Flow through gauge for drill bit

Abstract

An apparatus that includes one or more flow channels and method for fabricating such flow channels. The apparatus includes a body, one or more blades from one end of the body, and a corresponding gauge section disposed adjacently and in alignment with a respective blade. Each gauge section includes a leading section, a trailing section, a face section extending from one end of the leading section to an end of the trailing section, and at least one flow channel extending from the leading edge section to at least one of the trailing edge section or the face section.

What is claimed is: 
     
         1 . A downhole tool, comprising:
 a body;   one or more blades extending from one end of the bit body, the plurality of blades forming a cutting surface; and   one or more gauge sections, each gauge section disposed adjacently and in alignment with a respective blade, each gauge section comprising:
 a leading edge section; 
 a trailing edge section; and 
 a face section extending from one end of the leading edge section to one end of the trailing edge section, 
 wherein at least one flow channel is formed in the gauge section extending from the leading edge section to at least one of the trailing edge section or the face section. 
   
     
     
         2 . The downhole tool of  claim 1 , wherein the leading edge section comprises at least one inlet opening, the trailing edge section comprises at least one outlet opening, and the flow channel is formed extending from the inlet opening to the at least one outlet opening. 
     
     
         3 . The downhole tool of  claim 2 , wherein the flow channel is oriented at an upward angle. 
     
     
         4 . The downhole tool of  claim 2 , wherein at least one outlet opening is dimensioned larger than the corresponding inlet opening. 
     
     
         5 . The downhole tool of  claim 2 , wherein the flow channel is curved. 
     
     
         6 . The downhole tool of  claim 1 , wherein the leading edge section comprises at least one inlet opening, the face section comprises at least one outlet opening, and the flow channel is formed extending from the inlet opening to the at least one outlet opening. 
     
     
         7 . The downhole tool of  claim 6 , wherein the at least one outlet opening is dimensioned larger than the corresponding inlet opening. 
     
     
         8 . The downhole tool of  claim 6 , wherein the flow channel is curved. 
     
     
         9 . The downhole tool of  claim 6 , wherein the flow channel is oriented at an upward angle. 
     
     
         10 . The downhole tool of  claim 1 , wherein the leading edge section comprises at least one inlet opening, the face section comprises at least one outlet opening and a deep groove extending from the at least one outlet opening to the trailing edge section, and the flow channel is formed extending from the inlet opening to at least one outlet opening. 
     
     
         11 . The downhole tool of  claim 10 , wherein the deep groove comprises a depth of at least one-fourth inch. 
     
     
         12 . The downhole tool of  claim 10 , wherein the at least one outlet opening is dimensioned larger than the corresponding inlet opening. 
     
     
         13 . The downhole tool of  claim 10 , wherein the flow channel is curved. 
     
     
         14 . The downhole tool of  claim 10 , wherein the flow channel is oriented at an upward angle. 
     
     
         15 . The downhole tool of  claim 1 , wherein the leading edge section comprises at least one inlet opening, the face section comprises at least one outlet opening, the trailing edge section comprises at least one second outlet opening, and the flow channel is formed extending from the inlet opening to at least one outlet opening of the face section and to at least one second outlet opening of the trailing edge section. 
     
     
         16 . The downhole tool of  claim 15 , wherein at least a portion of the flow channel is curved. 
     
     
         17 . The downhole tool of  claim 15 , wherein at least a portion of the flow channel is oriented at an upward angle. 
     
     
         18 . The downhole tool of  claim 1 , wherein the leading edge section comprises at least one inlet opening, the face section comprises at least one outlet opening and a deep groove extending from the outlet opening to the trailing edge section, the trailing edge section comprises at least one second outlet opening, and the flow channel is formed extending from the inlet opening to at least one outlet opening of the face section and to at least one second outlet opening of the trailing edge section. 
     
     
         19 . The downhole tool of  claim 1 , wherein the flow channel is formed extending across a surface of the face section from the leading edge section to the trailing edge section. 
     
     
         20 . The downhole tool of  claim 19 , wherein the flow channel at the leading edge section and at the trailing edge section is wider than the flow channel therebetween. 
     
     
         21 . The downhole tool of  claim 19 , wherein the at least one flow channel comprises a plurality of flow channels, a first flow channel being parallel to a second flow channel. 
     
     
         22 . The downhole tool of  claim 19 , wherein the flow channel is oriented at an upward angle. 
     
     
         23 . The downhole tool of  claim 19 , wherein the flow channel is curved. 
     
     
         24 . The downhole tool of  claim 19 , wherein the flow channel is linear. 
     
     
         25 . The downhole tool of  claim 1 , wherein the face section comprises at least one pod and wherein the flow channel is formed extending across the face section from the leading edge section to the trailing edge section and surrounding the at least one pod. 
     
     
         26 . The downhole tool of  claim 25 , wherein the at least one pod is selected from the group consisting of circular-shaped, diamond-shaped, rectangular-shaped, triangular-shaped, and a non-geometric shape. 
     
     
         27 . A gauge section of a downhole tool, comprising:
 a leading edge section;   a trailing edge section; and   a face section extending from one end of the leading edge section to one end of the trailing edge section,   wherein at least one flow channel is formed in the gauge section extending from the leading edge section to at least one of the trailing edge section or the face section.   
     
     
         28 . The gauge section of  claim 27 , wherein the leading edge section comprises at least one inlet opening, the trailing edge section comprises at least one outlet opening, and the flow channel is formed extending from the inlet opening to the at least one outlet opening. 
     
     
         29 . The gauge section of  claim 28 , wherein the flow channel is oriented at an upward angle. 
     
     
         30 . The gauge section of  claim 28 , wherein at least one outlet opening is dimensioned larger than the corresponding inlet opening. 
     
     
         31 . The gauge section of  claim 28 , wherein the flow channel is curved. 
     
     
         32 . The gauge section of  claim 27 , wherein the leading edge section comprises at least one inlet opening, the face section comprises at least one outlet opening, and the flow channel is formed extending from the inlet opening to the at least one outlet opening. 
     
     
         33 . The gauge section of  claim 27 , wherein the leading edge section comprises at least one inlet opening, the face section comprises at least one outlet opening and a deep groove extending from the at least one outlet opening to the trailing edge section, and the flow channel is formed extending from the inlet opening to at least one outlet opening. 
     
     
         34 . The gauge section of  claim 27 , wherein the leading edge section comprises at least one inlet opening, the face section comprises at least one outlet opening, the trailing edge section comprises at least one second outlet opening, and the flow channel is formed extending from the inlet opening to at least one outlet opening of the face section and to at least one second outlet opening of the trailing edge section. 
     
     
         35 . The gauge section of  claim 27 , wherein the leading edge section comprises at least one inlet opening, the face section comprises at least one outlet opening and a deep groove extending from the outlet opening to the trailing edge section, the trailing edge section comprises at least one second outlet opening, and the flow channel is formed extending from the inlet opening to at least one outlet opening of the face section and to at least one second outlet opening of the trailing edge section. 
     
     
         36 . The gauge section of  claim 27 , wherein the flow channel is formed extending across a surface of the face section from the leading edge section to the trailing edge section. 
     
     
         37 . The gauge section of  claim 36 , wherein the flow channel at the leading edge section and at the trailing edge section is wider than the flow channel therebetween. 
     
     
         38 . The gauge section of  claim 27 , wherein the face section comprises at least one pod and wherein the flow channel is formed extending across the face section from the leading edge section to the trailing edge section and surrounding the at least one pod. 
     
     
         39 . A method of fabricating one or more flow channels in a downhole tool, the method comprising:
 obtaining a downhole tool, comprising:
 a body; 
 one or more blades extending from one end of the body, the plurality of blades forming a cutting surface; and 
 one or more gauge sections, each gauge section disposed adjacently and in alignment with a respective blade, each gauge section comprising:
 a leading edge section; 
 a trailing edge section; and 
 a face section extending from one end of the leading edge section to one end of the trailing edge section, 
 
   forming at least one flow channel in the gauge section, the flow channel extending from the leading edge section to at least one of the trailing edge section or the face section.   
     
     
         40 . The method of  claim 39 , wherein forming at least one flow channel in the gauge section comprises:
 forming at least one inlet opening in the leading edge section;   forming at least one outlet opening in the trailing edge section; and   forming the flow channel to extend from the at least one inlet opening to the at least one outlet opening.   
     
     
         41 . The method of  claim 40 , wherein the flow channel is oriented at an upward angle. 
     
     
         42 . The method of  claim 40 , wherein at least one outlet opening is dimensioned larger than the corresponding inlet opening. 
     
     
         43 . The method of  claim 40 , wherein the flow channel is curved. 
     
     
         44 . The method of  claim 39 , wherein forming at least one flow channel in the gauge section comprises:
 forming at least one inlet opening in the leading edge section;   forming at least one outlet opening in the face section; and   forming the flow channel to extend from the at least one inlet opening to the at least one outlet opening.   
     
     
         45 . The method of  claim 39 , wherein forming at least one flow channel in the gauge section comprises:
 forming at least one inlet opening in the leading edge section;   forming at least one outlet opening in the face section;   forming a deep groove in the face section extending from the at least one outlet opening to the trailing edge section; and   forming the flow channel to extend from the at least one inlet opening to the at least one outlet opening.   
     
     
         46 . The method of  claim 39 , wherein forming at least one flow channel in the gauge section comprises:
 forming at least one inlet opening in the leading edge section;   forming at least one outlet opening in the face section;   forming at least one second outlet opening in the trailing edge section; and   forming the flow channel to extend from the at least one inlet opening to the at least one outlet opening of the face section and to at least one second outlet opening of the trailing edge section.   
     
     
         47 . The method of  claim 39 , wherein forming at least one flow channel in the gauge section comprises:
 forming at least one inlet opening in the leading edge section;   forming at least one outlet opening in the face section;   forming a deep groove in the face section extending from the at least one outlet opening to the trailing edge section;   forming at least one second outlet opening in the trailing edge section; and   forming the flow channel to extend from the at least one inlet opening to the at least one outlet opening of the face section and to at least one second outlet opening of the trailing edge section.   
     
     
         48 . The method of  claim 39 , wherein forming at least one flow channel in the gauge section comprises forming the flow channel to extend across a surface of the face section from the leading edge section to the trailing edge section. 
     
     
         49 . The method of  claim 48 , wherein the flow channel at the leading edge section and at the trailing edge section is wider than the flow channel therebetween. 
     
     
         50 . The method of  claim 39 , wherein forming at least one flow channel in the gauge section comprises forming the flow channel to extend across a portion of a surface of the face section from the leading edge section to the trailing edge section, the flow channel surrounding one or more pods formed therein.