherein the drill head comprises a valve assembly comprising: a housing comprising: a bore; a first end; a first hole; a second hole; a third hole; a fourth hole; a first body groove interconnected to the first hole, wherein the first body groove corresponds to the first operating mode; a second body groove interconnected to the second hole, wherein the second body groove corresponds to a second operating mode of the at least four operating modes; a third body groove interconnected to the third hole, wherein the third body groove corresponds to a third operating mode of the at least four operating modes; and a fourth body groove interconnected to the fourth hole, wherein the fourth body groove corresponds to a fourth operating mode of the at least four operating modes; and a spool having an axial bore, a first end, and a second end, wherein the spool is moveable between a first position and a second position, wherein the first end of the spool receives the drilling fluid, and wherein the first position corresponds to a first pressure of the drilling fluid and the second position corresponds to a second pressure of the drilling fluid; wherein the first operating mode corresponds to the first pressure of the drilling fluid, the second operating mode corresponds to the second pressure of the drilling fluid, the third operating mode corresponds to a third pressure of the drilling fluid, and the fourth operating mode corresponds to a fourth pressure of the drilling fluid; wherein the first pressure of the drilling fluid is between about 40 kpsi and about 50 kpsi, the second pressure of the drilling fluid is between about 30 kpsi and about 40 kpsi, the third pressure of the drilling fluid is between about 20 kpsi and about 30 kpsi, and the fourth pressure of the drilling fluid is less than about 20 kpsi; a drill head body having a leading surface and a circumferential surface; and a swivel head interconnected to the leading surface of the drill head body, wherein the swivel head is angularly articulable relative to a longitudinal axis of the drill head body, and wherein the swivel head comprises: a first fluid jet cutter; a second fluid jet cutter; a first laser cutter; and a second laser cutter.
14. The drilling system of claim 13, further comprising a side panel cutting head positioned on the circumferential surface of the drill head body.
15. The drilling system of claim 13, wherein the first hole of the housing is positioned on a downstream surface of the housing.
16. The drilling system of claim 13, wherein the first hole of the housing is positioned on a lateral surface of the housing.
17. A drilling system comprising: a drill string; a drilling fluid for drilling into a geological formation, wherein the drilling fluid flows through the drill string; a drill head interconnected to the drill string, the drill head having at least four operating modes, wherein a first operating mode of the at least four operating modes is selected from a group consisting of a straight drilling mode, a radius bore drilling mode, a side panel cutting mode, a propulsion mode, and a non-operational mode, and wherein the drill head comprises a valve assembly comprising: a housing comprising: a bore; a first end; a first hole; a second hole; a first body groove interconnected to the first hole, wherein the first body groove corresponds to the first operating mode; and a second body groove interconnected to the second hole, wherein the second body groove corresponds to a second operating mode of the at least four operating modes; a spool having an axial bore, a first end, and a second end, wherein the spool is moveable between a first position and a second position, wherein the first end of the spool receives the drilling fluid, and wherein the first position corresponds to a first pressure of the drilling fluid and the second position corresponds to a second pressure of the drilling fluid, wherein the first operating mode corresponds to the first pressure of the drilling fluid and the second operating mode corresponds to the second pressure of the drilling fluid; and a detent assembly for locking the spool in the first position and in the second position, wherein the detent comprises a spring biased against a locking pin, wherein the locking pin is biased against a first notch of the spool when the spool is in the first position and the locking pin is biased against a second notch of the spool when the spool is in the second position, and wherein the locking pin of the detent assembly is selected from a group consisting of a ball, a pin, a sphere, a wheel, and a block; a drill head body having a leading surface and a circumferential surface; and a swivel head interconnected to the leading surface of the drill head body, wherein the swivel head is angularly articulable relative to a longitudinal axis of the drill head body, and wherein the swivel head comprises: a first fluid jet cutter; a second fluid jet cutter; a first laser cutter; and a second laser cutter.
18. The drilling system of claim 17, further comprising a side panel cutting head positioned on the circumferential surface of the drill head body.
19. The drilling system of claim 17, wherein the drill head comprises a laser distributor swivel.
20. The drilling system of claim 17, wherein the drill head body is displaced about fifteen degrees relative to the longitudinal axis of the drill head body.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Those of skill in the art will recognize that the following description is merely illustrative of the principles of the invention, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this invention and is not meant to limit the inventive concepts disclosed herein.
(2) The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of the invention.
(3) FIG. 1 is an embodiment of a control device for remotely changing between operating modes of a water jet drilling system.
(4) FIG. 2 is a cross-sectional view of an embodiment of a drill head assembly and a following link in a straight drilling mode.
(5) FIG. 3 is a cross-sectional view of an embodiment of a drill head assembly and a following link in a radius bore drilling mode.
(6) FIG. 4 is a front elevation view of an embodiment of a mode valve with exit ports.
(7) FIG. 5 is a partially sectioned top view of an embodiment of a drill head assembly with side panel cutting jets.
(8) FIG. 6 is a side view of an embodiment of a multi-function drill head with a device for cutting straight bores, radius bores, and side panels.
(9) FIG. 7 illustrates an embodiment of an ultra-short radius bore drilling system.
(10) FIG. 8 is a perspective view of an embodiment of a borehole with panels.
(11) FIG. 9A is a perspective view of an embodiment of an oil and gas reservoir with multiple boreholes and panels.
(12) FIG. 9B is front sectional view of an embodiment of a borehole with panels.
(13) FIG. 10 is a side view of an oil and gas reservoir with an embodiment of side panels extending from a borehole.
(14) FIG. 11A is a side view of an embodiment of a multi-function drill head with water jets and lasers.
(15) FIG. 11B is a side view of an embodiment of a multi-function drill head with water jets and lasers.
(16) FIG. 12 is a front elevation view of an embodiment of water jets and lasers on a drill.
(17) FIG. 13 is a side sectional view of water jets and lasers on a drill of an embodiment of the present invention.
(18) FIG. 14 is a front elevation view of an embodiment of water jets and lasers on a drill.
(19) FIG. 15 is a side sectional view of water jets and lasers on a drill of an embodiment of the present invention.
(20) FIG. 16 is a front elevation view of an embodiment of water jets and lasers on a drill.
(21) FIG. 17 is a side sectional view of water jets and lasers on a drill of an embodiment of the present invention.
(22) FIG. 18 is a front elevation view of an embodiment of water jets and lasers on a drill.
(23) FIG. 19 is a front elevation view of an embodiment of water jets and lasers on a drill.
(24) FIG. 20 is a front elevation view of an embodiment of water jets, lasers, and combination water jet/mechanical tool cutters on a drill.
(25) FIG. 21 is a front elevation view of an embodiment of water jets, lasers, and combination water jet/mechanical tool cutters on a drill.
(26) FIG. 22 is a front elevation view of an embodiment of a water jet and/or laser multi-function drill head having two concentric, rotatable, circular arrangements.
(27) FIG. 23 shows one application of an embodiment of a drilling system of the present invention.
(28) FIGS. 24A, 24B, 24C, and 24D are cross-sectional views of an embodiment of a valve placed different operating modes.
(29) FIG. 25 is a cross-sectional view of an embodiment of a drill head in a straight drilling mode.
(30) FIG. 26 is a cross-sectional view of an embodiment of a drill head in a radius bore drilling mode.
(31) FIG. 27 is a front elevation view of an embodiment of water jets and lasers on a drill.
(32) FIG. 28 is a side sectional view of water jets and lasers on a drill of an embodiment of the present invention.
(33) FIG. 29 is a front elevation view of an embodiment of water jets, lasers, and combination water jet/mechanical tool cutters on a drill.
(34) FIG. 30 is a front elevation view of an embodiment of a water jet and/or laser multi-function drill head having two concentric, rotatable, circular arrangements.
(35) FIG. 31 is a side sectional view of water jets and lasers on a drill of an embodiment of the present invention.
(36) FIG. 32A is a cross-sectional view of one embodiment of impinged laser beams.
(37) FIG. 32B is a top plan view of one embodiment of impinged laser beams.
(38) FIG. 32C is a top plan view of another embodiment of impinged laser beams.
(39) FIG. 33 is a cross-sectional view of another embodiment of impinged laser beams.
(40) FIG. 34 is a cross-sectional view of one embodiment of impinged laser beams and impinged water jets.
(41) FIG. 35 is a cross-sectional view of one embodiment of impinged laser beams and impinged water jets.
(42) FIG. 36 shows one embodiment of an underground system of panels and holes cut in different shapes and orientations.
(43) FIG. 37 depicts another embodiment of an underground system of panels and holes.
(44) FIGS. 38A-C show one embodiment of butterfly configuration panels.
(45) FIG. 39 shows a cavity cut into tar sands at a time early in the extraction process.
(46) FIG. 40 shows the cavity of FIG. 39 at a later time in the extraction process.
(47) FIGS. 41A-C show one embodiment of a cutter head or drill head.
(48) It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
(49) Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims as set forth at the end of this disclosure. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.
(50) The invention described herein relates to a novel system, device, and methods for drilling straight bores, short radius bores, and panels, with a device for remotely switching between various operating modes by variations in fluid pressure. The novel drilling system provided herein allows the drilling system to change from one operating mode, e.g. a drilling mode, to another operating mode, e.g. a panel cutting mode, without requiring the withdrawal of the drill string from the vertical wellbore. This invention utilizes water jet and/or laser drilling and panel cutting heads to cut narrow openings, e.g. panels, pancakes, and spirals, into the reservoir to permit oil and gas to flow into the drill hole. The drilling part of the water jet and/or laser drill tool is designed to create boreholes projecting out horizontally from a vertical well. The cutting part of the drill tool is also capable of cutting panels extending laterally from the drill hole by utilizing a second set of mounted water jets and/or lasers cutting outward from the produced horizontal hole. These panels increase the area of the reservoir exposed to the borehole and thereby significant enhance stimulated reservoir volume.
(51) FIG. 1 is an embodiment of a control device for remotely changing between operating modes of a water jet drilling system. The water jet drilling system may comprise a high-pressure hose 1 that leads from aboveground and is connected to a valve assembly 2. In some embodiments, the valve assembly 2 may incorporate a spool 3 that travels to different axial positions within a housing 4 based on the magnitude of the water pressure supplied. The spool 3 may be spring-loaded in some embodiments and may also be cylindrical in one embodiment.
(52) In one embodiment, the water jet drilling system may comprise a spring-loaded detent assembly 5 to maintain the desired spool position and thus a desired mode when small variations of pressure occur. The detent assembly 5 locks the spool 3 in position for each mode of operation as long as the pressure for each mode is within a pressure tolerance compatible with a spool retaining force caused by the detent assembly 5.
(53) The spool 3 may be positioned within a housing bore 6 that allows the spool 3 to move axially against a spring 7 positioned between the spool 3 and the housing 4. The spool 3 may have a center bore 8 that terminates at a radial groove 9. The radial groove 9 may be aligned with internal grooves 10, 11 in the housing 4. In some embodiments, the spool 3 may be positioned proximate to the internal grooves 10, 11 when biased against the spring 7 due to the different fluid pressures for the different modes of operation. The spool 3 may comprise notches 12, 13 that correspond axially with locations of the internal grooves 10, 11. The internal grooves 10, 11 may be in fluid communication with fluid passages. Different fluid passages may be used for each different mode of operation. Thus, the fluid passages may allow the pressurized fluid to pass through one or more sets of water jets when operating under different modes of operation. In some embodiments, a notch 12, 13, 14 may be provided to retain the spool 3 axially when there is little or no water pressure.
(54) The housing 4 may be mounted within a secondary housing 15. The secondary housing may be axially fixed in position by a preloaded spring cartridge 16. In some embodiments, the cartridge 16 remains a fixed length until the preload is exceeded. The system may comprise a threaded ring 17 to allow for the adjustment of the cartridge 16 so that the cartridge 16 will remain at a fixed length until a certain fluid pressure is reached. When the fluid pressure exerts a force on the housing 4 exceeding the adjusted preload of the cartridge 16, the housing 4 advances within the secondary housing 15 causing the angular articulation of a drilling head. The movement of the housing 4, which may be movement in an axial direction in some embodiments, and a protruding member 18 cause a bore to be cut at a specific radius. For example, a curved bore may be cut linking a vertical bore to a horizontal bore to which the vertical bore was not previously interconnected. Thus, the linking allows for the joining together of discrete vertical wellbores into a single contiguous system of bores.
(55) In some embodiments, fluid outlets 19, 20 may be provided in the valve assembly 2 for the two modes depicted in FIG. 1. One fluid outlet 19 may be for a highest-pressure mode. In the example shown in FIG. 1, fluid outlet 19 is configured to allow for straight drilling when the radial groove 9 of the spool 3 is aligned with both the internal groove 10 and an internal groove 21. Another fluid outlet 20 may be for a lower fluid pressure mode. In the example shown in FIG. 1, fluid outlet 20 is configured to allow for a panel cutting mode.
(56) Referring now to FIG. 2, a cross-sectional view of an embodiment of a drill head assembly and a following link in a straight drilling mode is provided. The drill head assembly may comprise a high-pressure hose 1, a valve assembly 2, a following link 23, a hinge pin 24, an exit port 25, a water jet assembly 26, a tube 27, a swivel head 28, a swivel fitting 29, a hollow shaft 30, an actuating rod 31, a link 32, a pin 33, a spherical surface 34, and a spherical clamp 35. The valve assembly 2 may be positioned within the drill head housing 22. The drill head housing may be interconnected to the following link 23. The following link 23 may be hinged to the drill head housing 22 and secured by a hinge pin 24. Additional following links 23 may be utilized, necessitated by the condition of the strata to be encountered.
(57) In some embodiments, pressurized fluid is supplied through a high-pressure hose 1 from an aboveground pump system to the valve assembly 2. The fluid pressure may be controlled and changed to the specific pressures needed to operate the drilling system in the desired mode. An exit port 25 supplies pressurized fluid to a water jet assembly 26 via a tube 27. The water jet assembly 26 may comprise a swivel head 28 on one end. The swivel head 28 may be interconnected to the tube 27 by a swivel fitting 29, which is fitted to a hollow shaft 30 with ports. The shaft 30 may be mounted stationarily relative to the swivel head 28 to allow the swivel head 28 to be rotated for a radius bore mode.
(58) The water jet assembly 26 contains fluid jet orifices and a rotary swivel to facilitate fluid jet cutting. An actuating rod 31 extends axially from the valve assembly 2 and is joined by a link 32 to a pin 33 in the swivel head 28, providing slight articulation of the link 32 to the actuating rod 31 due to the arc effect when the swivel head 28 is rotated to the angular position for cutting a radius bore.
(59) The swivel head 28 has a spherical interface with a spherical surface 34 at the front of the drill head housing 22. A spherical clamp 35 retains the swivel head 28 in position at the front of the drill head housing 22. The configuration shown in FIG. 2 may be used to produce straight radial bores outward from a vertical shaft, among other straight drilling applications.
(60) Referring now to FIG. 3, the swivel head 28 is rotated to the radius bore drilling mode position by increasing the fluid pressure to the valve assembly 2 to the highest operating level. The valve actuating rod 31 is in an extended position due to the fluid pressure on the spool 3 exceeding the preload value of the preloaded spring cartridge 16, causing the swivel head 28 to rotate to the angle shown to produce the required bore radius.
(61) The following link 23 is articulated about the hinge pin 24, closing the clearance angle between the drill head housing 22 and the following link 23 to clear a newly cut radius bore 36. The configuration shown in FIG. 3 may be used to produce curved radius bores.
(62) Referring now to FIGS. 4 and 5, the valve assembly 2 includes water jet exit ports 37, 38 positioned adjacently to the exit port 25. When fluid pressure is controlled to the pressure values needed to keep the drilling system operating in a panel cutting mode, the valve assembly redirects fluid away from the exit port 25 into the water jet exit ports 37, 38. Side panel cutting water jets 39, 40 are connected by connecting fluid pipes 41, 42 to the water jet exit ports 37, 38. When the drilling system is placed in the panel cutting mode, fluid directed toward the water jet exit ports 37, 38 by the valve assembly 2 flows through the connecting fluid pipes 41, 42 and outwardly from side panel cutting water jets 39, 40 into the surrounding reservoir. The side panel cutting water jets 39, 40 may be used to cut, by way of example only, panels, pancakes, and/or spirals into the reservoir, depending on the movement and rotation of the drill head housing 22 during cutting.
(63) Referring now to FIG. 6, fluid may be seen flowing out of the water jet cutters 43 of the swivel head 28. The swivel head 28 may be either oriented for straight drilling, or rotated for radius bore drilling. A side panel cutting water jet 39 may also be seen.
(64) Referring now to FIG. 7, the high-pressure hose 1 is protected by one or more linked jackets 44, a casing 72, and an outer well casing 70. The casing 72 also protects the radius cut from encroachment or wear. Different numbers of jackets 44 (one or more) and different jacket lengths may be used depending on the application and/or the condition of the strata to be encountered. The linked jackets 44 may rotate, tilt, or move with respect to one another. Thus, the linked jackets 44 may be angularly articulable with respect to one other to allow for radius bore drilling. The linked jackets 44 surround the high-pressure hose 1 when the hose 1 is underground to protect the hose from rocks, mud, water, oil, gas, and other natural or unnatural elements. Thus, only the drill head housing 22 is exposed to the natural or unnatural elements found underground.
(65) Referring now to FIG. 8, a horizontally extending borehole 45 has been cut into an oil and gas reservoir 46 with the present invention. Extending from the borehole are multiple panels 47 to enhance the effective permeability of the oil and gas reservoir 46.
(66) FIG. 9A shows a perspective view of an oil and gas reservoir 46 with boreholes 45 and panels 47. In this embodiment, multiple horizontally extending boreholes 45 have been cut into the oil and gas reservoir 46 using one embodiment of the drill system of the present invention. The boreholes extend horizontally from vertical wellbores 48. Extending from each horizontally extending borehole 45 are multiple panels 47 to enhance the effective permeability of the oil and gas reservoir 46. The figure shows how effective permeability may be enhanced at multiple locations and along multiple spatial dimensions throughout the oil and gas reservoir 46. FIG. 9B shows a side view of a borehole 45 with multiple panels 47.
(67) Referring now to FIG. 10, multiple panels 47 cut into the oil and gas reservoir 46 may be seen extending from the single horizontally extending borehole 45. In this example the panels 47 are separated by pillars 48 of undisturbed rock forming part of the oil and gas reservoir 46. The panels 47 have been cut by the drilling system of the present invention, embodied here by the drill head housing 22 and the high-pressure hose 1 protected by the linked jackets 44. In this image the system is being used to cut two additional panels 47, using side panel cutting water jets 39, 40.
(68) Referring now to FIG. 11A, fluid may be seen flowing out of the water jet cutters 43 of the swivel head 28. The swivel head 28 may be either oriented for straight drilling, or rotated about fifteen degrees for radius bore drilling. A side panel cutting water jet 39 may also be seen. In this embodiment, an incoming laser beam 49 is distributed, by a laser distributor swivel 50 inside the drill head housing 22, to laser cutters 51 located on the swivel head 28 and/or to a side panel cutting laser 52. Because the laser cutters 51 are located on the swivel head 28, they may be used for either straight drilling or radius bore drilling, depending on the orientation of the swivel head 28, in the same way as the water jet cutters 43.
(69) Referring now to FIG. 11B, fluid may be seen flowing out of the water jet cutters 43 of the swivel head 28. The swivel head 28 may be either oriented for straight drilling, or rotated about fifteen degrees for radius bore drilling. A side panel cutting water jet 39 may also be seen. In this embodiment, an incoming laser beam 49 is distributed, by a laser distributor swivel 50 inside the drill head housing 22, to laser cutters 51 located on the swivel head 28 and/or to a side panel cutting laser 52. Because the laser cutters 51 are located on the swivel head 28, they may be used for either straight drilling or radius bore drilling, depending on the orientation of the swivel head 28, in the same way as the water jet cutters 43.
(70) Referring now to FIGS. 12 and 13, one possible arrangement of cutting implements on the swivel head is shown. In particular, this embodiment comprises a single laser cutter 51 and two water jet cutters 43. A central portion 53 of the bore is excavated by spalling, while a peripheral portion 54 of the bore is excavated by cracking.
(71) Referring now to FIGS. 14 and 15, one possible arrangement of cutting implements on the swivel head 28 is shown. In particular, this embodiment comprises an inner circular arrangement 55 of two laser cutters 51 and two water jet cutters 43, and an outer circular arrangement 56 of six water jet cutters 43 and six laser cutters 51, arranged alternatingly. A central portion 53 of the bore is excavated by spalling, while a peripheral portion 54 of the bore is excavated by cracking.
(72) Referring now to FIGS. 16 and 17, one possible arrangement of cutting implements on the swivel head 28 is shown. In particular, this embodiment comprises an inner circular arrangement 55 of four laser cutters 51 and an outer circular arrangement 56 of eight laser cutters 51, surrounded by a single large water jet cutter 43. A central portion 53 of the bore is excavated by spalling, while a peripheral portion 54 of the bore is excavated by cracking.
(73) Referring now to FIG. 18, one possible arrangement of cutting implements on the swivel head 28 is shown. In particular, this embodiment comprises an inner circular arrangement 55 of four laser cutters 51, a middle circular arrangement 57 of eight water jet cutters 43, and an outer circular arrangement 56 of six water jet cutters 43 and six laser cutters 51, arranged alternatingly. This embodiment may be used, for example, to excavate small drill holes.
(74) Referring now to FIG. 19, one possible arrangement of cutting implements on the swivel head 28 is shown. In particular, this embodiment comprises an inner circular arrangement 55 of four laser cutters 51, a middle circular arrangement 57 of eight water jet cutters 43, and an outer circular arrangement 56 of twelve laser cutters 51. This embodiment may be used, for example, to excavate small drill holes.
(75) Referring now to FIG. 20, one possible arrangement of cutting implements on the swivel head 28 is shown. In particular, this embodiment comprises an innermost circular arrangement 58 of four laser cutters 51, an inner circular arrangement 55 of four water jet cutters 43, an outer circular arrangement 56 of eight combination water jet/mechanical tool cutters 59, and an outermost circular arrangement 60 of six water jet cutters 43 and six laser cutters 51, arranged alternatingly. This embodiment may be used, for example, to excavate an all-geological or alternating geological formation.
(76) Referring now to FIG. 21, one possible arrangement of cutting implements on the swivel head 28 is shown. In particular, this embodiment comprises an innermost circular arrangement 58 of four laser cutters 51, an inner circular arrangement 55 of eight water jet cutters 43, a middle circular arrangement 57 of eight combination water jet/mechanical tool cutters 59, an outer circular arrangement 56 of eight combination water jet/mechanical tool cutters 59, and an outermost circular arrangement 60 of eight laser cutters 51 and eight water jet cutters 43, arranged alternatingly. This embodiment may be used, for example, to excavate a large opening, or for tunnel and rise drilling.
(77) Referring now to FIG. 22, an embodiment of the swivel head 28 is shown. In particular, this embodiment comprises an inner circular arrangement 55 of two laser cutters 51 and two water jet cutters 43 arranged alternatingly, and an outer circular arrangement 56 of six water jet cutters 43 and six laser cutters 51, arranged alternatingly. The inner circular arrangement 55 and the outer circular arrangement 56 are each independently rotatable. In this case, the inner circular arrangement 55 rotates counterclockwise, and the outer circular arrangement 56 rotates clockwise.
(78) Referring now to FIG. 23, a land surface 61 and strata 62 underlying the land surface 61 are shown. The drilling system of the present invention is used to cut a T-shaped structural space 63 into the strata 62. The T-shaped structural space 63 may, for example, receive concrete, thus forming part of the foundation of a building.
(79) Referring now to FIGS. 24A through 24D, FIG. 24A shows the valve assembly 2 in a very high-pressure mode. The spool 3 compresses the spring 7 to the maximum extent. This position may correspond to, among others, a radius bore drilling mode or a straight drilling mode. FIG. 24B shows the valve assembly 2 in a high-pressure mode. The spool 3 compresses the spring 7 to a substantial extent. This position may correspond to, among others, a straight drilling mode or a side panel cutting mode. FIG. 24C shows the valve assembly 2 in a low-pressure mode. The spool 3 compresses the spring 7 to a slight extent. This position may correspond to, among others, a side panel cutting mode or a propulsion mode. FIG. 24D shows the valve assembly 2 in a very low-pressure mode. The spool 3 compresses the spring 7 to a minimal extent, or not at all. This position may correspond to, among others, an off mode.
(80) Referring now to FIGS. 25 and 26, FIG. 25 shows the drill head when the system is placed in a straight drilling mode. The swivel head 28 is oriented in the same direction as the longitudinal axis of the drill head housing 22. FIG. 26 shows the drill head when the system is placed in a radius bore drilling mode. The swivel head 28 is oriented at an angle relative to the longitudinal axis of the drill head housing 22.
(81) FIGS. 27 and 28 show one embodiment of cutting implements on the swivel 28. In particular, this embodiment of the swivel head 28 comprises a single laser cutter 51 and two water jet cutters 43. A central portion 53 of the bore is excavated by spalling and weakening (using the laser) and deformation and pulverization (using the water jets), while a peripheral portion 54 of the bore is excavated by cracking and removal.
(82) Referring now to FIG. 29, one embodiment of cutting implements on the swivel head 28 is shown. In particular, this embodiment of the swivel head 28 comprises an innermost circular arrangement 58 of four laser cutters 51 and four water jet cutters 43, arranged in four pairs of a water jet cutter 43 and a laser cutter 51, spaced at about 90-degree intervals; an inner circular arrangement 55 of eight combination water jet/mechanical tool cutters 59; an outer circular arrangement 56 of eight combination water jet/mechanical tool cutters 59, and an outermost circular arrangement 60 of eight laser cutters 51. This embodiment may be used, for example, to excavate a large opening, or for tunnel and rise drilling.
(83) Referring now to FIGS. 30 and 31, an embodiment of the swivel head 28 is shown. In particular, this embodiment comprises an inner circular arrangement 55 of two laser cutters 51 and two water jet cutters 43 arranged in an alternating pattern, and an outer circular arrangement 56 of six water jet cutters 43 and six laser cutters 51, arranged in an alternating pattern. The inner circular arrangement 55 and the outer circular arrangement 56 are each independently rotatable. In this case, the inner circular arrangement 55 rotates counterclockwise, and the outer circular arrangement 56 rotates clockwise. A central portion 53 of the bore is excavated by spalling, while a peripheral portion 54 of the bore is excavated by cracking.
(84) FIG. 32A is a cross-sectional view of one embodiment of impinged laser beams positioned on their target material 116. The target material 116 has an upper boundary 106 on an upper end and a lower boundary 158 on a lower end. In some embodiments, all six laser beams 100, 102, 120, 122, 140, 142 may be turned on and pointed at the target material 116 at the same time such that two laser beams 100, 102 intersect at a first impingement point 104, two laser beams 120, 122 intersect at a second impingement point 124, and two laser beams 140, 142 intersect at a third impingement point 144. In other embodiments, at time t1 a first laser is positioned toward the target material 116 such that its laser beam 100 is at a first angle Q1 relative to the laser beam 102 of a second laser. The angle Q1 is between about 10 degrees and about 90 degrees. The first and second laser beams 100, 102 intersect at a first impingement point 104 on the target material's upper boundary 106. The angle Q1 of the laser beams is dependent upon where the user wants the two beams to intersect. This intersection point (also called an impingement point herein) may be at the upper boundary 106 of the target material 116, or well into the target material 106. In the embodiment shown, the first laser beam 100 and the second laser beam 102 are positioned at substantially the same angle A1 relative to a vertical centerline CL.sub.V, where A1=Q1/2. However, in other embodiments, one laser beam 100, 102 may be at an angle greater than A1 while the other laser beam 100, 102 is at an angle less than A1 such that the sum of the two angles equals Q1. After or below the first impingement point 104, residual portions 110, 112, 114 of the laser beams 100, 102 continue into the target material 116. The residual portion 110 extending downwardly along the vertical axis may be a combined beam 110 that has enhanced strength compared to the first laser beam 100 and the second laser beam 102 alone.
(85) At time t2 the first laser is positioned toward the target material 116 such that its laser beam 120 is at a second angle Q2 relative to the laser beam 122 of the second laser. The angle Q2 is between about 10 degrees and about 90 degrees. The first and second laser beams 120, 122 intersect at a second impingement point 124 below the target material's upper boundary 106. The first laser beam 120 crosses the upper boundary 106 of the target material 116 at a point 132 and the second laser beam 122 crosses the upper boundary 106 of the target material 116 at a point 134. In the embodiment shown, the first laser beam 120 and the second laser beam 122 are positioned at substantially the same angle A2 relative to a vertical centerline CL.sub.V, where A2=Q2/2. However, in other embodiments, one laser beam 120, 122 may be at an angle greater than A2 while the other laser beam 120, 122 is at an angle less than A2 such that the sum of the two angles equals Q2. After or below the impingement point 124, residual portions 126, 128, 130 of the laser beams 120, 122 continue into the target material 116. The residual portion 126 extending downwardly along the vertical axis may be a combined beam 126 that has enhanced strength compared to the first laser beam 120 and the second laser beam 122 alone.
(86) At time t3 the first laser is positioned toward the target material 116 such that its laser beam 140 is at a third angle Q3 relative to the laser beam 142 of the second laser. The angle Q3 is between about 10 degrees and about 90 degrees. The first and second laser beams 140, 142 intersect at a third impingement point 144 below the second impingement point 124. The first laser beam 140 crosses the upper boundary 106 of the target material 116 at a point 152 and the second laser beam 142 crosses the upper boundary 106 of the target material 116 at a point 154. In the embodiment shown, the first laser beam 140 and the second laser beam 142 are positioned at substantially the same angle A3 relative to a vertical centerline CL.sub.V, where A3=Q3/2. However, in other embodiments, one laser beam 140, 142 may be at an angle greater than A3 while the other laser beam 140, 142 is at an angle less than A3 such that the sum of the two angles equals Q3. After or below the impingement point 144, residual portions 146, 148, 150 of the laser beams 140, 142 continue into the target material 116. The residual portion 146 extending downwardly along the vertical axis may be a combined beam 146 that has enhanced strength compared to the first laser beam 140 and the second laser beam 142 alone. The portion of the target material that is being hit by the laser beams 100, 102, 120, 122, 140, 142 is called the weakened zone 108. The lower boundary 156 of the weakened zone 108 is shown by the line 156.
(87) The drill head according to embodiments of the present invention includes at least one laser, and preferably two or more lasers. The advantages of the impinged laser beams include that the cutting power of the lasers at the impingement points is greater than at locations other than the impingement points. Additionally, the impinged laser beams save energy and are a more efficient use of the lasers. Additionally, the angles of the laser beams 100, 102, 120, 122, 140, 142 can be adjusted to move the impingement point 104, 124, 144 up and down and left to right, which allows the user to cut or alter target material 116 in different locations. The target material 116 can be cut in any sequence, meaning top to bottom (i.e., impingement point 104 first, then impingement point 124, then impingement point 144) or bottom to top (i.e., impingement point 144 first, then impingement point 124, then impingement point 104). Alternatively, the target material 116 can be cut horizontally, where the second impingement point would be to the left or right of the first impingement point and at the same depth as the first impingement point. Additionally, any combination of the above order or any other cutting order can be used depending on the geological formation of the target material 116.
(88) FIG. 32B is a top plan view of one embodiment of impinged laser beams positioned on their target material and the dots shown are in the plane of the upper boundary (106 in FIG. 32A) of the target material (116 in FIG. 32A). In one embodiment, four laser beams 160, 162, 164, 166 are used to cut or alter the target material and are positioned at different angles at different times. Additionally, any number of laser beams 160, 162, 164, 166 (i.e., one laser beam to four laser beams) may be pointed at the target material at any given time. For example, at time t1, one laser beam 160 may be pointed at the target point 104. Alternatively, at time t1 two laser beams 160, 164 may be pointed at the target point 104 and thus create an impingement point 104. Alternatively, at time t1 the other two laser beams 162, 166 may be pointed at the target point 104 and thus create an impingement point 104. Alternatively, at time t1 all four laser beams 160, 162, 164, 166 may be pointed at the target point 104 and thus create an impingement point 104. Still further, any combination of two or three laser beams 160, 162, 164, 166 may be pointed at the impingement point 104 at time t1 in some embodiments.
(89) At time t2, any combination of one to four laser beams 160, 162, 164, 166 may be pointed at a target/impingement point (not shown in FIG. 32B, point 124 in FIG. 32A) positioned directly below target/impingement point 104 such that the first laser beam 160 crosses the upper boundary of the target material at point 172, the second laser beam 162 crosses the upper boundary of the target material at point 134, the third laser beam 164 crosses the upper boundary of the target material at point 174, and the fourth laser beam 166 crosses the upper boundary of the target material at point 132. Accordingly, the portion of the first laser beam 160 shown between points 172 and 104 is in the target material (i.e., below the upper boundary of the target material) and is angled downward at the target/impingement point (point 124 in FIG. 32A); the portion of the second laser beam 162 shown between points 134 and 104 is in the target material (i.e., below the upper boundary of the target material) and is angled downward at the target/impingement point (point 124 in FIG. 32A); the portion of the third laser beam 164 shown between points 174 and 104 is in the target material (i.e., below the upper boundary of the target material) and is angled downward at the target/impingement point (point 124 in FIG. 32A); and the portion of the fourth laser beam 166 shown between points 132 and 104 is in the target material (i.e., below the upper boundary of the target material) and is angled downward at the target/impingement point (point 124 in FIG. 32A).
(90) At time t3, any combination of one to four laser beams 160, 162, 164, 166 may be pointed at a target/impingement point (not shown in FIG. 32B, point 144 in FIG. 32A) positioned directly below target/impingement point 104 such that the first laser beam 160 crosses the upper boundary of the target material at point 168, the second laser beam 162 crosses the upper boundary of the target material at point 154, the third laser beam 164 crosses the upper boundary of the target material at point 170, and the fourth laser beam 166 crosses the upper boundary of the target material at point 152. Accordingly, the portion of the first laser beam 160 shown between points 168 and 104 is in the target material (i.e., below the upper boundary of the target material) and is angled downward at the target/impingement point (point 144 in FIG. 32A); the portion of the second laser beam 162 shown between points 154 and 104 is in the target material (i.e., below the upper boundary of the target material) and is angled downward at the target/impingement point (point 144 in FIG. 32A); the portion of the third laser beam 164 shown between points 170 and 104 is in the target material (i.e., below the upper boundary of the target material) and is angled downward at the target/impingement point (point 144 in FIG. 32A); and the portion of the fourth laser beam 166 shown between points 152 and 104 is in the target material (i.e., below the upper boundary of the target material) and is angled downward at the target/impingement point (point 144 in FIG. 32A).
(91) In an alternative embodiment, ten lasers may be used such that the first and second laser beams intersect at impingement point 104; the third, fourth, fifth, and sixth laser beams are pointed at a target/impingement point (not shown in FIG. 32B, point 124 in FIG. 32A) positioned directly below impingement point 104 such that the third laser beam crosses the upper boundary of the target material at point 172, the fourth laser beam crosses the upper boundary of the target material at point 134, the fifth laser beam crosses the upper boundary of the target material at point 174, and the sixth laser beam crosses the upper boundary of the target material at point 132; and the seventh, eighth, ninth, and tenth laser beams are pointed at a target/impingement point (not shown in FIG. 32B, point 144 in FIG. 32A) positioned directly below impingement point 104 such that the seventh laser beam crosses the upper boundary of the target material at point 168, the eighth laser beam crosses the upper boundary of the target material at point 154, the ninth laser beam crosses the upper boundary of the target material at point 170, and the tenth laser beam crosses the upper boundary of the target material at point 152. In additional embodiments, one or more additional lasers may also be pointed at impingement point 104.
(92) In various embodiments, more than four lasers can be used. For example, eight lasers can be used, as shown in FIG. 32C, which is a top plan view of an embodiment of impinged laser beams positioned on their target material. The dots shown are in the plane of the upper boundary (106 in FIG. 32A) of the target material (116 in FIG. 32A). FIG. 32C is similar to FIG. 32B except that four additional laser beams are used to cut or alter the target material. In one embodiment, eight laser beams 200, 202, 204, 208, 210, 212, 214 are used to cut or alter the target material and are positioned at different angles at different times.
(93) FIG. 33 is a cross-sectional view of another embodiment of impinged laser beams. Here, two laser beams 300, 302 are positioned at an angle Q relative to one another, where the angle Q is between about 10 degrees and about 90 degrees. The laser beams 300, 302 intersect at an impingement point 304 above the upper boundary 308 of the target material 310. After the impingement point 304, the laser beams 300, 302 form a combined beam 306 that is stronger and more powerful than each beam 300, 302 alone. The combined beam 306 cuts or alters the target material 310. Additionally, the user can move the combined beam 306 around (e.g., side-to-side and up-and-down) to cut or alter the target material 310 by remotely moving the individual beams 300, 302 and the impingement point 304. In an additional embodiment (not shown), the system also includes two laser jets positioned outside of the laser beams 300, 302 that intersect at an impingement point at or below the impingement point 304. Further, two additional laser beams may be positioned in the Y plane (i.e., perpendicular to laser beams 300, 302 and not shown in this cross-section) and intersect laser beams 300, 302 at impingement point 304.
(94) FIG. 34 is a cross-sectional view of one embodiment of impinged laser beams and impinged water jets. In this embodiment, the drill head includes two laser beams 300, 302 and two water jets 312, 314. The laser beams 300, 302 are positioned at an angle Q relative to one another, where the angle Q is between about 10 degrees and about 90 degrees. The laser beams 300, 302 intersect at an impingement point 304 around the upper boundary 308 of the target material 310. The impingement point 304 may be slightly above the upper boundary 308, at the upper boundary 308, or slightly below the upper boundary 308. After the impingement point 304, the laser beams 300, 302 form a combined beam that is stronger and more powerful than each beam 300, 302 alone. The combined beam cuts or alters the target material 310. The water jets 312, 314 are positioned outside of the laser beams 300, 302 because the angle between the water jets 312, 314 is larger than the angle Q. The first water jet 312 is positioned at an angle A1 relative to the vertical axis and the second water jet 314 is positioned at an angle A2 relative to the vertical axis. Thus, A1 plus A2 is greater than Q. The water jets 312, 314 intersect at an impingement point 316 just below the impingement point 304 of the laser beams 300, 302 to push the rock or other target material 310 cut by the combined laser out and away from cutting area. In one embodiment, the combined laser beam is shown by the line 326 because the liquid from the water jets is pushing the rock and target material 310 out. In some embodiments, a portion of the fluid of the water jets 312, 314 continues along its original path as shown by lines 318 and 320. In other embodiments, a portion of the fluid of the water jets 312, 314 combines to form a combined stream as shown by line 326. In still further embodiments, the line 326 is a combined laser beam and a combined fluid stream. The combined beam/stream 326 can cut or alter the target material 310 and push the cut material away from the cutting zone. The laser beams 300, 302 initiate weakening and fractures in the target material 310 and the water jets 312, 314 remove the weakened material. Additionally, the water jets 312, 314 enhance and compliment the laser beams 300, 302 by forming the combined beam/stream 326, which is a magnified bundle of energy. In some embodiments, the laser beams 300, 312 strike the target material 310 first and then shortly thereafter the water jets 312, 314 strike the target material 310 at or near the laser beam impingement point 304 such that the laser beams 300, 302 crack the target material 310 and the water jets 312, 314 shatter and remove the shattered target material 310. In alternative embodiments, the water jets 312, 314 strike the target material 310 first and then shortly thereafter the laser beams 300, 302 strike the target material 310 at or near the water jet impingement point 316. In some embodiments (not shown), the laser beams 300, 302 and water jets 312, 314 have the same impingement point. If the laser beams 300, 302 and water jets 312, 314 have the same impingement point, then typically one will strike first and the other will strike second such that the laser beams 300, 302 and water jets 312, 314 are not striking the exact same location at the same time. However, although unlikely, there may be situations where both the laser beams 300, 302 and water jets 312, 314 need to strike the same impingement point at the same time. Various inputs of the drill head can be adjusted depending on the drilling conditions, target material, and desired outcomes, for example: the laser energy level, the water jet pressure, the water jet flow volume, angle Q of the laser beams, the angles A1, A2 of the water jets, and the locations of the impingement points. In some embodiments, percussive jets are used in place of the water jets 312, 314. Further, two additional laser beams may be positioned in the Y plane (i.e., perpendicular to laser beams 300, 302 and not shown in this cross-section) and intersect laser beams 300, 302 at impingement point 304.
(95) FIG. 35 is a cross-sectional view of one embodiment of impinged laser beams and impinged water jets. FIG. 35 may be the system of FIG. 34, but shown at a later point in time, i.e., FIG. 34 is at time t1 and FIG. 35 is at time t2. In FIG. 35, the drill head includes at least two laser beams 300, 302 and at least two water jets 312, 314. The laser beams 300, 302 are positioned at an angle Q relative to one another, where the angle Q is between about 10 degrees and about 90 degrees. The laser beams 300, 302 intersect at an impingement point 304 below the upper boundary 308 of the target material 310. After the impingement point 304, the laser beams 300, 302 form a combined beam that is stronger and more powerful than each beam 300, 302 alone. The combined beam cuts or alters the target material 310. The water jets 312, 314 are positioned outside of the laser beams 300, 302 because the angle between the water jets 312, 314 is larger than the angle Q. The first water jet 312 is positioned at an angle A1 relative to the vertical axis and the second water jet 314 is positioned at an angle A2 relative to the vertical axis. Thus, A1 plus A2 is greater than Q. The water jets 312, 314 intersect at an impingement point 316 just below the impingement point 304 of the laser beams 300, 302 to push the rock or other target material 310 cut by the combined laser out and away from cutting area. In one embodiment, the combined laser beam is shown by the line 326 because the liquid from the water jets is pushing the rock and target material 310 out of the cutting zone and thus does not continue as a combined stream. In other embodiments, a portion of the fluid of the water jets 312, 314 combines to form a combined stream as shown by line 326. In still further embodiments, the line 326 is a combined laser beam and a combined fluid stream. The combined beam/stream 326 can cut or alter the target material 310 and push the cut material away from the cutting zone. In some embodiments, the laser beams 300, 312 strike the target material 310 first and then shortly thereafter the water jets 312, 314 strike the target material 310 at or near the laser beam impingement point 304 such that the laser beams 300, 302 crack the target material 310 and the water jets 312, 314 shatter and remove the shattered target material 310. In alternative embodiments, the water jets 312, 314 strike the target material 310 first and then shortly thereafter the laser beams 300, 302 strike the target material 310 at or near the water jet impingement point 316. In some embodiments (not shown), the laser beams 300, 302 and water jets 312, 314 have the same impingement point. If the laser beams 300, 302 and water jets 312, 314 have the same impingement point, then typically one will strike first and the other will strike second such that the laser beams 300, 302 and water jets 312, 314 are not striking the exact same location at the same time. However, although unlikely, there may be situations where both the laser beams 300, 302 and water jets 312, 314 need to strike the same impingement point at the same time. Further, two additional laser beams may be positioned in the Y plane (i.e., perpendicular to laser beams 300, 302 and not shown in this cross-section) and intersect laser beams 300, 302 at impingement point 304.
(96) FIG. 36 shows one embodiment of a system 350 of panels 360, 362 and holes 358, 364 cut in different shapes and orientations. The system 350 is below the surface 352 in the target material 354 while the drilling equipment 356 is above ground. A well bore or drill hole 358 extends downwardly from the surface 352 and extends in various directions depending on the location of the target resources or minerals (e.g., oil and gas). Additional arms or drill holes 364 extend outwardly from the main well bore 358. The system 350 includes multiple panels 360, 362 in all different directions, orientations, locations, shapes, and sizes. The panels 360, 362 may be traditional rectangular panels 360 or they may be round pancakes 362. The system 350 can include any number of panels 360, 362 in a combination of shapes and sizes.
(97) FIG. 37 depicts another embodiment of an underground system 350 of panels 370 and holes 358, 374 in the process of being cut. A well bore or drill hole 358 extends downwardly from the surface and can extend in various directions depending on the location of the target resources or minerals (e.g., oil and gas). Arms or additional drill holes 374 extend outwardly from the main well bore 358 and multiple panels 370 are cut on each arm 374. Each arm 374 with its multiple panels 370 extending therefrom form a panel group 382. Here, the completed panel groups 382 are positioned on one end of the system 350 and comprise completed panels 370 and completed arms 374. A panel group in progress 372 is shown between the completed panel groups 382 and the planned panel groups 380. Each planned panel group 380 includes a planned arm 378 and planned panels 376. The panels 370, 376 can be cut using lasers, water jets (including percussive water jets), and/or a combination of lasers and water jets.
(98) FIGS. 38A-C are one embodiment of butterfly configuration panels 390. The butterfly panels 390 can be cut using lasers, water jets (including percussive water jets), and/or a combination of lasers and water jets. The advantage of butterfly panels is that the user can cut a larger area with only one drill hole. In the past, multiple drill holes were needed to cut the same amount of area. Additionally, the paneling system described herein is between about 10 and 100 times more effective than traditional fracking methods at recovering underground oil and gas.
(99) FIG. 38A is a perspective view of the butterfly panels 390 positioned below the surface 352 and predominantly in the target material 354. A layer of material (often called the overburden) 355 is positioned between the target material 354 and the surface 352. The drilling equipment 356 is positioned above the surface 352 and a well bore or drill hole 358 extends downwardly from the drilling equipment 356 to the target material 354. The butterfly panels 390 are formed by cutting multiple rectangular panels 392 extending outwardly from the drill hole 358 in different radial directions. In some embodiments, the rectangular panels 392 are only cut above a predetermined horizontal angle. However, in other embodiments, the butterfly panels 390 can be cut on a vertical drill hole 358. Additionally, the rectangular panels 392 can be cut around the entire drill hole axis (i.e., around 360 degrees of the drill hole 358). In other embodiments, the panels 392 can be cut in different shapes, e.g., square, round, oval, etc.
(100) FIG. 38B is a perspective view of the butterfly panels 390, which are formed by cutting multiple panels 392 off of the drill hole 358 in different radial directions. FIG. 38C is a side view of the butterfly panel 390. The butterfly panel 390 includes multiple panels 392 extending radially from a horizontal portion of the drill hole 358. The panels 392 are positioned an angle B from one another and an angle C from the vertical portion of the drill hole 358. The angle B generally ranges from about 10 degrees to about 90 degrees. The angle C generally ranges from about 10 degrees to about 90 degrees. In the embodiment shown, the butterfly panel 390 includes four panels 392. However, any number of panels 392 can be used in different embodiments.
(101) FIGS. 39 and 40 are cross-sectional views of a well bore 404 and a cavity 406 cut into tar sands 412 at two times in the extraction process, where FIG. 39 is at time t1 and FIG. 40 is at time t2. At time t1 during the extraction process 400 an initial cavity 406 is cut just below the overburden 410 and at the top or upper portion of the tar sands 412. The tar sands 412 are sandwiched between the overburden 410 and a lower material 414, which is likely rock of some type. The well bore 404 extends from the surface to the initial cavity 406. The initial cavity 406 has a long/wide and flat shape. For example, the length L of half of the initial cavity 406 may be between about 50 feet and 200 feet. In a preferred embodiment, the initial cavity 406 has a length L from one end to the well bore 404 of between about 75 feet and 150 feet. In a more preferred embodiment, the length L is about 100 feet. The initial cavity 406 is substantially shorter (height-wise) than it is long (lengthwise), meaning that the initial cavity 406 is substantially longer than it is deep. Thus, the initial cavity 406 may have a traditional rectangular or circular panel shape when viewed from above. If the initial cavity 406 is circular, then length L is the radius of the initial cavity 406. Water 408 is pumped into the initial cavity 406. A heater 418 extends down into the initial cavity 406 through the well bore 404 and is positioned at the top of the initial cavity 406 and top of the water 408.
(102) As more warm water 408 and/or steam is pumped into the cavity 406, the water 408 mixes with the tar sands 412 and the cavity 406 gets bigger. FIG. 40 shows the extraction process 402 and the cavity 406 at time t2. The heater 418 extends down through the well bore 404 to the top of the water 408 region to maintain the water's 408 high temperature in the heated region 422. The heated region 422 is the area proximate the heater 418. Because hydrocarbons or oil 420 is less dense than water 408, the oil 420 (also called hydrocarbons herein) rises to the top of the cavity 406 and separates from the rest of the tar sands 412 material. At time t2, the oil 420 is floating on top of the warm water 408. As the water 408 moves downward in the cavity 406 and the oil 420 rises in the cavity 406, the heater 418 extends further into the cavity 406 to maintain its position at the top of the water 408 region. A horizontal drill hole may be drilled past the cavity 406 to increase the effect of the hot water in some embodiments.
(103) FIGS. 41A-C are cross-sectional views of a drill head or cutter head 500 according to embodiments of the present invention. The head 500 includes a hydraulic motor 502 interconnected to a shaft 506 interconnected to a modulator 504 with a stator 508 and a rotor 510. The drill head or cutter head 500 also includes a valve mechanism 512 and a nozzle insert 520 for cutting from the sides of the head 500. The head 500 further includes a swivel 514, eccentric nozzle 516, and an axial nozzle 518. In one embodiment, the head 500 has a length L between about 10.00 inches and about 20.00 inches. In a preferred embodiment, the head 500 has a length L between about 12.00 inches and 17.00 about inches. In a more preferred embodiment, the cutter head 500 has a length L1 between about 14.40 inches and 14.50 inches. The nozzle insert 520 is at an angle A relative to the vertical axis of the head 500. In some embodiments, the angle A of the nozzle insert 520 is between about 15 degrees and about 40 degrees. The two nozzles inserts are at the same angle A, but pointed in opposite directions to balance the head 500.
(104) While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of these embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. Further, the invention described herein is capable of other embodiments and of being practiced or of being carried out in various ways. It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
