Apparatus and method for providing electrical transmission of power and signals in a directional drilling apparatus

Abstract

The apparatus, system and method is capable of providing power from a directional or vertical drilling apparatus at an origin above the ground to an electronic device located in a drill head of the directional or vertical drilling apparatus located below the ground. The apparatus, system and method is also capable of providing an electrical signal from below ground back to the origin, above ground, from the electronic device. Accordingly, the mechanism for feeding electrical power down a hole to the electronic device located in the drill head and transmitting a signal back to the origin, greatly enhances the drilling process making it faster, more reliable and more efficient.

1. A drill head forming a portion of a drill string for boring a hole through the ground, comprising:
 a member having a generally longitudinally extending housing including an outer surface, an inner surface defining a hollow passage therethrough, said housing further defining a chamber, a first end adapted and configured for boring through the ground and a second end adapted and configured to be coupled to any one of a starter rod and a drill stem;  
 an electrically insulative ring radially disposed about said second end  
 an electrically conductive ring radially disposed within said electrically insulative ring;  
 an electrically conductive piercing means located about said electrically insulative ring, said piercing means for piercing through said electrically insulative ring to establish electrical continuity with said electrically conductive ring beyond said electrically insulative ring in response to pressure applied to said electrically conductive piercing means;  
 an electrical conductor encapsulated by an electrically insulative material, said electrical conductor disposed within said hollow passage and being electrically connectable between said conductive ring and an electronic device disposed within said chamber, said electrically insulative ring providing electrical isolation between said conductive ring and said outer surface of said drill head and between said piercing means and said electrical conductor when no pressure is applied to said piercing means, and said electrically insulative material providing electrical isolation between said electrical conductor and said inner surface of said hollow passage.  
 
     
     
       2. A drill head according to  claim 1 , further comprising an electronic device disposed within said chamber. 
     
     
       3. A drill head according to  claim 2 , wherein said electronic device is a sonde. 
     
     
       4. A drill head according to  claim 1 , wherein said electrically conductive ring is formed from a copper material. 
     
     
       5. A drill head according to  claim 1 , wherein said electrically insulative ring is formed from a polymer material. 
     
     
       6. A drill head according to  claim 5 , wherein said polymer ring is a polyurethane material. 
     
     
       7. A drill head according to  claim 1 , wherein said electrically insulative ring is formed from a ceramic material. 
     
     
       8. A drill head according to  claim 1 , wherein said electrically insulative material encapsulating said electrical conductor is formed from a polymer material. 
     
     
       9. A drill head according to  claim 8 , wherein said polymer material encapsulating said electrical conductor is a polyurethane material. 
     
     
       10. A drill head according to  claim 1 , wherein said electrically insulative material encapsulating said electrical conductor is formed from a ceramic material. 
     
     
       11. A drill head according to  claim 1 , wherein said generally longitudinally extending housing further comprises a second hollow passage therethrough forming an access tunnel. 
     
     
       12. A drill head according to  claim 11 , wherein said electrical conductor encapsulated by said electrically insulative material, is disposed within said second hollow passage. 
     
     
       13. A drill pipe forming a portion of a drill string for boring a hole through the ground, comprising:
 a member having a generally longitudinally extending housing including an outer surface, an inner surface defining a hollow passage therethrough and first and second ends adapted and configured to be coupled to a second member;  
 first and second electrically conductive rings radially disposed about first and second distal ends of said member, the first and second rings have two or more isolated segments;  
 first and second electrically insulative rings radially disposed about said first and second ends and proximate to said first and second electrically conductive rings; and  
 a first and second electrical conductor encapsulated by an electrically insulative material, said first and second electrical conductor disposed within said hollow passage and said first electrical conductor being electrically connectable between one of the two or more isolated segments of said first and second conductive rings and said second electrical conductor being electrically connectable between one of the two or more isolated segments of said first and second conductive rings not connected to the first electrical conductor, and said first and second electrically insulative rings providing electrical isolation between said first and second conductive rings and said outer surface of said drill pipe, and said electrically insulative material providing electrical isolation between said electrical conductor and said inner surface of said hollow passage.  
 
     
     
       14. A drill pipe according to  claim 13 , wherein said member is a starter rod. 
     
     
       15. A drill pipe according to  claim 14 , wherein said second member is any one of a drill head and drill stem. 
     
     
       16. A drill pipe according to  claim 13 , wherein said member is a drill stem. 
     
     
       17. A drill pipe according to  claim 16 , wherein said second member is any one of a drill head, a drill stem and a starter rod. 
     
     
       18. A starter rod according to  claim 13 , wherein said electrically conductive ring is formed from a copper material. 
     
     
       19. A starter rod according to  claim 13 , wherein said electrically insulative ring is formed from a polymer material. 
     
     
       20. A starter rod according to  claim 19 , wherein said polymer is a polyurethane material. 
     
     
       21. A starter rod according to  claim 13 , wherein said electrically insulative ring is formed from a ceramic material. 
     
     
       22. A starter rod according to  claim 13 , wherein said electrically insulative material encapsulating said electrical conductor is made from a polymer material. 
     
     
       23. A starter rod according to  claim 22 , wherein said polymer material encapsulating said electrical conductor is a polyurethane material. 
     
     
       24. A starter rod according to  claim 13 , wherein said electrically insulative material encapsulating said electrical conductor is formed from a ceramic material. 
     
     
       25. A starter rod according to  claim 13 , wherein said electrically conductive ring further comprises means for piercing said insulative material and electrically connecting said conductive ring to said electrical conductor. 
     
     
       26. A starter rod according to  claim 13 , wherein said generally longitudinally extending housing further comprises a second hollow passage therethrough forming an access tunnel. 
     
     
       27. A starter rod according to  claim 26 , wherein said electrical conductor encapsulated by said electrically insulative material, is disposed within said second hollow passage. 
     
     
       28. A drill string for boring a hole through the ground having a first end adapted and configured to be coupled to a drilling apparatus and a second end adapted and configured for boring a hole through the ground, comprising:
 one or more members having generally longitudinally extending housings, each of said housings including an outer surface and an inner surface defining a hollow passage therethrough and first and second ends adapted and configured to be coupled to any one of a drill head, a drill stem and a starter rod;  
 electrical connection means between each of said members, electrical connection means including a conductive ring on each of said members separated from a conductive ring of an adjacent member by an insulator thereby establishing a capacitance between the conductive ring of each of said members and an adjacent member;  
 electrical insulation means between said electrical connection means and said outer surfaces of each of said members; and  
 one or more electrical conductors encapsulated by an electrically insulative material, each electrical conductor being disposed within each of said hollow passages of each of said members and being capacitively connected through said electrical connection means to an electrical conductor of an adjacent member throughout the length of said drill string.  
 
     
     
       29. A drill string according to  claim 28 , wherein said electrical connection means are electrically conductive rings. 
     
     
       30. A drill string according to  claim 29 , wherein said electronically conductive rings are formed from a copper material. 
     
     
       31. A drill string according to  claim 28 , wherein said electrical insulative means are electrically insulative rings. 
     
     
       32. A drill string according to  claim 31 , wherein said electrically insulative rings are formed from a polymer material. 
     
     
       33. A drill string according to  claim 32 , wherein said polymer is a polyurethane material. 
     
     
       34. A drill string according to  claim 31 , wherein said electrically insulative rings are formed from a ceramic material. 
     
     
       35. A drill string according to  claim 28 , wherein said electrically insulative material encapsulating said electrical conductor is formed from a polymer material. 
     
     
       36. A drill string according to  claim 35 , wherein said polymer material encapsulating said electrical conductor is a polyurethane material. 
     
     
       37. A drill string according to  claim 28 , wherein said electrically insulative material encapsulating said electrical conductor is formed from a ceramic material. 
     
     
       38. A drill string according to  claim 28 , wherein said electrical connection means further comprises means for piercing said insulative material and electrically connecting said conductive ring to said electrical conductor. 
     
     
       39. A drill string according to  claim 28 , wherein said generally longitudinally extending housing further comprises a second hollow passage therethrough forming an access tunnel. 
     
     
       40. A drill string according to  claim 39 , wherein said electrical conductor encapsulated by said electrically insulative material, is disposed within said second hollow passage. 
     
     
       41. A drilling apparatus for boring a hole through the ground, comprising:
 a frame having a longitudinal axis extending from a first frame end to a second frame end;  
 a drill string having a first end adapted and configured to be coupled to a drilling apparatus and a second end adapted and configured for boring a hole through the ground, said drill string further comprising one or more adjacently disposed members including electrical connection means disposed therebetween and providing electrical continuity between said members, said electrical connection means including an electrical ring having two or more isolated segments disposed within an electrical insulator and a piercing means, the piercing means for piercing through the electrical insulator to establish electrical continuity with at least one of the two or more isolated segments beyond the electrical insulator in response to pressure applied to the piercing means;  
 a drive mechanism mounted on said frame for movement along said axis, said drill string being connected to said drive mechanism for said drive mechanism to rotate said drill string and to longitudinally advance and retract said drill string in response to said drive mechanism moving along said axis; and  
 means for providing electrical continuity between said first and second ends of said drill string.  
 
     
     
       42. A drilling apparatus according to  claim 41 , wherein said means for providing electrical continuity further comprises:
 one or more members having generally longitudinally extending housings, each of said housings including an outer surface and an inner surface defining a hollow passage therethrough and first and second ends adapted and configured to be coupled to any one of a drill head, a drill stem and a starter rod;  
 electrical connection means between ends of each said members;  
 electrical insulation means between said electrical connections and said outer surfaces of each said members; and  
 one or more electrical conductors encapsulated by an electrically insulative material, each electrical conductor being disposed within said hollow passage of each of said members and being electrically connected through said electrical connection means to an electrical conductor of an adjacent member throughout the length of said drill string.  
 
     
     
       43. A drill string according to  claim 42 , wherein said electrical connection means are electrically conductive rings. 
     
     
       44. A drilling apparatus according to  claim 42 , wherein said electrically conductive rings are formed from a copper material. 
     
     
       45. A drill string according to  claim 42 , wherein said electrical insulation means are electrically insulative rings. 
     
     
       46. A drilling apparatus according to  claim 42 , wherein said electrically insulative rings are formed from a polymer material. 
     
     
       47. A drilling apparatus according to  claim 46 , wherein said polymer is a polyurethane material. 
     
     
       48. A drilling apparatus according to  claim 43 , wherein said electrically insulative rings are formed from a ceramic material. 
     
     
       49. A drilling apparatus according to  claim 42 , wherein said electrically insulative material encapsulating said electrical conductor is formed from a polymer material. 
     
     
       50. A drilling apparatus according to  claim 49 , wherein said polymer material encapsulating said electrical conductor is formed from a polyurethane material. 
     
     
       51. A drilling apparatus according to  claim 42 , wherein said electrically insulative material encapsulating said electrical conductor is formed from a ceramic material. 
     
     
       52. A drilling apparatus according to  claim 42 , wherein said generally longitudinally extending housing further comprises a second hollow passage therethrough forming an access tunnel. 
     
     
       53. A drilling apparatus according to  claim 52 , wherein said electrical conductor encapsulated by said electrically insulative material, is disposed within said second hollow passage. 
     
     
       54. A drilling apparatus for boring a hole through the ground, comprising:
 a frame having a longitudinal axis extending from a first frame end to a second frame end;  
 a drill string having a first end adapted and configured to be coupled to a drilling apparatus and a second end adapted and configured for boring a hole through the ground, and said drill string further comprising one or more adjacently disposed members and signal flow path connection means disposed therebetween providing signal continuity between said members, said signal flow path connection means including a first electrically conductive ring having two or more isolated segments disposed within an electrically insulative ring, said electrically insulative ring separating said two or more isolated segments of said first electrically conductive ring of one member from an electrically conductive ring having two or more isolated segments of an adjacent member to create a capacitance between said two or more isolated segments of said first electrically conductive ring of one member and said two or more isolated segments of said electrically conductive ring of the adjacent member;  
 a drive mechanism mounted on said frame form movement along said axis, said drill string being connected to said drive mechanism for said drive mechanism to rotate said drill string and to longitudinally advance and retract said drill string in response to said drive mechanism moving along said axis;  
 one or more signal flow path means disposed within said drill string, said signal flow path means providing signal continuity between first and second ends of each member and said first and second ends of said drill string.  
 
     
     
       55. A method of providing an electrical connection throughout the length of a drill string, said drill string including one or more members having generally longitudinally extending housings, each of said members including an outer surface and an inner surface defining a hollow passage therethrough and first and second ends adapted and configured to be coupled to any one of a drill head, a drill stem and a starter rod, electrical connection means including a first electrically conductive ring and an electrically conductive piercing means between ends of each of said members, electrical insulation means enclosing said first electrically conductive ring of said electrical connection means, and one or more electrical conductors encapsulated by an electrically insulative material, each electrical conductor being disposed within said hollow passage of each of said members and being electrically connected through said electrical connection means to an electrical conductor of an adjacent member throughout the length of said drill string, the method comprising:
 moving a first member into coaxial alignment with a drill axis;  
 coupling a second member to said first member; and  
 engaging said electrical connection means between adjacent ends of said members while coupling said first member to said second member to apply pressure to said piercing means causing said piercing means to pierce said electrical insulation means and establish electrical continuity with said first electrically conductive ring beyond said electrical insulation means.  
 
     
     
       56. A system for locating a drill head located below the ground from a location above the ground, comprising:
 a drilling apparatus;  
 a drill string arranged and configured to be coupled to said drilling apparatus at one end and coupled to a drill head at anther end, said drill string further comprising two or more members having generally longitudinally extending housings, each of said housings including an outer surface and an inner surface defining a hollow passage therethrough and first and second ends adapted and configured to be coupled to any one of a drill head, a drill stein and a starter rod, electrical connection means including a first electrically conductive ring between each of said members, electrical insulation means between said electrical connection means and said outer surfaces of each of said members and one or more electrical conductors encapsulated by an electrically insulative material and between said first electrically conductive ring of a member and an electrically conductive ring of an adjacent member to form a capacitance between the first electrically conductive ring of the member and the electrically conductive ring on the adjacent member, each electrical conductor being disposed within said hollow passage of each of said members and being capacitively connected through said electrical connection means to an electrical conductor of an adjacent member throughout the length of said drill string;  
 an electronic transmitter disposed within said drill head, said transmitter emitting electromagnetic energy; and  
 an electronic receiver disposed above ground, said electronic receiver receiving said electromagnetic energy.  
 
     
     
       57. A drill head forming a portion of a drill string for boring a hole through the ground, comprising:
 a member having a generally longitudinally extending housing including an outer surface, an inner surface defining a first hollow passage therethrough, said housing further defining a chamber, a first end adapted and configured for boring through the ground and a second end adapted and configured to be coupled to any one of a starter rod and a drill stem;  
 an electrically insulative ring radially disposed about said second end;  
 an electrically conductive ring having two or more isolated segments disposed about the electrically conductive ring;  
 one or more second hollow passages defined through said member, said one or more second hollow passages forming one or more access tunnels for providing a signal flow path; and  
 two or more electrical conductors disposed within the one or more second hollow passages and electrically connected to the two or more isolated segments of said electrically conductive ring.  
 
     
     
       58. A drill pipe forming a portion of a drill string for boring a hole through the ground, comprising:
 a member having a generally longitudinally extending housing including an outer surface, an inner surface defining a first hollow passage therethrough and first and second ends adapted and configured to be coupled to a second drill pipe;  
 an electrically insulative ring radially disposed about said second end;  
 an electrically conductive ring disposed within the electrically insulative ring;  
 a piercing means deposed about the electrically insulative ring for piercing the electrically insulative ring to establish electrical continuity with the electrically conductive ring beyond the electrically insulative ring in response to pressure applied to the piercing means; and  
 one or more second hollow passages defined through said member, said one or more second hollow passages forming one or more access tunnels for providing a signal flow path to said electrically conductive ring.  
 
     
     
       59. A drill pipe according to  claim 58 , wherein said member is a starter rod. 
     
     
       60. A drill pipe according to  claim 59 , wherein said second member is any one of a drill head and drill stem. 
     
     
       61. A drill pipe according to  claim 58 , wherein said member is a drill stem. 
     
     
       62. A drill pipe according to  claim 61 , wherein said second member is any one of a drill head, a starter rod and drill stem. 
     
     
       63. A drill string for boring a hole through the ground having a first end adapted and configured to be coupled to a drilling apparatus and a second end adapted and configured for boring a hole through the ground, comprising:
 one or more members having generally longitudinally extending housings, each of said housings including an outer surface and an inner surface defining a hollow passage therethrough and first and second ends adapted and configured to be coupled to any one of a drill head, a drill stem and a starter rod;  
 electrical insulation means between said members;  
 an electrically conductive ring disposed within said electrical insulation means, said electrically conductive ring having two or more isolated segments;  
 a piercing means disposed about the electrical insulation means, the piercing means for piercing through the electrical insulation means to establish electrical contact with at least one segment of the two or more segments beyond the electrical insulation means in response to pressure being applied to the piercing means; and  
 one or more second hollow passages defined through said member, said one or more second hollow passages forming one or more access tunnels for providing a signal flow path.  
 
     
     
       64. A method for providing an capacitive connection between first and second pipes in a drill string, the pipes including electrical conductors that extend through the pipes, the electrical conductors including electrical contact locations attached to the pipes adjacent the ends of the pipes, the electrical contact locations including a first electrical contact location corresponding to the first pipe and a second electrical contact location corresponding to the second pipe, the first and second electrical contact locations being positioned such that when the first and second pipes are threaded together, the first electrical contact location contacts the second electrical contact location, the first and second electrical contact locations including an electrical ring having two or more isolated segments disposed within an electrically insulative ring, the method comprising:
 capacitively connecting the electrical conductors of the first and second pipes by threading the first and second pipes together thereby causing the electrically insulative ring of the first electrical contact location to be brought into contact with the electrically insulative ring of the second electrical contact location.  
 
     
     
       65. A drilling apparatus for boring a hole through the ground, comprising:
   a frame having a longitudinal axis extending from a first frame end to a second frame end;        a drill string having a first end adapted and configured to be coupled to a drilling apparatus and a second end adapted and configured for boring a hole through the ground, and said drill string further comprising one or more adjacently disposed members and signal flow path connection means disposed therebetween providing signal continuity between said members, said signal flow path connection means including a first electrically conductive ring, having one or more isolated segments disposed within an electrically insulative ring, said electrically insulative ring separating said one or more isolated segments of said first electrically conductive ring of one member from an electrically conductive ring having one or more isolated segments of an adjacent member to create a capacitance between said one or more isolated segments of said first electrically conductive ring of one member and said one or more isolated segments of said electrically conductive ring of the adjacent member;        a drive mechanism mounted on said frame for movement along said axis, said drill string being connected to said drive mechanism for said drive mechanism to rotate said drill string and to longitudinally advance and retract said drill string in response to said drive mechanism moving along said axis;        one or more signal flow path means disposed within said drill string, said signal flow path means providing signal continuity between first and second ends of each member and said first and second ends of said drill string.     
     
     
       66. A method for providing an capacitive connection between first and second pipes in a drill string, the pipes including electrical conductors that extend through the pipes, the electrical conductors including electrical contact locations attached to the pipes adjacent the ends of the pipes, the electrical contact locations including a first electrical contact location corresponding to the first pipe and a second electrical contact location corresponding to the second pipe, the first and second electrical contact locations being positioned such that when the first and second pipes are threaded together, the first electrical contact location being in close proximity to the second electrical contact location, the first and second electrical contact locations including an electrical ring having one or more isolated segments disposed within an electrically insulative ring, the method comprising:
   capacitively connecting the electrical conductors of the first and second pipes by threading the first and second pipes together thereby causing the electrically insulative ring of the first electrical contact location to be brought into close proximity with the electrically insulative ring of the second electrical contact location.     
     
     
       67. A drill string for boring a hole through the ground having a first end adapted and configured to be coupled to a drilling apparatus and a second end adapted and configured for boring a hole through the ground, comprising:
   one or more members having generally longitudinally extending housings, each of said housings including an outer surface and an inner surface defining a hollow passage therethrough and first and second ends adapted and configured to be coupled to any one of a drill head, a drill stem and a starter rod;        electrical connecting means between each of said members, electrical connection means including a conductive ring on each of said members separated from a conductive ring of an adjacent member by an insulator thereby establishing non - contacting electrical communication between the conductive ring of each of said members and an adjacent member;        electrical insulation means between said electrical connection means and said outer surfaces of each of said members; and        one or more electrical conductors encapsulated by an electrically insulative material, each electrical conductor being disposed within each of said hollow passages of each of said members and being electrically connected through said electrical connection means to an electrical conductor of an adjacent member throughout the length of said drill string.     
     
     
       68. A drill string for boring a hole through the ground, comprising:
   at least a first drill pipe and a second drill pipe, each of said first and second drill pipes having an outer surface and an inner surface defining a hollow passage;        a first conductive element located at an end of said first drill pipe and a second conductive element located at an end of said second drill pipe, each of said first and second conductive elements being separated from one another by an insulator when said drill pipes are mechanically coupled together; and        a first electrical conductor electrically connected to said first conductive element and a second electrical conductor electrically connected to said second conductive element, each of said first and second electrical conductors being encapsulated by electrically insulative material and positioned within said hollow passages of said first and second drill pipes;        wherein said first and second conductive elements provide a non - contacting electrical connection between said first and second electrical conductors when said first and second drill pipes are mechanically coupled together.