WO2008042945A2 - Wellbore casing and method of forming same - Google Patents

Wellbore casing and method of forming same Download PDF

Info

Publication number
WO2008042945A2
WO2008042945A2 PCT/US2007/080280 US2007080280W WO2008042945A2 WO 2008042945 A2 WO2008042945 A2 WO 2008042945A2 US 2007080280 W US2007080280 W US 2007080280W WO 2008042945 A2 WO2008042945 A2 WO 2008042945A2
Authority
WO
WIPO (PCT)
Prior art keywords
filed
attorney docket
casing
application serial
patent application
Prior art date
Application number
PCT/US2007/080280
Other languages
French (fr)
Other versions
WO2008042945A3 (en
Inventor
Darrell Scott Costa
Larry Kendziora
Original Assignee
Enventure Global Technology, L.L.C.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Enventure Global Technology, L.L.C. filed Critical Enventure Global Technology, L.L.C.
Publication of WO2008042945A2 publication Critical patent/WO2008042945A2/en
Publication of WO2008042945A3 publication Critical patent/WO2008042945A3/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
    • E21B17/042—Threaded
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/106—Couplings or joints therefor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L13/00—Non-disconnectible pipe-joints, e.g. soldered, adhesive or caulked joints
    • F16L13/02—Welded joints
    • F16L13/0209—Male-female welded joints
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L13/00—Non-disconnectible pipe-joints, e.g. soldered, adhesive or caulked joints
    • F16L13/02—Welded joints
    • F16L13/0218—Welded joints having an inner or outer ring
    • F16L13/0236—Welded joints having an inner or outer ring having an outer ring

Definitions

  • patent number 6,575,240 which was filed as patent application serial no. 09/511 ,941 , attorney docket no. 25791.16.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,907, filed on 2/26/99, (9)
  • U.S. patent number 6,557,640 which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (10)
  • Patent Number 6,497,289 which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (33)
  • U.S. patent number 6,561 ,227 which was filed as patent application serial number 09/852,026 , filed on 5/9/01 , attorney docket no. 25791.56, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no.
  • Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (40) U.S. patent application serial no. 09/962,470, filed on 9/25/01 , attorney docket no. 25791.63, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (41) U.S. patent application serial no. 09/962,471, filed on 9/25/01 , now U.S.
  • Patent 6,739,392 which issued 5/25/2004, attorney docket no. 25791.64, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (42) U.S. patent application serial no. 09/962,467, filed on 9/25/01, now U.S. Patent 6,725,919 which issued 4/27/2004, attorney docket no. 25791.65, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no.
  • Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (44) PCT application US 02/25727, filed on 8/14/02, attorney docket no. 25791.67.03, which claims priority from U.S. provisional patent application serial no. 60/317,985, attorney docket no. 25791.67, filed on 9/6/2001, and U.S. provisional patent application serial no. 60/318,386, attorney docket no. 25791.67.02, filed on 9/10/2001, (45) PCT application US 02/39425, filed on 12/10/02, attorney docket no. 25791.68.02, which claims priority from U.S. provisional patent application serial no.
  • patent number 6,568,471 which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (50) U.S. patent application serial no. 10/074,244, attorney docket no. 25791.75, filed on 2/12/02, now U.S. Patent 6,631,759 which issued 10/14/2003, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
  • Patent 6,631 ,769 which issued 10/14/2003, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (53) U.S. patent application serial no. 10/076,659, attorney docket no. 25791.78, filed on 2/15/02, now U.S. Patent 7,063,142 which issued 6/20/2006, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
  • patent number 6,557,640 which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (60) U.S. patent application serial no. 10/092,481, attorney docket no. 25791.85, filed on 3/7/02, now U.S. Patent 6,857,473 which issued 2/22/2005, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
  • patent application serial no. 10/331 ,718, attorney docket no. 25791.94, filed on 12/30/02 which is a divisional U.S. patent application serial no. 09/679,906, filed on 10/5/00, attorney docket no. 25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (69) PCT application US 03/04837, filed on 2/29/03, attorney docket no. 25791.95.02, which claims priority from U.S. provisional patent application serial no. 60/363,829, attorney docket no. 25791.95, filed on 3/13/02, (70) U.S. patent application serial no.
  • patent number 6,557,640 which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (72) U.S. patent application serial no. 10/261 ,925, attorney docket no. 25791.99, filed on 10/1/02, now U.S. Patent 7,044,218 which issued 5/16/2006, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no.
  • provisional patent application serial no. 60/398,061 attorney docket no. 25791.110, filed on 7/24/02, (81) PCT application US 03/20870, filed on 7/2/03, attorney docket no. 25791.111.02, which claims priority from U.S. provisional patent application serial no. 60/399,240, attorney docket no. 25791.111, filed on 7/29/02, (82) U.S. provisional patent application serial no. 60/412,487, attorney docket no. 25791.112, filed on 9/20/02, (83) U.S. provisional patent application serial no. 60/412,488, attorney docket no. 25791.114, filed on 9/20/02, (84) U.S. patent application serial no.
  • Patent 7,021,390 which issued 4/4/2006, (105) U.S. provisional patent application serial no. 60/454,896, attorney docket no. 25791.236, filed on 3/14/03, (106) U.S. provisional patent application serial no. 60/450,504, attorney docket no. 25791.238, filed on 2/26/03, (107) U.S. provisional patent application serial no. 60/451,152, attorney docket no. 25791.239, filed on 3/9/03, (108) U.S. provisional patent application serial no. 60/455,124, attorney docket no. 25791.241 , filed on 3/17/03, (109) U.S. provisional patent application serial no. 60/453,678, attorney docket no.
  • Patent 6,550,821 which issued 4/22/2003, attorney docket no. 25791.263; (201) U.S. Patent Application No. 10/767,953, filed 1/29/2004, attorney docket no. 25791.309, now U.S. Patent 7077211 which issued 7/18/2006; (202) U.S. Patent Application No. 10/769,726, filed 1/30/2004, attorney docket no. 25791.310; (203) U.S. Patent Application No. 10/770363 filed 2/2/2004, attorney docket no. 25791.311 ; (204) U.S. utility patent application serial no. 11/068,595, attorney docket no. 25791.349, filed on 2/28/2005; (205) U.S. utility patent application serial no.
  • This invention relates generally to oil and gas exploration, and in particular to forming a well bore casing from a series of casing sections to facilitate oil and gas recovery.
  • a well bore typically traverses a number of zones within a subterranean formation.
  • Well bore casings are often formed in the well bore by a series of casing sections that are coupled to one another, usually by threaded connections. In many of these installations the coupled casing sections are plastically deformed and radially expanded to the inner wall of the well bore.
  • the coupling between the threaded connections is often insufficient to permit the transmission of energy through the casing sections from the surface to the downhole location.
  • the threads of the threaded connections are easily damaged and, as such, may permit undesirable leakage between the inside of the casing and the exterior of the casing.
  • the threaded connections can be compromised during the expansion process.
  • FIG. 1 is a fragmentary cross-sectional schematic illustration of a casing section disposed in a well bore.
  • FIG. 2 is a fragmentary cross-sectional schematic illustration of the casing section of Fig. 1 , along with an aligned additional casing section.
  • Fig. 3 is a fragmentary cross-sectional schematic illustration of the casing sections of Fig. 2 in a threaded, coupled engagement.
  • Fig. 4 is a view similar to that of Fig. 3, but depicting a sleeve surrounding portions of the casing sections.
  • Fig. 5 is a view similar to that of Fig. 4, but depicting a magnetic impulse apparatus associated with the components of Fig. 4.
  • Fig. 6 is a view similar to that of Fig. 5, but depicting the magnetic flux and resultant force fields generated by the magnetic impulse apparatus of Fig. 5.
  • FIGs. 7-9 are views similar to that of Fig. 4 but depicting alternate embodiments of the assembly of Fig. 4.
  • Fig. 10 is a partial sectional view of an alternate embodiment of a component of the embodiment of Fig. 9.
  • FIGs. 11 and 12 are views similar to that of Fig. 3 but depicting alternate embodiments of the assembly of Fig. 3,
  • the reference numeral 10 refers to a well bore 10 that traverses a subterranean formation 12.
  • a tubular casing section 14 is positioned within the well bore 10 and is shown partially for the convenience of presentation.
  • a tubular casing section 16 is also positioned in the bore and is adapted to be coupled to the casing section 14.
  • the inner wall of an end portion of the casing section 14 is provided with threads 22, and the outer surface of the corresponding end portion of the casing section 16 is provided with complementary threads 24.
  • the sections 14 and 16 can be threadedly engaged by applying torque to one member and rotating it in the proper direction relative to the other member.
  • a small groove 16a is formed in the outer surface of the casing section 16 between the uppermost thread 24 and the non-threaded portion of the member, for reasons to be described.
  • the outer diameter of the casing section 14 is the same, or substantially the same, as the outer diameter of the non-threaded portion of the casing section 16.
  • a channel 30 is defined by the groove 16a (Fig. 2) and the corresponding end of the casing section 14.
  • a sleeve 40 overlaps a portion of the coupled portions of the sections 14 and 16, as well as a portion of the casing section 16 extending adjacent the threads 24.
  • the sleeve 40 is preferably fabricated from electrically conductive material that is suitably malleable or flowable so that it can be shaped mechanically. Examples of such a material are copper, aluminum, light metal, metal alloys, and steel alloys, it being understood that other metal alloys with suitable electrical conductivity and with suitable malleability or suitable flow behavior may also be used.
  • the inside diameter of the sleeve 40 is slightly larger than the outside diameters of the sections 14 and 16 so that a cylindrical gap 44 is formed between the sleeve 40 and the sections 14 and 16, respectively.
  • the radial thickness of the sleeve 40 is less than the radial thickness of each casing section 14 and 16.
  • a magnetic impulse energy apparatus 50 includes an impulse conductor ring 52 extending around the sleeve 40 and having an axial dimension slightly greater than that of the sleeve.
  • the inside diameter of the ring 52 is slightly larger than the outside diameter of the sleeve 40, thereby defining a cylindrical gap 56 therebetween.
  • the ring 52 is operatively connected to an impulse generator 54, such that magnetic impulse power flows from the generator and circumferentially around the ring.
  • the impulse generator is conventional and is disclosed generally (but not in the context of the present invention), for example, in U. S. Patent 5,444,963; U. S. Patent 5,586,460; U. S.
  • Fig. 6 is similar to that of Fig. 5 but depicts the magnetic fields generated by the apparatus 50 and applied to the structure of Fig. 5.
  • the impulse generator 54 provides a magnetic impulse to the conductor ring 52, causing a magnetic field 60 to be produced and simultaneously cause a counter-current magnetic pulse 62 to be produced that extends into the sleeve 40.
  • An extremely high concentration of magnetic flux 64 extends in the gap 56 between the sleeve 40 and the ring 52 and generates a relatively large force field F that is directed radially inwardly from the ring 52 towards the sleeve 40.
  • the force field F collapses the sleeve 40 onto the corresponding portions of the sections 14 and 16.
  • the malleable material of the sleeve 40 melts and flows around the joint between the interlocked sections 14 and 16 and into the channel 30. This produces a surface-to-surface air tight metallic seal entirely over the threaded coupling between the sections 14 and 16 that aids in retaining the members together.
  • the sleeve 40 protects the corresponding exterior surfaces of the tubular sections 14 and 16 during handling and insertion of the members within the well bore 10. In this manner, extensive damage to the exterior surfaces of the tubular sections 14 and 16 is prevented that could otherwise cause stress concentrations that could result in a catastrophic failure, especially during subsequent radial expansion operations that are described below. Also, misalignment that could result in damage to the threads 22 and 24 is avoided, or at least reduced.
  • the sleeve 40 provides a significant resistance to any relative rotation between the coupled tubular sections 14 and 16. The sleeve 40 may also provide an indication of the quality of the threaded coupling between the sections 14 and 16. For example, if the sleeve 40 can be easily rotated, that would indicate that the first and second casing sections, 14 and
  • tubular casing sections 80 and 82 are provided that are similar to the sections 14 and 16 of the previous embodiments, but vary to the extent that the threads formed on the latter members are eliminated and a different interlocking system is provided.
  • the casing section 80 is provided with a stepped inner diameter that defines an end portion 80a having a larger inner diameter than that of the remaining portion of the member.
  • the casing section 82 is provided with a stepped outer diameter that defines an end portion 82a having a smaller outer diameter than that of the remaining portion of the member.
  • Three axially-spaced, raised ridge rings 84a, 84b, and 84c extend radially from the portion 80a of the member 80, and a series of corresponding grooves are formed in the member 80b that are located and sized so as to receive the respective rings.
  • a sleeve 86 which is identical to the sleeve 40 of the previous embodiment except for size, extends over the interlocked portions 80a and 82a.
  • the axial length of the sleeve 86 is slightly greater than that of the interlocked portions 80a and 82a so as to extend around a portion of the sections 80 and 82 adjacent the interlocked portions.
  • the inner diameter of the sleeve 86 extends around the sections 14 and 16 with minimum clearance to provide sealing and to force the portions 80a and 82a into their interlocking relationship.
  • the radial thickness of the sleeve 86 is less than the radial thickness of the casing section 14 and the casing section 16.
  • the magnetic impulse energy apparatus 50 of Figs. 5 and 6 can be applied to the arrangement of Fig. 7 in the same manner as discussed above, so as to develop the magnetic flux and the force fields described above.
  • the malleable material of the sleeve 86 melts and flows around the joint between the sections 80 and 82 and into the gap 84. This produces a surface-to-surface air tight metallic seal entirely over the coupling between the sections 80 and 82 that aids in retaining the members together.
  • the use of the sleeve 86 thus also provides the advantages of the sleeve 40 of the previous embodiment.
  • tubular casing sections 90 and 92 are provided that are similar to the tubular sections 14 and 16 of the embodiments of Figs. 1-6, but vary to the extent that the threads formed on the latter members are eliminated and a different interlocking system is provided.
  • the tubular section 90 is provided with a stepped inner diameter that defines an end portion 90a having a larger inner diameter than that of the remaining portion of the member.
  • the tubular section 92 is provided with a stepped outer diameter that defines an end portion 92a having a smaller outer diameter than that of the remaining portion of the member.
  • a sleeve 94 which is identical to the sleeves 40 and 86 of the previous embodiments except for size, extends within interlocked portions 90a and 92a in a coaxial relationship.
  • the axial length of the sleeve 94 is greater than that of the interlocked portions 90a and 92a, and the outer diameter of the sleeve 94 is less than the inner diameters of the sections 90 and 92 so as to define a cylindrical gap 96.
  • the radial thickness of the sleeve 94 is less than the radial thickness of the section 90 and the member 92.
  • the magnetic impulse generator 54 is operatively connected to the ring 52. [0032] In operation, the generator 54 provides a magnetic pulse to the conductor ring 52, causing a magnetic field to be produced and simultaneously causing a counter-current magnetic pulse to be produced that extends into the sleeve 94.
  • An extremely high concentration of magnetic flux thus enters the gap 98 between the sleeve 94 and the ring 52 and generates a relatively large force field that is directed radially outwardly from the ring 52 towards the sleeve 94, thereby expanding the sleeve across the gap 96 and into engagement with the inner surfaces of the coupled sections 90 and 92.
  • This forms sealing interfaces between the outside surfaces of the sleeve 94 and the corresponding inner surfaces of the sections 90 and 92.
  • the malleable material of the sleeve 94 melts and flows over the corresponding surfaces of the sections 90 and 92 to produce a surface-to-surface air tight metallic seal entirely over the coupled sections 90 and 92 that aids in retaining the members together.
  • FIG. 9 Referring to the embodiment of Figs. 9 and 10, two tubular casing sections 114 and 116 are positioned within the well bore 10, and are shown partially for the convenience of presentation.
  • a series of threads 122 are provided on the inner surface of the end portion of the member 114, and complementary threads 124 are formed on the outer surface of the corresponding end portion of the casing section 116.
  • the threads 122 and 124 are sized so that a gap is formed when they are engaged, and a layer 126, of a material to be described, is disposed in the gap.
  • the layer 126 can be attached to either the threads 122 or the threads 124 in any conventional manner such as by deposition, or the like.
  • the material forming the layer 126 is preferably a material that is softer than the sections 114 and 116, and examples include plastic or metals such as copper, zinc, cadmium, tin and alloy.
  • the layer 126 can be formed of an exothermic alloy material having a low melting temperature during joining and a much higher temperature after solidification of the solid joint as a result of plastic deformation, stress and/or temperature.
  • the above gap between the teeth 122 and 124 can be filled by a single layer 126 or by two or more multiple, stacked, abutting layers.
  • Fig. 10 depicts an example in which four stacked abutting layers 126a, 126b, 126c, and 126d are provided in the gap.
  • Each layer can be identical to the layer 126 with the exceptions noted below.
  • One or more of the layers 126a, 126b, 126c, and 126d can be different from the remaining layers.
  • one or more of the layers 126a, 126b, 126c, and 126d can have a different modulus of elasticity and, as such, can be fabricated of a different material, than the others.
  • the layer 126a for example, could be fabricated from a relatively soft material such as copper, and the layer 126b could be fabricated from a relatively hard material, such cadmium.
  • the copper layer 126a would plastically deform to seal along the entire joint surface and the cadmium layer 126b would provide a micro-sealing layer.
  • one or both of the other layers 126c and 12 ⁇ d could have a different modulus of elasticity and form another micro-seal.
  • the layer 126, and/or one or both of the layers 12 ⁇ a and 126d could be in the form of flux that melts when heated and bonds to the adjacent threads 122 and 124 to form a relatively strong soldered joint having a relatively high melting temperature.
  • the layer 126 and/or one or more of the layers 126a, 126b, 126c, and 126d could be of a material that has a relatively low initial melting point during any deformation and/or or heating, and has a higher melting point after the deformation and/or heating.
  • the layer 126 and/or one or more of the layers 126a, 126b, 126c, and 126d may be of an exothermic material that initially releases energy upon stress or heat input thereby melting or plastically flowing at one temperature, and, subsequently, without the further release of such heat energy having a higher melting point or plastic flow temperature.
  • the layer 126, and/or one or more of the layers 126a, 126b, 126c, and 12 ⁇ d can be fabricated of a reactive bonding agent that, when reacted, forms a seal and bond between the sections 114 and 116.
  • the bonding agent can be reacted in several manners to form the seal and the bond.
  • the bonding agent can be reacted by the pressure and/or heat when the connection is made and/or when
  • I S torque is applied to the connection.
  • the increase of pressure and/or temperature when running the casing sections 114 and 116 into the well can cause the bonding agent to react.
  • a downhole tool could be used to excite the bonding agent downhole.
  • a protective layer could be placed over the bonding agent to protect it from air, water, etc. and couid later be removed using the makeup and/or torque of the connection, so that air, water, or any of the above techniques could then be used to react the bonding agent. Since the bonding agent is conventional, it will not be described in detail.
  • sleeve 40 of the embodiment of Figs. 4-6, the sleeve 86 of the embodiment of Fig. 7, or the sleeve 94 of the embodiment of Fig. 8 could be placed around the coupled sections 114 and 116 and function in the same manner as described above.
  • FIG. 11 two tubular casing sections 130 and 132 are positioned within the well bore 10 and are shown partially for the convenience of presentation.
  • An end portion 130a of the section 130 is tapered in a radial direction along its axial length, and the corresponding end portion 132a of the section 132 is flared outwardly to a degree that the inner surface of the flared end portion can engage the tapered outer surface of the end portion 130a to define an interface along which a material 136 is disposed.
  • the material 136 can be of a type that flashes at a certain elevated temperate that can be achieved when the casing sections 130 and 132 are rotated relative to each other.
  • two tubular casing sections 140 and 142 are positioned within the well bore 10, and are shown partially for the convenience of presentation.
  • An end portion 140a of the casing section 140 is tapered in a radial direction along its axial length, and the corresponding end portion 142a of the casing section 142 is flared outwardly.
  • a series of threads 146 are provided on the outer surface of the end portion 140a, and a series of corresponding threads 148 are provided on the inner surface of the flared portion 142a.
  • the threads 146 and 148 are in threaded engagement to couple the members 140 and 142. It is understood that, as an option, the material 140 of the previous embodiment can be placed between the engaging threads 146 and 148 and functions in the same manner as described above.
  • the coupled casing sections can be radially expanded and plastically deformed in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (2) U.S. patent application serial no. 09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, which claims priority from provisional application 60/121 ,702, filed on 2/25/99, (3) U.S.
  • Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (40) U.S. patent application serial no. 09/962,470, filed on 9/25/01 , attorney docket no. 25791.63, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99,
  • patent number 6,568,471 which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (59)
  • U.S. patent application serial no. 10/262,009, attorney docket no. 25791.84, filed on 10/1/02 which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (60)
  • patent number 6,557,640 which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (73) U.S. patent application serial no. 10/199,524, attorney docket no. 25791.100, filed on 7/19/02, which is a continuation of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no.
  • Patent Number 6,497,289 which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (85) U.S. provisional patent application serial no. 60/412,177, attorney docket no. 25791.117, filed on 9/20/02, (86) U.S. provisional patent application serial no. 60/412,653, attorney docket no. 25791.118, filed on 9/20/02, (87) U.S. provisional patent application serial no. 60/405,610, attorney docket no. 25791.119, filed on 8/23/02, (88) U.S.
  • provisional patent application serial number 60/725181 attorney docket number 25791.184, filed on 10/11/2005
  • PCT patent application serial number PCT/US2005/023391 attorney docket number 25791.299.02 filed 6/29/2005 which claims priority from U.S. provisional patent application serial number 60/585370, attorney docket number 25791.299, filed on 7/2/2004
  • U.S. provisional patent application serial number 60/721579, attorney docket number 25791.327, filed on 9/28/2005 (156)
  • U.S. provisional patent application serial number 60/717391 attorney docket number 25791.214, filed on 9/15/2005
  • the surface-to-surface air tight metallic seal provided by the sleeves 40, 86 and 94 holds the sections together during the expansion process and increases the collapse strength of the casing sections. Also, the sleeves 40, 86 and 94 prevent, or at least reduce, crack propagation during the radial expansion and plastic deformation and provide fluid-tight, metai-to-metal seals between the interior surface of the sleeves and the exterior surfaces of the casing sections to prevent fluidic materials from passing through the threaded connections. Furthermore, following the radial expansion and plastic deformation of the casing sections, the sleeves 40, 86 and 94 are maintained in circumferential tension and the casing sections are maintained in circumferential compression, thus permitting axial and/or torque loads to be transmitted through the sleeves.
  • the thickness of the layer 126 or the layers 126a, 126b, 126c and 126d is calculated in order to fill the above gap before and after the radial expansion and plastic deformation of the casing sections 114 and 116 in accordance with one or more of the above techniques.
  • the lengths of the sleeves 40, 86 and 94 can vary.
  • the ridge rings 88a, 88b, and 88c can be formed on the casing section 82 rather than the casing section 80 and can take shapes and sizes other than that shown and described.
  • the number and thicknesses of the layers disposed in the gap between the threads can vary.
  • the sleeve 40 of the embodiment of Fig. 4-6, the sleeve 86 of the embodiment of Fig. 7, and/or the sleeve 94 of the embodiment of Fig. 8 can be used in one or more of the embodiments of Figs. 9-12.
  • the magnetic impulse energy apparatus 50 of the embodiments of Figs. 6 and 8 can be used in one or more of the embodiments of Figs. 7, and 9-12.
  • the magnetic impulse energy apparatus 50 of the embodiments of Figs. 6 and 8 can be used in one or more of the embodiments of Figs. 7, and 9-12.

Abstract

A method of forming a well bore casing for insertion in a well bore, according to which a first casing section is coupled to a second casing section and a seal is provided between the coupled portions of the sections.

Description

WELLBORE CASING AND METHOD OF FORMING SAME
Cross-Reference To Related Applications
[0001] The present application claims the benefit of the fling date of U.S. Application No. 11/538,228, attorney docket no. 25791.156, filed on 10/3/2006, which is a continuation-in- part of U.S. Application No.10/525,402, attorney docket no. 25791.120.05, filed on 2/23/2005, which is the National Stage patent application for PCT patent application serial number PCT/US2003/025676, attorney docket number 25791.120.02, filed on 08/18/2003, which claimed the benefit of the filing dates of (1) U.S. provisional patent application serial no. 60/405,394, attorney docket no 25791.120, filed on 8/23/2002, and co-pending US provisional patent application no. 60/405,610, attorney docket 29751.119, filed on 08/23/2002, the disclosure of which are incorporated herein by reference. [0002] This application is related to the following co-pending applications: (1) U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111,293, filed on 12/7/98, (2) U.S. patent application serial no. 09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, which claims priority from provisional application 60/121,702, filed on 2/25/99, (3) U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, now U.S. Patent 6,823,937 which issued 11/30/2004, which claims priority from provisional application 60/119,611 , filed on 2/11/99, (4) U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (5) U.S. patent application serial no. 10/169,434, attorney docket no. 25791.10.04, filed on 7/1/02, which claims priority from provisional application 60/183,546, filed on 2/18/00, (6) U.S. patent no. 6,640,903 which was filed as U.S. patent application serial no. 09/52-3,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (7) U.S. patent number 6,568,471, which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (8) U.S. patent number 6,575,240, which was filed as patent application serial no. 09/511 ,941 , attorney docket no. 25791.16.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,907, filed on 2/26/99, (9) U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (10) U.S. patent application serial no. 09/981 ,916, attorney docket no. 25791.18, filed on 10/18/01 as a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (11) U.S. patent number 6,604,763, which was filed as application serial no. 09/559,122, attorney docket no.
25791.23.02, filed on 4/26/2000, which claims priority from provisional application 60/131 ,106, filed on 4/26/99, (12) U.S. patent application serial no. 10/030,593, attorney docket no. 25791.25.08, filed on 1/8/02, which claims priority from provisional application 60/146,203, filed on 7/29/99, (13) U.S. provisional patent application serial no. 60/143,039, attorney docket no. 25791.26, filed on 7/9/99, (14) U.S. patent application serial no. 10/111,982, attorney docket no. 25791.27.08, filed on 4/30/02, which claims priority from provisional patent application serial no. 60/162,671 , attorney docket no. 25791.27, filed on
11/1/1999, (15) U.S. provisional patent application serial no. 60/154,047, attorney docket no. 25791.29, filed on 9/16/1999, (16) U.S. provisional patent application serial no. 60/438,828, attorney docket no. 25791.31 , filed on 1/9/03, (17) U.S. patent number 6,564,875, which was filed as application serial no. 09/679,907, attorney docket no. 25791.34.02, on 10/5/00, which claims priority from provisional patent application serial no. 60/159,082, attorney docket no. 25791.34, filed on 10/12/1999, (18) U.S. patent application serial no. 10/089,419, filed on 3/27/02, now U.S. Patent 6,695,012 which issued 2/24/2004, attorney docket no.
25791.36.03, which claims priority from provisional patent application serial no. 60/159,039, attorney docket no. 25791.36, filed on 10/12/1999, (19) U.S. patent application serial no. 09/679,906, filed on 10/5/00, attorney docket no. 25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (20) U.S. patent application serial no. 10/303,992, filed on 11/22/02, attorney docket no. 25791.38.07, which claims priority from provisional patent application serial no. 60/212,359, attorney docket no. 25791.38, filed on 6/19/2000, (21) U.S. provisional patent application serial no. 60/165,228, attorney docket no. 25791.39, filed on 11/12/1999, (22) U.S. provisional patent application serial no. 60/455,051 , attorney docket no. 25791.40, filed on 3/14/03, (23) PCT application US02/2477, filed on 6/26/02, attorney docket no. 25791.44.02, which claims priority from U.S. provisional patent application serial no. 60/303,711 , attorney docket no. 25791.44, filed on 7/6/01 , (24) U.S. patent application serial no. 10/311 ,412, filed on 12/12/02, attorney docket no. 25791.45.07, which claims priority from provisional patent application serial no. 60/221 ,443, attorney docket no. 25791.45, filed on 7/28/2000, (25) U.S. patent application serial no. 10/322947, filed on 12/18/02, attorney docket no. 25791.46.07, which claims priority from provisional patent application serial no. 60/221 ,645, attorney docket no. 25791.46, filed on 7/28/2000, (26) U.S. patent application serial no. 10/322,947, filed on 1/22/03, now U.S. Patent 6,976,541 which issued 12/20/2005, attorney docket no. 25791.47.07, which claims priority from provisional patent application serial no. 60/233,638, attorney docket no. 25791.47, filed on 9/18/2000, (27) U.S. patent application serial no. 10/406,648, filed on 3/31/03, attorney docket no. 25791.48.06, which claims priority from provisional patent application serial no. 60/237,334, attorney docket no. 25791.48, filed on 10/2/2000, (28) PCT application US02/04353, filed on 2/14/02, attorney docket no. 25791.50.02, which claims priority from U.S. provisional patent application serial no. 60/270,007, attorney docket no. 25791.50, filed on 2/20/2001 , (29) U.S. patent application serial no. 10/465,835, filed on 6/13/03, attorney docket no. 25791.51.06, which claims priority from provisional patent application serial no. 60/262,434, attorney docket no. 25791.51, filed on 1/17/2001, (30) U.S. patent application serial no. 10/465,831 , filed on 6/13/03, attorney docket no. 25791.52.06, which claims priority from U.S. provisional patent application serial no. 60/259,486, attorney docket no. 25791.52, filed on 1/3/2001 , (31) U.S. provisional patent application serial no. 60/452,303, filed on 3/5/03, attorney docket no. 25791.53, (32) U.S. patent number 6,470,966, which was filed as patent application serial number 09/850,093, filed on 5/7/01 , attorney docket no. 25791.55, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (33) U.S. patent number 6,561 ,227, which was filed as patent application serial number 09/852,026 , filed on 5/9/01 , attorney docket no. 25791.56, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (34) U.S. patent application serial number 09/852,027, filed on 5/9/01, attorney docket no. 25791.57, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (35) PCT Application US02/25608, attorney docket no. 25791.58.02, filed on 8/13/02, which claims priority from provisional application 60/318,021 , filed on 9/7/01, attorney docket no. 25791.58, (36) PCT Application US02/24399, attorney docket no. 25791.59.02, filed on 8/1/02, which claims priority from U.S. provisional patent application serial no. 60/313,453, attorney docket no. 25791.59, filed on 8/20/2001 , (37) PCT Application US02/29856, attorney docket no. 25791.60.02, filed on 9/19/02, which claims priority from U.S. provisional patent application serial no. 60/326,886, attorney docket no. 25791.60, filed on 10/3/2001, (38) PCT Application US02/20256, attorney docket no. 25791.61.02, filed on 6/26/02, which claims priority from U.S. provisional patent application serial no. 60/303,740, attorney docket no. 25791.61, filed on 7/6/2001 , (39) U.S. patent application serial no. 09/962,469, filed on 9/25/01 , now U.S. Patent 6892819 which issued 5/17/2005, attorney docket no. 25791.62, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (40) U.S. patent application serial no. 09/962,470, filed on 9/25/01 , attorney docket no. 25791.63, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (41) U.S. patent application serial no. 09/962,471, filed on 9/25/01 , now U.S. Patent 6,739,392 which issued 5/25/2004, attorney docket no. 25791.64, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (42) U.S. patent application serial no. 09/962,467, filed on 9/25/01, now U.S. Patent 6,725,919 which issued 4/27/2004, attorney docket no. 25791.65, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (43) U.S. patent application serial no. 09/962,468, filed on 9/25/01, now U.S. Patent 6,758,278 which issued 7/6/2004, attorney docket no. 25791.66, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (44) PCT application US 02/25727, filed on 8/14/02, attorney docket no. 25791.67.03, which claims priority from U.S. provisional patent application serial no. 60/317,985, attorney docket no. 25791.67, filed on 9/6/2001, and U.S. provisional patent application serial no. 60/318,386, attorney docket no. 25791.67.02, filed on 9/10/2001, (45) PCT application US 02/39425, filed on 12/10/02, attorney docket no. 25791.68.02, which claims priority from U.S. provisional patent application serial no. 60/343,674 , attorney docket no. 25791.68, filed on 12/27/2001 , (46) U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001, (now U.S. Patent 6,634,431 which issued 10/21/2003), which is a continuation-in- part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (47) U.S. utility patent application serial no. 10/516,467, now U.S. Patent No. 6745845 which issued 6/8/2004, attorney docket no. 25791.70, filed on 12/10/01 , which is a continuation application of U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001 , (now U.S. Patent 6,634,431 which issued 10/21/2003), which is a continuation-in- part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (48) PCT application US 03/00609, filed on 1/9/03, attorney docket no. 25791.71.02, which claims priority from U.S. provisional patent application serial no. 60/357,372 , attorney docket no. 25791.71 , filed on 2/15/02, (49) U.S. patent application serial no. 10/074,703, now U.S. Patent 6,705,395 which issued 3/16/2004, attorney docket no. 25791.74, filed on 2/12/02, which is a divisional of U.S. patent number 6,568,471, which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (50) U.S. patent application serial no. 10/074,244, attorney docket no. 25791.75, filed on 2/12/02, now U.S. Patent 6,631,759 which issued 10/14/2003, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (51) U.S. patent application serial no. 10/076,660, attorney docket no. 25791.76, filed on 2/15/02, which is a divisional of U.S. patent number 6,568,471, which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (52) U.S. patent application serial no. 10/076,661 , attorney docket no. 25791.77, filed on 2/15/02, now U.S. Patent 6,631 ,769 which issued 10/14/2003, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (53) U.S. patent application serial no. 10/076,659, attorney docket no. 25791.78, filed on 2/15/02, now U.S. Patent 7,063,142 which issued 6/20/2006, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (54) U.S. patent application serial no. 10/078,928, attorney docket no. 25791.79, filed on 2/20/02, now U.S. Patent 6,684,947 which issued 2/3/2004, which is a divisional of U.S. patent number 6,568,471, which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (55) U.S. patent application serial no. 10/078,922, attorney docket no. 25791.80, filed on 2/20/02, now U.S. Patent 6,966,370 which issued 11/22/2005, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841, filed on 2/26/99, (56) U.S. patent application serial no. 10/078,921 , attorney docket no. 25791.81 , filed on 2/20/02, now U.S. Patent 7,044,221 which issued 5/16/2006, which is a divisional of U.S. patent number 6,568,471, which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121,841, filed on 2/26/99, (57) U.S. patent application serial no. 10/261 ,928, attorney docket no. 25791.82, filed on 10/1/02, now U.S. Patent 7,011,161 which issued 3/14/2006, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (58) U.S. patent application serial no. 10/079,276, attorney docket no. 25791.83, filed on 2/20/02, now U.S. Patent 7,040,396 which issued 5/9/2006, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841, filed on 2/26/99, (59) U.S. patent application serial no. 10/262,009, attorney docket no. 25791.84, filed on 10/1/02, now U.S. 7048062 which issued 5/23/2006, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (60) U.S. patent application serial no. 10/092,481, attorney docket no. 25791.85, filed on 3/7/02, now U.S. Patent 6,857,473 which issued 2/22/2005, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121,841, filed on 2/26/99, (61) U.S. patent application serial no. 10/261,926, attorney docket no. 25791.86, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (62) PCT application US 02/36157, filed on 11/12/02, attorney docket no. 25791.87.02, which claims priority from U.S. provisional patent application serial no. 60/338,996, attorney docket no. 25791.87, filed on 11/12/01 , (63) PCT application US 02/36267, filed on 11/12/02, attorney docket no. 25791.88.02, which claims priority from U.S. provisional patent application serial no. 60/339,013, attorney docket no. 25791.88, filed on 11/12/01 , (64) PCT application US 03/11765, filed on 4/16/03, attorney docket no. 25791.89.02, which claims priority from U.S. provisional patent application serial no. 60/383,917, attorney docket no. 25791.89, filed on 5/29/02, (65) PCT application US 03/15020, filed on 5/12/03, attorney docket no. 25791.90.02, which claims priority from U.S. provisional patent application serial no. 60/391 ,703, attorney docket no. 25791.90, filed on 6/26/02, (66) PCT application US 02/39418, filed on 12/10/02, attorney docket no. 25791.92.02, which claims priority from U.S. provisional patent application serial no. 60/346,309, attorney docket no. 25791.92, filed on 1/7/02, (67) PCT application US 03/06544, filed on 3/4/03, attorney docket no. 25791.93.02, which claims priority from U.S. provisional patent application serial no. 60/372,048, attorney docket no. 25791.93, filed on 4/12/02, (68) U.S. patent application serial no. 10/331 ,718, attorney docket no. 25791.94, filed on 12/30/02, which is a divisional U.S. patent application serial no. 09/679,906, filed on 10/5/00, attorney docket no. 25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (69) PCT application US 03/04837, filed on 2/29/03, attorney docket no. 25791.95.02, which claims priority from U.S. provisional patent application serial no. 60/363,829, attorney docket no. 25791.95, filed on 3/13/02, (70) U.S. patent application serial no. 10/261 ,927, attorney docket no. 25791.97, filed on 10/1/02, now U.S. Patent 7077213 which issued 7/18/2006, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (71) U.S. patent application serial no. 10/262,008, attorney docket no. 25791.98, filed on 10/1/02, now U.S. Patent 7,036,582 which issued 5/2/2006, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (72) U.S. patent application serial no. 10/261 ,925, attorney docket no. 25791.99, filed on 10/1/02, now U.S. Patent 7,044,218 which issued 5/16/2006, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (73) U.S. patent application serial no. 10/199,524, attorney docket no. 25791.100, filed on 7/19/02, which is a continuation of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (74) PCT application US 03/10144, filed on 3/28/03, attorney docket no. 25791.101.02, which claims priority from U.S. provisional patent application serial no. 60/372,632, attorney docket no. 25791.101 , filed on 4/15/02, (75) U.S. provisional patent application serial no. 60/412,542, attorney docket no. 25791.102, filed on 9/20/02, (76) PCT application US 03/14153, filed on 5/6/03, attorney docket no. 25791.104.02, which claims priority from U.S. provisional patent application serial no. 60/380,147, attorney docket no. 25791.104, filed on 5/6/02, (77) PCT application US 03/19993, filed on 6/24/03, attorney docket no. 25791.106.02, which claims priority from U.S. provisional patent application serial no. 60/397,284, attorney docket no. 25791.106, filed on 7/19/02, (78) PCT application US 03/13787, filed on 5/5/03, attorney docket no. 25791.107.02, which claims priority from U.S. provisional patent application serial no. 60/387,486, attorney docket no. 25791.107, filed on 6/10/02, (79) PCT application US 03/18530, filed on 6/11/03, attorney docket no. 25791.108.02, which claims priority from U.S. provisional patent application serial no. 60/387,961, attorney docket no. 25791.108, filed on 6/12/02, (80) PCT application US 03/20694, filed on 7/1/03, attorney docket no. 25791.110.02, which claims priority from U.S. provisional patent application serial no. 60/398,061 , attorney docket no. 25791.110, filed on 7/24/02, (81) PCT application US 03/20870, filed on 7/2/03, attorney docket no. 25791.111.02, which claims priority from U.S. provisional patent application serial no. 60/399,240, attorney docket no. 25791.111, filed on 7/29/02, (82) U.S. provisional patent application serial no. 60/412,487, attorney docket no. 25791.112, filed on 9/20/02, (83) U.S. provisional patent application serial no. 60/412,488, attorney docket no. 25791.114, filed on 9/20/02, (84) U.S. patent application serial no. 10/280,356, attorney docket no. 25791.115, filed on 10/25/02, which is a continuation of U.S. patent number 6,470,966, which was filed as patent application serial number 09/850,093, filed on 5/7/01 , attorney docket no. 25791.55, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (85) U.S. provisional patent application serial no. 60/412,177, attorney docket no. 25791.117, filed on 9/20/02, (86) U.S. provisional patent application serial no. 60/412,653, attorney docket no. 25791.118, filed on 9/20/02, (87) U.S. provisional patent application serial no. 60/405,610, attorney docket no. 25791.119, filed on 8/23/02, (88) U.S. provisional patent application serial no. 60/405,394, attorney docket no. 25791.120, filed on 8/23/02, (89) U.S. provisional patent application serial no. 60/412,544, attorney docket no. 25791.121 , filed on 9/20/02, (90) PCT application US 03/24779, filed on 8/8/03, attorney docket no. 25791.125.02, which claims priority from U.S. provisional patent application serial no. 60/407,442, attorney docket no. 25791.125, filed on 8/30/02, (91) U.S. provisional patent application serial no. 60/423,363, attorney docket no. 25791.126, filed on 12/10/02, (92) U.S. provisional patent application serial no. 60/412,196, attorney docket no. 25791.127, filed on 9/20/02, (93) U.S. provisional patent application serial no. 60/412,187, attorney docket no. 25791.128, filed on 9/20/02, (94) U.S. provisional patent application serial no. 60/412,371 , attorney docket no. 25791.129, filed on 9/20/02, (95) U.S. patent application serial no. 10/382,325, attorney docket no. 25791.145, filed on 3/5/03, which is a continuation of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (96) U.S. patent application serial no. 10/624,842, attorney docket no. 25791.151 , filed on 7/22/03, which is a divisional of U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, now U.S. Patent 6,823,937 which issued 11/30/2004, which claims priority from provisional application 60/119,611 , filed on 2/11/99, (97) U.S. provisional patent application serial no. 60/431 ,184, attorney docket no. 25791.157, filed on 12/5/02, (98) U.S. provisional patent application serial no. 60/448,526, attorney docket no. 25791.185, filed on 2/18/03, (99) U.S. provisional patent application serial no. 60/461 ,539, attorney docket no. 25791.186, filed on 4/9/03, (100) U.S. provisional patent application serial no. 60/462,750, attorney docket no. 25791.193, filed on 4/14/03, (101) U.S. provisional patent application serial no. 60/436,106, attorney docket no. 25791.200, filed on 12/23/02, (102) U.S. provisional patent application serial no. 60/442,942, attorney docket no. 25791.213, filed on 1/27/03, (103) U.S. provisional patent application serial no. 60/442,938, attorney docket no. 25791.225, filed on 1/27/03, (104) U.S. patent application serial no. 10/418,687, attorney docket no. 25791.228, filed on 4/18/03, now U.S. Patent 7,021,390 which issued 4/4/2006, (105) U.S. provisional patent application serial no. 60/454,896, attorney docket no. 25791.236, filed on 3/14/03, (106) U.S. provisional patent application serial no. 60/450,504, attorney docket no. 25791.238, filed on 2/26/03, (107) U.S. provisional patent application serial no. 60/451,152, attorney docket no. 25791.239, filed on 3/9/03, (108) U.S. provisional patent application serial no. 60/455,124, attorney docket no. 25791.241 , filed on 3/17/03, (109) U.S. provisional patent application serial no. 60/453,678, attorney docket no. 25791.253, filed on 3/11/03, (110) U.S. patent application serial no. 10/421 ,682, attorney docket no. 25791.256, filed on 4/23/03, which is a continuation of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (111) U.S. provisional patent application serial no. 60/457,965, attorney docket no. 25791.260, filed on 3/27/03, (112) U.S. provisional patent application serial no. 60/455,718, attorney docket no. 25791.262, filed on 3/18/03, (113) U.S. patent number 6,550,821 , which was filed as patent application serial no. 09/81 1 ,734, filed on 3/19/01 , (114) U.S. patent application serial no. 10/436,467, attorney docket no. 25791.268, filed on 5/12/03, now U.S. Patent 6,968,618 which issued 11/29/2005, which is a continuation of U.S. patent number 6,604,763, which was filed as application serial no. 09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, which claims priority from provisional application 60/131 ,106, filed on 4/26/99, (115) U.S. provisional patent application serial no. 60/459,776, attorney docket no. 25791.270, filed on 4/2/03, (116) U.S. provisional patent application serial no. 60/461 ,094, attorney docket no. 25791.272, filed on 4/8/03, (117) U.S. provisional patent application serial no. 60/461 ,038, attorney docket no. 25791.273, filed on 4/7/03, (118) U.S. provisional patent application serial no. 60/463,586, attorney docket no. 25791.277, filed on 4/17/03, (119) U.S. provisional patent application serial no. 60/472,240, attorney docket no. 25791.286, filed on 5/20/03, (120) U.S. patent application serial no. 10/619,285, attorney docket no. 25791.292, filed on 7/14/03, which is a continuation-in-part of U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001 , (now U.S. Patent 6,634,431 which issued 10/21/2003), which is a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (121) U.S. utility patent application serial no. 10/418,688, attorney docket no. 25791.257, now U.S. Patent 7,055,608 which issued 6/6/2006, which was filed on 4/18/03, as a division of U.S. utility patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99; (122) PCT patent application serial no. PCT/US2004/06246, attor ney docket no. 25791.238.02, filed on 2/26/2004; (123) PCT patent application serial number PCT/US2004/08170, attorney docket number 25791.40.02, filed on 3/15/04; (124) PCT patent application serial number PCT/US2004/08171 , attorney docket number 25791.236.02, filed on 3/15/04; (125) PCT patent application serial number PCT/US2004/08073, attorney docket number 25791.262.02, filed on 3/18/04; (126) PCT patent application serial number PCT/US2004/07711 , attorney docket number 25791.253.02, filed on 3/11/2004; (127) PCT patent application serial number PCT/US2004/029025, attorney docket number 25791.260.02, filed on 3/26/2004; (128) PCT patent application serial number PCT/US2004/010317, attorney docket number 25791.270.02 , filed on 4/2/2004; (129) PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/6/2004; (130) PCT patent application serial number PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004; (131) PCT patent application serial number PCT/US2004/011973, attorney docket number 25791.277.02, filed on 4/15/2004; (132) U.S. provisional patent application serial number 60/495056, attorney docket number 25791.301, filed on 8/14/2003; (133) U.S. provisional patent application serial number 60/600679, attorney docket number 25791.194, filed on 8/11/2004; (134) PCT patent application serial number PCT/US2005/027318, attorney docket number 25791.329.02, filed on 7/29/2005; (135) PCT patent application serial number PCT/US2005/028936, attorney docket number 25791.338.02, filed on 8/12/2005; (136) PCT patent application serial number PCT/US2005/028669, attorney docket number 25791.194.02, filed on 8/11/2005; (137) PCT patent application serial number PCT/US2005/028453, attorney docket number 25791.371, filed on 8/11/2005; (138) PCT patent application serial number PCT/US2005/028641, attorney docket number 25791.372, filed on 8/11/2005; (139) PCT patent application serial number PCT/US2005/028819, attorney docket number 25791.373, filed on 8/11/2005; (140) PCT patent application serial number PCT/US2005/028446, attorney docket number 25791.374, filed on 8/11/2005; (141) PCT patent application serial number PCT/US2005/028642, attorney docket number 25791.375, filed on 8/11/2005; (142) PCT patent application serial number PCT/US2005/028451 , attorney docket number 25791.376, filed on 8/11/2005, and (143). PCT patent application serial number PCT/US2005/028473, attorney docket number 25791.377, filed on 8/11/2005, (144) U.S. utility patent application serial number 10/546082, attorney docket number 25791.378, filed on 8/16/2005, (145) U.S. utility patent application
IO serial number 10/546076, attorney docket number 25791.379, filed on 8/16/2005, (146) U.S. utility patent application serial number 10/545936, attorney docket number 25791.380, filed on 8/16/2005, (147) U.S. utility patent application serial number 10/546079, attorney docket number 25791.381 , filed on 8/16/2005 (148) U.S. utility patent application serial number 10/545941, attorney docket number 25791.382, filed on 8/16/2005, (149) U.S. utility patent application serial number 546078, attorney docket number 25791.383, filed on 8/16/2005, filed on 8/11/2005., (150) U.S. utility patent application serial number 10/545941 , attorney docket number 25791.185.05, filed on 8/16/2005, (151) U.S. utility patent application serial number 11/249967, attorney docket number 25791.384, filed on 10/13//2005, (152) U.S. provisional patent application serial number 60/734302, attorney docket number 25791.24, filed on 11/7/2005, (153) U.S. provisional patent application serial number 60/725181, attorney docket number 25791.184, filed on 10/11/2005, (154) PCT patent application serial number PCT/US2005/023391 , attorney docket number 25791.299.02 filed 6/29/2005 which claims priority from U.S. provisional patent application serial number 60/585370, attorney docket number 25791.299, filed on 7/2/2004, (155) U.S. provisional patent application serial number 60/721579, attorney docket number 25791.327, filed on 9/28/2005, (156) U.S. provisional patent application serial number 60/717391 , attorney docket number 25791.214, filed on 9/15/2005, (157) U.S. provisional patent application serial number 60/702935, attorney docket number 25791.133, filed on 7/27/2005, (158) U.S. provisional patent application serial number 60/663913, attorney docket number 25791.32, filed on 3/21/2005, (159) U.S. provisional patent application serial number 60/652564, attorney docket number 25791.348, filed on 2/14/2005, (160) U.S. provisional patent application serial number 60/645840, attorney docket number 25791.324, filed on 1/21/2005, (161) PCT patent application serial number PCT/US2005/043122, attorney docket number 25791.326.02, filed on 11/29/2005 which claims priority from U.S. provisional patent application serial number 60/631703, attorney docket number 25791.326, filed on 11/30/2004, (162) U.S. provisional patent application serial number 60/752787, attorney docket number 25791.339, filed on 12/22/2005, (163) U.S. National Stage application serial no. 10/548934, attorney docket no.
25791.253.05, filed on 9/12/2005; (164) U.S. National Stage application serial no. 10/549410, attorney docket no. 25791.262.05, filed on 9/13/2005; (165) U.S. Provisional Patent Application No. 60/717391 , attorney docket no. 25791.214 filed on 9/15/2005; (166) U.S. National Stage application serial no. 10/550906, attorney docket no. 25791.260.06, filed on 9/27/2005; (167) U.S. National Stage application serial no. 10/551880, attorney docket no.
25791.270.06, filed on 9/30/2005; (168) U.S. National Stage application serial no. 10/552253, attorney docket no. 25791.273.06, filed on 10/4/2005; (169) U.S. National Stage application serial no. 10/552790, attorney docket no. 25791.272.06, filed on 10/11/2005; (170) U.S. Provisional Patent Application No. 60/725181 , attorney docket no. 25791.184 filed
I l on 10/11/2005; (171) U.S. National Stage application serial no. 10/553094, attorney docket no. 25791.193.03, filed on 10/13/2005; (172) U.S. National Stage application serial no. 10/553566, attorney docket no. 25791.277.06, filed on 10/17/05; (173) PCT Patent Application No. PCT/US2006/002449, attorney docket no. 25791.324.02 filed on 1/20/06, (174) PCT Patent Application No. PCT/US2006/004809, attorney docket no. 25791.348.02 filed on 2/9/06; (175) U.S. Utility Patent application serial no. 11/356899, attorney docket no. 25791.386, filed on 2/17/06, (176) U.S. National Stage application serial no. 10/568200, attorney docket no. 25791.301.06, filed on 2/13/2006, (177) U.S. National Stage application serial no. 10/568719, attorney docket no. 25791.137.04, filed on 2/16/06, filed on 2/16/06, (178) U.S. National Stage application serial no. 10/569323, attorney docket no. 25791.215.06, filed on 2/17/06, (179) U.S. National State patent application serial no. 10/571041 , attorney docket no. 25791.305.05, filed on 3/3/06; (180) U.S. National State patent application serial no. 10/571017, attorney docket no. 25791.306.04, filed on 3/3/06; (181) U.S. National State patent application serial no. 10/571086, attorney docket no. 25791.307.04, filed on 3/6/06; and (182) U.S. National State patent application serial no. 10/571085, attorney docket no. 25791.308.07, filed on 3/6/06, (183) U.S. utility patent application serial number 10/938788, attorney docket number 25791.330, filed on 9/10/04, (184) U.S. utility patent application serial number 10/938225, attorney docket number 25791.331 , filed on 9/10/04, (185) U.S. utility patent application serial number 10/952288, attorney docket number 25791.332, filed on 9/28/04, (186) U.S. utility patent application serial number 10/952416, attorney docket number 25791.333, filed on 9/28/04, (187) U.S. utility patent application serial number 10/950749, attorney docket number 25791.334, filed on 9/27/04, (188)U.S. utility patent application serial number 10/950869, attorney docket number 25791.335, filed on 9/27/04; (189) U.S. provisional patent application serial number 60/761324, attorney docket number 25791.340, filed on 1/23/06, (190) U.S. provisional patent application serial number 60/754556, attorney docket number 25791.342, filed on 12/28/05, (191) U.S. utility patent application serial number 11/380051 , attorney docket number 25791.388, filed on 4/25/06, (192) U.S. utility patent application serial number 11 /380055, attorney docket number 25791.389, filed on 4/25/06, (193) U.S. utility patent application serial number 10/522039, attorney docket number 25791.106.05, filed on 3/10/2006; (194) U.S. provisional patent application serial number 60/746,813, attorney docket number 25791.259, filed on 5/9/2006; (195) U.S. utility patent application serial number 11/456584, attorney docket number 25791.403, filed on 7/11/2006; and (196) U.S. utility patent application serial number 11/456587, attorney docket number 25791.404, filed on 7/11/2006; (197) PCT Patent Application No. PCT/US2006/009886, attorney docket no. 25791.32.02 filed on 3/21/2006; (198) PCT Patent Application No. PCT/US2006/010674, attorney docket no. 25791.337.02 filed on 3/21/2006; (199) U.S. Patent 6,409,175 which issued 6/25/2002, attorney docket no. 25791.159; (200) U.S. Patent 6,550,821 which issued 4/22/2003, attorney docket no. 25791.263; (201) U.S. Patent Application No. 10/767,953, filed 1/29/2004, attorney docket no. 25791.309, now U.S. Patent 7077211 which issued 7/18/2006; (202) U.S. Patent Application No. 10/769,726, filed 1/30/2004, attorney docket no. 25791.310; (203) U.S. Patent Application No. 10/770363 filed 2/2/2004, attorney docket no. 25791.311 ; (204) U.S. utility patent application serial no. 11/068,595, attorney docket no. 25791.349, filed on 2/28/2005; (205) U.S. utility patent application serial no. 11/070,147, attorney docket no. 25791.351 , filed on 3/2/2005; (206) U.S. utility patent application serial no. 11/071 ,409, attorney docket no. 25791.352, filed on 3/2/2005; (207) U.S. utility patent application serial no. 11/071 ,557, attorney docket no. 25791.353, filed on 3/3/2005; (208) U.S. utility patent application serial no. 11/072,578, attorney docket no. 25791.354, filed on 3/4/2005; (209) U.S. utility patent application serial no. 11/072,893, attorney docket no. 25791.355, filed on 3/4/2005; (210) U.S. utility patent application serial no. 11/072,594, attorney docket no. 25791.356, filed on 3/4/2005; (211) U.S. utility patent application serial no. 11/074,366, attorney docket no. 25791.357, filed on 3/7/2005; and (212) U.S. utility patent application serial no. 11/074,266, attorney docket no. 25791.358, filed on 3/7/2005.
Background of the Invention
[0003] This invention relates generally to oil and gas exploration, and in particular to forming a well bore casing from a series of casing sections to facilitate oil and gas recovery. [0004] During oil exploration, a well bore typically traverses a number of zones within a subterranean formation. Well bore casings are often formed in the well bore by a series of casing sections that are coupled to one another, usually by threaded connections. In many of these installations the coupled casing sections are plastically deformed and radially expanded to the inner wall of the well bore.
[0005] However, the coupling between the threaded connections is often insufficient to permit the transmission of energy through the casing sections from the surface to the downhole location. Also, the threads of the threaded connections are easily damaged and, as such, may permit undesirable leakage between the inside of the casing and the exterior of the casing. Further, if the connected casing sections are radially expanded and plastically deformed, the threaded connections can be compromised during the expansion process. [0006] The present invention is directed to overcoming the above problems.
Brief Description of the Drawings
[0007] Fig. 1 is a fragmentary cross-sectional schematic illustration of a casing section disposed in a well bore.
[0008] Fig. 2 is a fragmentary cross-sectional schematic illustration of the casing section of Fig. 1 , along with an aligned additional casing section. [0009] Fig. 3 is a fragmentary cross-sectional schematic illustration of the casing sections of Fig. 2 in a threaded, coupled engagement.
[00010] Fig. 4 is a view similar to that of Fig. 3, but depicting a sleeve surrounding portions of the casing sections.
[0010] Fig. 5 is a view similar to that of Fig. 4, but depicting a magnetic impulse apparatus associated with the components of Fig. 4.
[0011] Fig. 6 is a view similar to that of Fig. 5, but depicting the magnetic flux and resultant force fields generated by the magnetic impulse apparatus of Fig. 5.
[0012] Figs. 7-9 are views similar to that of Fig. 4 but depicting alternate embodiments of the assembly of Fig. 4.
[0013] Fig. 10 is a partial sectional view of an alternate embodiment of a component of the embodiment of Fig. 9.
[0014] Figs. 11 and 12 are views similar to that of Fig. 3 but depicting alternate embodiments of the assembly of Fig. 3,
Detailed Description
[0015] Referring to Fig. 1 , the reference numeral 10 refers to a well bore 10 that traverses a subterranean formation 12. A tubular casing section 14 is positioned within the well bore 10 and is shown partially for the convenience of presentation. As shown in Fig. 2, a tubular casing section 16 is also positioned in the bore and is adapted to be coupled to the casing section 14. To this end, the inner wall of an end portion of the casing section 14 is provided with threads 22, and the outer surface of the corresponding end portion of the casing section 16 is provided with complementary threads 24. Thus, the sections 14 and 16 can be threadedly engaged by applying torque to one member and rotating it in the proper direction relative to the other member. A small groove 16a is formed in the outer surface of the casing section 16 between the uppermost thread 24 and the non-threaded portion of the member, for reasons to be described. The outer diameter of the casing section 14 is the same, or substantially the same, as the outer diameter of the non-threaded portion of the casing section 16.
[0016] In the coupled position of the sections 14 and 16 shown in Fig. 3, a channel 30 is defined by the groove 16a (Fig. 2) and the corresponding end of the casing section 14. [0017] Referring to Fig. 4, a sleeve 40 overlaps a portion of the coupled portions of the sections 14 and 16, as well as a portion of the casing section 16 extending adjacent the threads 24. The sleeve 40 is preferably fabricated from electrically conductive material that is suitably malleable or flowable so that it can be shaped mechanically. Examples of such a material are copper, aluminum, light metal, metal alloys, and steel alloys, it being understood that other metal alloys with suitable electrical conductivity and with suitable malleability or suitable flow behavior may also be used. [0018] The inside diameter of the sleeve 40 is slightly larger than the outside diameters of the sections 14 and 16 so that a cylindrical gap 44 is formed between the sleeve 40 and the sections 14 and 16, respectively. The radial thickness of the sleeve 40 is less than the radial thickness of each casing section 14 and 16.
[0019] As shown in Fig. 5, a magnetic impulse energy apparatus 50 is provided and includes an impulse conductor ring 52 extending around the sleeve 40 and having an axial dimension slightly greater than that of the sleeve. The inside diameter of the ring 52 is slightly larger than the outside diameter of the sleeve 40, thereby defining a cylindrical gap 56 therebetween. The ring 52 is operatively connected to an impulse generator 54, such that magnetic impulse power flows from the generator and circumferentially around the ring. The impulse generator is conventional and is disclosed generally (but not in the context of the present invention), for example, in U. S. Patent 5,444,963; U. S. Patent 5,586,460; U. S. Patent 5,953,805, as well as on the web page of Magnetic-Physics, Inc. (http://www.magnet- physics.com/st_magnetopuls,html), the disclosures of which are incorporated by reference. [0020] Fig. 6 is similar to that of Fig. 5 but depicts the magnetic fields generated by the apparatus 50 and applied to the structure of Fig. 5. In particular, the impulse generator 54 provides a magnetic impulse to the conductor ring 52, causing a magnetic field 60 to be produced and simultaneously cause a counter-current magnetic pulse 62 to be produced that extends into the sleeve 40. An extremely high concentration of magnetic flux 64 extends in the gap 56 between the sleeve 40 and the ring 52 and generates a relatively large force field F that is directed radially inwardly from the ring 52 towards the sleeve 40. The force field F collapses the sleeve 40 onto the corresponding portions of the sections 14 and 16. As the force field F continues to increase, the malleable material of the sleeve 40 melts and flows around the joint between the interlocked sections 14 and 16 and into the channel 30. This produces a surface-to-surface air tight metallic seal entirely over the threaded coupling between the sections 14 and 16 that aids in retaining the members together. [0021] In addition to providing the sealing functions discussed above, the sleeve 40 protects the corresponding exterior surfaces of the tubular sections 14 and 16 during handling and insertion of the members within the well bore 10. In this manner, extensive damage to the exterior surfaces of the tubular sections 14 and 16 is prevented that could otherwise cause stress concentrations that could result in a catastrophic failure, especially during subsequent radial expansion operations that are described below. Also, misalignment that could result in damage to the threads 22 and 24 is avoided, or at least reduced. In addition, the sleeve 40 provides a significant resistance to any relative rotation between the coupled tubular sections 14 and 16. The sleeve 40 may also provide an indication of the quality of the threaded coupling between the sections 14 and 16. For example, if the sleeve 40 can be easily rotated, that would indicate that the first and second casing sections, 14 and
16, are not adequately coupled.
[0022] According to the embodiment of Fig. 7, two tubular casing sections 80 and 82 are provided that are similar to the sections 14 and 16 of the previous embodiments, but vary to the extent that the threads formed on the latter members are eliminated and a different interlocking system is provided.
[0023] In particular, the casing section 80 is provided with a stepped inner diameter that defines an end portion 80a having a larger inner diameter than that of the remaining portion of the member. Similarly, the casing section 82 is provided with a stepped outer diameter that defines an end portion 82a having a smaller outer diameter than that of the remaining portion of the member.
[0024] Three axially-spaced, raised ridge rings 84a, 84b, and 84c extend radially from the portion 80a of the member 80, and a series of corresponding grooves are formed in the member 80b that are located and sized so as to receive the respective rings.
[0025] To couple the sections 80 and 82, the end portion 82a is placed in the end portion
80a with the end portions flexing slightly to permit the rings 84a, 84b and 84c in the portion
80a to extend into their respective grooves in the portion 82a. In this coupled position, a gap
84 is defined between the end of the portion 80a and the shoulder defined by the end portion
82a.
[0026] A sleeve 86, which is identical to the sleeve 40 of the previous embodiment except for size, extends over the interlocked portions 80a and 82a. The axial length of the sleeve 86 is slightly greater than that of the interlocked portions 80a and 82a so as to extend around a portion of the sections 80 and 82 adjacent the interlocked portions. The inner diameter of the sleeve 86 extends around the sections 14 and 16 with minimum clearance to provide sealing and to force the portions 80a and 82a into their interlocking relationship. The radial thickness of the sleeve 86 is less than the radial thickness of the casing section 14 and the casing section 16.
[0027] It is understood that the magnetic impulse energy apparatus 50 of Figs. 5 and 6 can be applied to the arrangement of Fig. 7 in the same manner as discussed above, so as to develop the magnetic flux and the force fields described above. Thus, when the force field is sufficiently high, the malleable material of the sleeve 86 melts and flows around the joint between the sections 80 and 82 and into the gap 84. This produces a surface-to-surface air tight metallic seal entirely over the coupling between the sections 80 and 82 that aids in retaining the members together. The use of the sleeve 86 thus also provides the advantages of the sleeve 40 of the previous embodiment.
[0028] According to the embodiment of Fig. 8, two tubular casing sections 90 and 92 are provided that are similar to the tubular sections 14 and 16 of the embodiments of Figs. 1-6, but vary to the extent that the threads formed on the latter members are eliminated and a different interlocking system is provided.
[0029] In particular, the tubular section 90 is provided with a stepped inner diameter that defines an end portion 90a having a larger inner diameter than that of the remaining portion of the member. Similarly, the tubular section 92 is provided with a stepped outer diameter that defines an end portion 92a having a smaller outer diameter than that of the remaining portion of the member.
[0030] A sleeve 94, which is identical to the sleeves 40 and 86 of the previous embodiments except for size, extends within interlocked portions 90a and 92a in a coaxial relationship. The axial length of the sleeve 94 is greater than that of the interlocked portions 90a and 92a, and the outer diameter of the sleeve 94 is less than the inner diameters of the sections 90 and 92 so as to define a cylindrical gap 96. The radial thickness of the sleeve 94 is less than the radial thickness of the section 90 and the member 92. [0031] The magnetic impulse energy apparatus 50 of the embodiment of Figs. 5 and 6 is provided within the sleeve 94 so as to develop the magnetic flux and the force fields discussed in the latter embodiment. In particular, the ring 52 of the apparatus 50 is less than the inner diameter of the sleeve 94 so as to define a cylindrical gap 98. As in the previous embodiment, the magnetic impulse generator 54 is operatively connected to the ring 52. [0032] In operation, the generator 54 provides a magnetic pulse to the conductor ring 52, causing a magnetic field to be produced and simultaneously causing a counter-current magnetic pulse to be produced that extends into the sleeve 94. An extremely high concentration of magnetic flux thus enters the gap 98 between the sleeve 94 and the ring 52 and generates a relatively large force field that is directed radially outwardly from the ring 52 towards the sleeve 94, thereby expanding the sleeve across the gap 96 and into engagement with the inner surfaces of the coupled sections 90 and 92. This forms sealing interfaces between the outside surfaces of the sleeve 94 and the corresponding inner surfaces of the sections 90 and 92. As the force field increases, the malleable material of the sleeve 94 melts and flows over the corresponding surfaces of the sections 90 and 92 to produce a surface-to-surface air tight metallic seal entirely over the coupled sections 90 and 92 that aids in retaining the members together.
[0033] Referring to the embodiment of Figs. 9 and 10, two tubular casing sections 114 and 116 are positioned within the well bore 10, and are shown partially for the convenience of presentation. A series of threads 122 are provided on the inner surface of the end portion of the member 114, and complementary threads 124 are formed on the outer surface of the corresponding end portion of the casing section 116. The threads 122 and 124 are sized so that a gap is formed when they are engaged, and a layer 126, of a material to be described, is disposed in the gap. [0034] It is understood that, prior to coupling the sections 114 and 116, the layer 126 can be attached to either the threads 122 or the threads 124 in any conventional manner such as by deposition, or the like.
[0035] The material forming the layer 126 is preferably a material that is softer than the sections 114 and 116, and examples include plastic or metals such as copper, zinc, cadmium, tin and alloy. Alternately, the layer 126 can be formed of an exothermic alloy material having a low melting temperature during joining and a much higher temperature after solidification of the solid joint as a result of plastic deformation, stress and/or temperature.
[0036] The above gap between the teeth 122 and 124 can be filled by a single layer 126 or by two or more multiple, stacked, abutting layers. In the latter context, Fig. 10 depicts an example in which four stacked abutting layers 126a, 126b, 126c, and 126d are provided in the gap. Each layer can be identical to the layer 126 with the exceptions noted below. [0037] One or more of the layers 126a, 126b, 126c, and 126d can be different from the remaining layers. For example, one or more of the layers 126a, 126b, 126c, and 126d can have a different modulus of elasticity and, as such, can be fabricated of a different material, than the others. Thus, the layer 126a, for example, could be fabricated from a relatively soft material such as copper, and the layer 126b could be fabricated from a relatively hard material, such cadmium. In this case, the copper layer 126a would plastically deform to seal along the entire joint surface and the cadmium layer 126b would provide a micro-sealing layer. Also, one or both of the other layers 126c and 12δd could have a different modulus of elasticity and form another micro-seal.
[0038] Also, the layer 126, and/or one or both of the layers 12δa and 126d could be in the form of flux that melts when heated and bonds to the adjacent threads 122 and 124 to form a relatively strong soldered joint having a relatively high melting temperature. Further, the layer 126 and/or one or more of the layers 126a, 126b, 126c, and 126d could be of a material that has a relatively low initial melting point during any deformation and/or or heating, and has a higher melting point after the deformation and/or heating.
[0039] Further, the layer 126 and/or one or more of the layers 126a, 126b, 126c, and 126d may be of an exothermic material that initially releases energy upon stress or heat input thereby melting or plastically flowing at one temperature, and, subsequently, without the further release of such heat energy having a higher melting point or plastic flow temperature. [0040] According to another embodiment, the layer 126, and/or one or more of the layers 126a, 126b, 126c, and 12δd can be fabricated of a reactive bonding agent that, when reacted, forms a seal and bond between the sections 114 and 116. The bonding agent can be reacted in several manners to form the seal and the bond. For example, the bonding agent can be reacted by the pressure and/or heat when the connection is made and/or when
I S torque is applied to the connection. Also, the increase of pressure and/or temperature when running the casing sections 114 and 116 into the well can cause the bonding agent to react. Further, a downhole tool could be used to excite the bonding agent downhole. Still further, a protective layer could be placed over the bonding agent to protect it from air, water, etc. and couid later be removed using the makeup and/or torque of the connection, so that air, water, or any of the above techniques could then be used to react the bonding agent. Since the bonding agent is conventional, it will not be described in detail.
[0041] It is understood that the sleeve 40 of the embodiment of Figs. 4-6, the sleeve 86 of the embodiment of Fig. 7, or the sleeve 94 of the embodiment of Fig. 8 could be placed around the coupled sections 114 and 116 and function in the same manner as described above.
[0042] According to the embodiment of Fig. 11 , two tubular casing sections 130 and 132 are positioned within the well bore 10 and are shown partially for the convenience of presentation. An end portion 130a of the section 130 is tapered in a radial direction along its axial length, and the corresponding end portion 132a of the section 132 is flared outwardly to a degree that the inner surface of the flared end portion can engage the tapered outer surface of the end portion 130a to define an interface along which a material 136 is disposed. The material 136 can be of a type that flashes at a certain elevated temperate that can be achieved when the casing sections 130 and 132 are rotated relative to each other. [0043] According to the embodiment of Fig. 12, two tubular casing sections 140 and 142 are positioned within the well bore 10, and are shown partially for the convenience of presentation. An end portion 140a of the casing section 140 is tapered in a radial direction along its axial length, and the corresponding end portion 142a of the casing section 142 is flared outwardly.
[0044] A series of threads 146 are provided on the outer surface of the end portion 140a, and a series of corresponding threads 148 are provided on the inner surface of the flared portion 142a. The threads 146 and 148 are in threaded engagement to couple the members 140 and 142. It is understood that, as an option, the material 140 of the previous embodiment can be placed between the engaging threads 146 and 148 and functions in the same manner as described above.
[0045] In each of the above embodiments, the coupled casing sections can be radially expanded and plastically deformed in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (2) U.S. patent application serial no. 09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, which claims priority from provisional application 60/121 ,702, filed on 2/25/99, (3) U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, which claims priority from provisional application 60/119,611 , filed on 2/11/99, (4) U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (5) U.S. patent application serial no. 10/169,434, attorney docket no. 25791.10.04, filed on 7/1/02, which claims priority from provisional application 60/183,546, filed on 2/18/00, (6) U.S. patent no. 6,640,903 which was filed as U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (7) U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (8) U.S. patent number 6,575,240, which was filed as patent application serial no. 09/511 ,941 , attorney docket no. 25791.16.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,907, filed on 2/26/99, (9) U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (10) U.S. patent application serial no. 09/981,916, attorney docket no. 25791.18, filed on 10/18/01 as a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (11) U.S. patent number 6,604,763, which was filed as application serial no. 09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, which claims priority from provisional application 60/131 ,106, filed on 4/26/99, (12) U.S. patent application serial no. 10/030,593, attorney docket no. 25791.25.08, filed on 1/8/02, which claims priority from provisional application 60/146,203, filed on 7/29/99, (13) U.S. provisional patent application serial no. 60/143,039, attorney docket no. 25791.26, filed on 7/9/99, (14) U.S. patent application serial no. 10/111 ,982, attorney docket no. 25791.27.08, filed on 4/30/02, which claims priority from provisional patent application serial no. 60/162,671, attorney docket no. 25791.27, filed on 11/1/1999, (15) U.S. provisional patent application serial no. 60/154,047, attorney docket no. 25791.29, filed on 9/16/1999, (16) U.S. provisional patent application serial no. 60/438,828, attorney docket no. 25791.31 , filed on 1/9/03, (17) U.S. patent number 6,564,875, which was filed as application serial no. 09/679,907, attorney docket no. 25791.34.02, on 10/5/00, which claims priority from provisional patent application serial no. 60/159,082, attorney docket no. 25791.34, filed on 10/12/1999, (18) U.S. patent application serial no. 10/089,419, filed on 3/27/02, attorney docket no. 25791.36.03, which claims priority from provisional patent application serial no. 60/159,039, attorney docket no. 25791.36, filed on 10/12/1999, (19) U.S. patent application serial no. 09/679,906, filed on 10/5/00, attorney docket no. 25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (20) U.S. patent application serial no. 10/303,992, filed on 11/22/02, attorney docket no. 25791.38.07, which claims priority from provisional patent application serial no. 60/212,359, attorney docket no. 25791.38, filed on 6/19/2000, (21) U.S. provisional patent application serial no. 60/165,228, attorney docket no. 25791.39, filed on 11/12/1999, (22) U.S. provisional patent application serial no. 60/455,051 , attorney docket no. 25791.40, filed on 3/14/03, (23) PCT application US02/2477, filed on 6/26/02, attorney docket no. 25791.44.02, which claims priority from U.S. provisional patent application serial no. 60/303,711 , attorney docket no. 25791.44, filed on 7/6/01 , (24) U.S. patent application serial no. 10/311 ,412, filed on 12/12/02, attorney docket no. 25791.45.07, which claims priority from provisional patent application serial no. 60/221,443, attorney docket no. 25791.45, filed on 7/28/2000, (25) U.S. patent application serial no. 10/, filed on 12/18/02, attorney docket no. 25791.46.07, which claims priority from provisional patent application serial no. 60/221 ,645, attorney docket no. 25791.46, filed on 7/28/2000, (26) U.S. patent application serial no. 10/322,947, filed on 1/22/03, attorney docket no. 25791.47.03, which claims priority from provisional patent application serial no. 60/233,638, attorney docket no. 25791.47, filed on 9/18/2000, (27) U.S. patent application serial no. 10/406,648, filed on 3/31/03, attorney docket no. 25791.48.06, which claims priority from provisional patent application serial no. 60/237,334, attorney docket no. 25791.48, filed on 10/2/2000, (28) PCT application US02/04353, filed on 2/14/02, attorney docket no. 25791.50.02, which claims priority from U.S. provisional patent application serial no. 60/270,007, attorney docket no. 25791.50, filed on 2/20/2001 , (29) U.S. patent application serial no. 10/465,835, filed on 6/13/03, attorney docket no. 25791.51.06, which claims priority from provisional patent application serial no. 60/262,434, attorney docket no. 25791.51 , filed on 1/17/2001 , (30) U.S. patent application serial no. 10/465,831 , filed on 6/13/03, attorney docket no. 25791.52.06, which claims priority from U.S. provisional patent application serial no. 60/259,486, attorney docket no. 25791.52, filed on 1/3/2001 , (31) U.S. provisional patent application serial no. 60/452,303, filed on 3/5/03, attorney docket no. 25791.53, (32) U.S. patent number 6,470,966, which was filed as patent application serial number 09/850,093, filed on 5/7/01 , attorney docket no. 25791.55, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (33) U.S. patent number 6,561 ,227, which was filed as patent application serial number 09/852,026, filed on 5/9/01 , attorney docket no. 25791.56, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which
2I claims priority from provisional application 60/111 ,293, filed on 12/7/98, (34) U.S. patent application serial number 09/852,027, filed on 5/9/01, attorney docket no. 25791.57, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111,293, filed on 12/7/98, (35) PCT Application US02/25608, attorney docket no. 25791.58.02, filed on 8/13/02, which claims priority from provisional application 60/318,021 , filed on 9/7/01 , attorney docket no. 25791.58, (36) PCT Application US02/24399, attorney docket no. 25791.59.02, filed on 8/1/02, which claims priority from U.S. provisional patent application serial no. 60/313,453, attorney docket no. 25791.59, filed on 8/20/2001 , (37) PCT Application US02/29856, attorney docket no. 25791.60.02, filed on 9/19/02, which claims priority from U.S. provisional patent application serial no. 60/326,886, attorney docket no. 25791.60, filed on 10/3/2001, (38) PCT Application US02/20256, attorney docket no. 25791.61.02, filed on 6/26/02, which claims priority from U.S. provisional patent application serial no. 60/303,740, attorney docket no. 25791.61 , filed on 7/6/2001 , (39) U.S. patent application serial no. 09/962,469. filed on 9/25/01 , attorney docket no. 25791.62, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99, (40) U.S. patent application serial no. 09/962,470, filed on 9/25/01 , attorney docket no. 25791.63, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99,
(41) U.S. patent application serial no. 09/962,471 , filed on 9/25/01 , attorney docket no.
25791.64, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued
11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99,
(42) U.S. patent application serial no. 09/962,467, filed on 9/25/01, attorney docket no.
25791.65, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued
11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99,
(43) U.S. patent application serial no. 09/962,468, filed on 9/25/01 , attorney docket no.
25791.66, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued
11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99,
(44) PCT application US 02/25727, filed on 8/14/02, attorney docket no. 25791.67.03, which claims priority from U.S. provisional patent application serial no. 60/317,985, attorney docket no. 25791.67, filed on 9/6/2001 , and U.S. provisional patent application serial no. 60/318,386, attorney docket no. 25791.67.02, filed on 9/10/2001, (45) PCT application US 02/39425, filed on 12/10/02, attorney docket no. 25791.68.02, which claims priority from U.S. provisional patent application serial no. 60/343,674 , attorney docket no. 25791.68, filed on 12/27/2001 , (46) U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001 , (now U.S. Patent 6,634,431 which issued 10/21/2003), which is a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (47) U.S. utility patent application serial no. 10/516,467, attorney docket no. 25791.70, filed on 12/10/01 , which is a continuation application of U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001, (now U.S. Patent 6,634,431 which issued 10/21/2003), which is a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (48) PCT application US 03/00609, filed on 1/9/03, attorney docket no. 25791.71.02, which claims priority from U.S. provisional patent application serial no. 60/357,372, attorney docket no. 25791.71 , filed on 2/15/02, (49) U.S. patent application serial no. 10/074,703, attorney docket no. 25791.74, filed on 2/12/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (50) U.S. patent application serial no. 10/074,244, attorney docket no. 25791.75, filed on 2/12/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121,841 , filed on 2/26/99, (51) U.S. patent application serial no. 10/076,660, attorney docket no. 25791.76, filed on 2/15/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (52) U.S. patent application serial no. 10/076,661, attorney docket no. 25791.77, filed on 2/15/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (53) U.S. patent application serial no. 10/076,659, attorney docket no. 25791.78, filed on 2/15/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (54) U.S. patent application serial no. 10/078,928, attorney docket no. 25791.79, filed on 2/20/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (55) U.S. patent application serial no. 10/078,922, attorney docket no. 25791.80, filed on 2/20/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121,841 , filed on 2/26/99, (56) U.S. patent application serial no. 10/078,921. attorney docket no. 25791.81 , filed on 2/20/02, which is a divisional of U.S. patent number 6,568,471, which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (57) U.S. patent application serial no. 10/261,928, attorney docket no. 25791.82, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (58) U.S. patent application serial no. 10/079,276, attorney docket no. 25791.83, filed on 2/20/02, which is a divisional of U.S. patent number 6,568,471, which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (59) U.S. patent application serial no. 10/262,009, attorney docket no. 25791.84, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (60) U.S. patent application serial no. 10/092,481 , attorney docket no. 25791.85, filed on 3/7/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121,841 , filed on 2/26/99, (61) U.S. patent application serial no. 10/261 ,926, attorney docket no. 25791.86, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (62) PCT application US 02/36157, filed on 11/12/02, attorney docket no. 25791.87.02, which claims priority from U.S. provisional patent application serial no. 60/338,996, attorney docket no. 25791.87, filed on 11/12/01 , (63) PCT application US 02/36267, filed on 11/12/02, attorney docket no. 25791.88.02, which claims priority from U.S. provisional patent application serial no. 60/339,013, attorney docket no. 25791.88, filed on 11/12/01 , (64) PCT application US 03/11765, filed on 4/16/03, attorney docket no. 25791.89.02, which claims priority from U.S. provisional patent application serial no. 60/383,917, attorney docket no. 25791.89, filed on 5/29/02, (65) PCT application US 03/15020, filed on 5/12/03, attorney docket no. 25791.90.02, which claims priority from U.S. provisional patent application serial no. 60/391 ,703, attorney docket no. 25791.90, filed on 6/26/02, (66) PCT application US 02/39418, filed on 12/10/02, attorney docket no. 25791.92.02, which claims priority from U.S. provisional patent application serial no. 60/346,309, attorney docket no. 25791.92, filed on 1/7/02, (67) PCT application US 03/06544, filed on 3/4/03, attorney docket no. 25791.93.02, which claims priority from U.S. provisional patent application serial no. 60/372,048, attorney docket no. 25791.93, filed on 4/12/02, (68) U.S. patent application serial no. 10/331 ,718, attorney docket no. 25791.94, filed on 12/30/02, which is a divisional U.S. patent application serial no. 09/679,906, filed on 10/5/00, attorney docket no. 25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (69) PCT application US 03/04837, filed on 2/29/03, attorney docket no. 25791.95.02, which claims priority from U.S. provisional patent application serial no. 60/363,829, attorney docket no. 25791.95, filed on 3/13/02, (70) U.S. patent application serial no. 10/261 ,927, attorney docket no. 25791.97, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (71) U.S. patent application serial no. 10/262,008, attorney docket no. 25791.98, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (72) U.S. patent application serial no. 10/261 ,925, attorney docket no. 25791.99, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (73) U.S. patent application serial no. 10/199,524, attorney docket no. 25791.100, filed on 7/19/02, which is a continuation of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (74) PCT application US 03/10144, filed on 3/28/03, attorney docket no. 25791.101.02, which claims priority from U.S. provisional patent application serial no. 60/372,632, attorney docket no. 25791.101 , filed on 4/15/02, (75) U.S. provisional patent application serial no. 60/412,542, attorney docket no. 25791.102, filed on 9/20/02, (76) PCT application US 03/14153, filed on 5/6/03, attorney docket no. 25791.104.02, which claims priority from U.S. provisional patent application serial no. 60/380,147, attorney docket no. 25791.104, filed on 5/6/02, (77) PCT application US 03/19993, filed on 6/24/03, attorney docket no. 25791.106.02, which claims priority from U.S. provisional patent application serial no. 60/397,284, attorney docket no. 25791.106, filed on 7/19/02, (78) PCT application US 03/13787, filed on 5/5/03, attorney docket no. 25791.107.02, which claims priority from U.S. provisional patent application serial no. 60/387,486, attorney docket no. 25791.107, filed on 6/10/02, (79) PCT application US 03/18530, filed on 6/11/03, attorney docket no. 25791.108.02, which claims priority from U.S. provisional patent application serial no. 60/387,961 , attorney docket no. 25791.108, filed on 6/12/02, (80) PCT application US 03/20694, filed on 7/1/03, attorney docket no. 25791.110.02, which claims priority from U.S. provisional patent application serial no. 60/398,061 , attorney docket no. 25791.110, filed on 7/24/02, (81) PCT application US 03/20870, filed on 7/2/03, attorney docket no. 25791.111.02, which claims priority from U.S. provisional patent application serial no. 60/399,240, attorney docket no. 25791.111 , filed on 7/29/02, (82) U.S. provisional patent application serial no. 60/412,487, attorney docket no. 25791.112, filed on 9/20/02, (83) U.S. provisional patent application serial no. 60/412,488, attorney docket no. 25791.114, filed on 9/20/02, (84) U.S. patent application serial no. 10/280,356, attorney docket no. 25791.115, filed on 10/25/02, which is a continuation of U.S. patent number 6,470,966, which was filed as patent application serial number 09/850,093, filed on 5/7/01, attorney docket no. 25791.55, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (85) U.S. provisional patent application serial no. 60/412,177, attorney docket no. 25791.117, filed on 9/20/02, (86) U.S. provisional patent application serial no. 60/412,653, attorney docket no. 25791.118, filed on 9/20/02, (87) U.S. provisional patent application serial no. 60/405,610, attorney docket no. 25791.119, filed on 8/23/02, (88) U.S. provisional patent application serial no. 60/405,394, attorney docket no. 25791.120, filed on 8/23/02, (89) U.S. provisional patent application serial no. 60/412,544, attorney docket no. 25791.121, filed on 9/20/02, (90) PCT application US 03/24779, filed on 8/8/03, attorney docket no. 25791.125.02, which claims priority from U.S. provisional patent application serial no. 60/407,442, attorney docket no. 25791.125, filed on 8/30/02, (91) U.S. provisional patent application serial no. 60/423,363, attorney docket no. 25791.126, filed on 12/10/02, (92) U.S. provisional patent application serial no. 60/412,196, attorney docket no. 25791.127, filed on 9/20/02, (93) U.S. provisional patent application serial no. 60/412,187, attorney docket no. 25791.128, filed on 9/20/02, (94) U.S. provisional patent application serial no. 60/412,371, attorney docket no. 25791.129, filed on 9/20/02, (95) U.S. patent application serial no. 10/382,325, attorney docket no. 25791.145, filed on 3/5/03, which is a continuation of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (96) U.S. patent application serial no. 10/624,842, attorney docket no. 25791.151, filed on 7/22/03, which is a divisional of U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, which claims priority from provisional application 60/119,611, filed on 2/11/99, (97) U.S. provisional patent application serial no. 60/431 ,184, attorney docket no. 25791.157, filed on 12/5/02, (98) U.S. provisional patent application serial no. 60/448,526, attorney docket no. 25791.185, filed on 2/18/03, (99) U.S. provisional patent application serial no. 60/461 ,539, attorney docket no. 25791.186, filed on 4/9/03, (100) U.S. provisional patent application serial no. 60/462,750, attorney docket no. 25791.193, filed on 4/14/03, (101) U.S. provisional patent application serial no. 60/436,106, attorney docket no. 25791.200, filed on 12/23/02, (102) U.S. provisional patent application serial no. 60/442,942, attorney docket no. 25791.213, filed on 1/27/03, (103) U.S. provisional patent application serial no. 60/442,938, attorney docket no. 25791.225, filed on 1/27/03, (104) U.S. provisional patent application serial no. 60/418,687, attorney docket no. 25791.228, filed on 4/18/03, (105) U.S. provisional patent application serial no. 60/454,896, attorney docket no. 25791.236, filed on 3/14/03, (106) U.S. provisional patent application serial no. 60/450,504, attorney docket no. 25791.238, filed on 2/26/03, (107) U.S. provisional patent application serial no. 60/451 ,152, attorney docket no. 25791.239, filed on 3/9/03, (108) U.S. provisional patent application serial no. 60/455,124, attorney docket no. 25791.241 , filed on 3/17/03, (109) U.S. provisional patent application serial no. 60/453,678, attorney docket no. 25791.253, filed on 3/11/03,
(110) U.S. patent application serial no. 10/421 ,682, attorney docket no. 25791.256, filed on 4/23/03, which is a continuation of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued
11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99,
(111 ) U.S. provisional patent application serial no. 60/457,965, attorney docket no. 25791.260, filed on 3/27/03, (112) U.S. provisional patent application serial no. 60/455,718, attorney docket no. 25791.262, filed on 3/18/03, (113) U.S. patent number 6,550,821 , which was filed as patent application serial no. 09/811 ,734, filed on 3/19/01 , (114) U.S. patent application serial no. 10/436,467, attorney docket no. 25791.268, filed on 5/12/03, which is a continuation of U.S. patent number 6,604,763, which was filed as application serial no. 09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, which claims priority from provisional application 60/131,106, filed on 4/26/99, (115) U.S. provisional patent application serial no. 60/459,776, attorney docket no. 25791.270, filed on 4/2/03, (116) U.S. provisional patent application serial no. 60/461 ,094, attorney docket no. 25791.272, filed on 4/8/03, (117) U.S. provisional patent application serial no. 60/461 ,038, attorney docket no. 25791.273, filed on 4/7/03, (118) U.S. provisional patent application serial no. 60/463,586, attorney docket no. 25791.277, filed on 4/17/03, (119) U.S. provisional patent application serial no. 60/472,240, attorney docket no. 25791.286, filed on 5/20/03, (120) U.S. patent application serial no. 10/619,285, attorney docket no. 25791.292, filed on 7/14/03, which is a continuation-in-part of U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001 , (now U.S. Patent 6,634,431 which issued 10/21/2003), which is a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (121) U.S. utility patent application serial no. 10/418,688, attorney docket no. 25791.257, which was filed on 4/18/03, as a division of U.S. utility patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, (now U.S. Patent 6,640,903 which issued 11/4/2003), which claims priority from provisional application 60/124,042, filed on 3/11/99; (122) PCT patent application serial no. PCT/US2004/06246, attorney docket no. 25791.238.02, filed on 2/26/2004; (123) PCT patent application serial number PCT/US2004/08170, attorney docket number 25791.40.02, filed on 3/15/04; (124) PCT patent application serial number PCT/US2004/08171 , attorney docket number 25791.236.02, filed on 3/15/04; (125) PCT patent application serial number PCT/US2004/08073, attorney docket number 25791.262.02, filed on 3/18/04; (126) PCT patent application serial number PCT/US2004/07711 , attorney docket number 25791.253.02, filed on 3/11/2004; (127) PCT patent application serial number PCT/US2004/029025, attorney docket number 25791.260.02, filed on 3/26/2004; (128) PCT patent application serial number PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004; (129) PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/6/2004; (130) PCT patent application serial number PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004; (131) PCT patent application serial number PCT/US2004/011973, attorney docket number 25791.277.02, filed on 4/15/2004; (132) U.S. provisional patent application serial number 60/495056, attorney docket number 25791.301 , filed on 8/14/2003; (133) U.S. provisional patent application serial number 60/600679, attorney docket number 25791.194, filed on 8/11/2004; (134) PCT patent application serial number PCT/US2005/027318, attorney docket number 25791.329.02, filed on 7/29/2005; (135) PCT patent application serial number PCT/US2005/028936, attorney docket number 25791.338.02, filed on 8/12/2005; (136) PCT patent application serial number PCT/US2005/028669, attorney docket number 25791.194.02, filed on 8/11/2005; (137) PCT patent application serial number PCT/US2005/028453, attorney docket number 25791.371, filed on 8/11/2005; (138) PCT patent application serial number PCT/US2005/028641, attorney docket number 25791.372, filed on 8/11/2005; (139) PCT patent application serial number PCT/US2005/028819, attorney docket number 25791.373, filed on 8/11/2005; (140) PCT patent application serial number PCT/US2005/028446, attorney docket number 25791.374, filed on 8/11/2005; (141) PCT patent application serial number PCT/US2005/028642, attorney docket number 25791.375, filed on 8/11/2005; (142) PCT patent application serial number PCT/US2005/028451 , attorney docket number 25791.376, filed on 8/11 /2005, and (143). PCT patent application serial number PCT/US2005/028473, attorney docket number 25791.377, filed on 8/11/2005, (144) U.S. utility patent application serial number 10/546082, attorney docket number 25791.378, filed on 8/16/2005, (145) U.S. utility patent application serial number 10/546076, attorney docket number 25791.379, filed on 8/16/2005, (146) U.S. utility patent application serial number 10/545936, attorney docket number 25791.380, filed on 8/16/2005, (147) U.S. utility patent application serial number 10/546079, attorney docket number 25791.381 , filed on 8/16/2005 (148) U.S. utility patent application serial number 10/545941 , attorney docket number 25791.382, filed on 8/16/2005, (149) U.S. utility patent application serial number 546078, attorney docket number 25791.383, filed on 8/16/2005, filed on 8/11/2005., (150) U.S. utility patent application serial number 10/545941 , attorney docket number 25791.185.05, filed on 8/16/2005, (151) U.S. utility patent application serial number 11/249967, attorney docket number 25791.384, filed on 10/13//2005, (152) U.S. provisional patent application serial number 60/734302, attorney docket number 25791.24, filed on 11/7/2005, (153) U.S. provisional patent application serial number 60/725181 , attorney docket number 25791.184, filed on 10/11/2005, (154) PCT patent application serial number PCT/US2005/023391 , attorney docket number 25791.299.02 filed 6/29/2005 which claims priority from U.S. provisional patent application serial number 60/585370, attorney docket number 25791.299, filed on 7/2/2004, (155) U.S. provisional patent application serial number 60/721579, attorney docket number 25791.327, filed on 9/28/2005, (156) U.S. provisional patent application serial number 60/717391 , attorney docket number 25791.214, filed on 9/15/2005, (157) U.S. provisional patent application serial number 60/702935, attorney docket number 25791.133, filed on 7/27/2005, (158) U.S. provisional patent application serial number 60/663913, attorney docket number 25791.32, filed on 3/21/2005, (159) U.S. provisional patent application serial number 60/652564, attorney docket number 25791.348, filed on 2/14/2005, (160) U.S. provisional patent application serial number 60/645840, attorney docket number 25791.324, filed on 1/21/2005, (161) PCT patent application serial number PCT/US2005/043122, attorney docket number 25791.326.02, filed on 11/29/2005 which claims priority from U.S. provisional patent application serial number 60/631703, attorney docket number 25791.326, filed on 11/30/2004, (162) U.S. provisional patent application serial number 60/752787, attorney docket number 25791.339, filed on 12/22/2005, (163) U.S. National Stage application serial no. 10/548934, attorney docket no. 25791.253.05, filed on 9/12/2005; (164) U.S. National Stage application serial no. 10/549410, attorney docket no. 25791.262.05, filed on 9/13/2005; (165) U.S. Provisional Patent Application No. 60/717391 , attorney docket no. 25791.214 filed on 9/15/2005; (166) U.S. National Stage application serial no. 10/550906, attorney docket no. 25791.260.06, filed on 9/27/2005; (167) U.S. National Stage application serial no. 10/551880, attorney docket no. 25791.270.06, filed on 9/30/2005; (168) U.S. National Stage application serial no. 10/552253, attorney docket no. 25791.273.06, filed on 10/4/2005; (169) U.S. National Stage application serial no. 10/552790, attorney docket no. 25791.272.06, filed on 10/11/2005; (170) U.S. Provisional Patent Application No. 60/725181 , attorney docket no. 25791.184 filed on 10/11/2005; (171) U.S. National Stage application serial no. 10/553094, attorney docket no. 25791.193.03, filed on 10/13/2005; (172) U.S. National Stage application serial no. 10/553566, attorney docket no. 25791.277.06, filed on 10/17/05; (173) PCT Patent Application No. PCT/US2006/002449, attorney docket no. 25791.324.02 filed on 1/20/06, (174) PCT Patent Application No. PCT/US2006/004809, attorney docket no. 25791.348.02 filed on 2/9/06; (175) U.S. Utility Patent application serial no. 11/356899, attorney docket no. 25791.386, filed on 2/17/06, (176) U.S. National Stage application serial no. 10/568200, attorney docket no. 25791.301.06, filed on 2/13/2006, (177) U.S. National Stage application serial no. 10/568719, attorney docket no. 25791.137.04, filed on 2/16/06, filed on 2/16/06, (178) U.S. National Stage application serial no. 10/569323, attorney docket no. 25791.215.06, filed on 2/17/06, (179) U.S. National State patent application serial no. 10/571041 , attorney docket no. 25791.305.05, filed on 3/3/06; (180) U.S. National State patent application serial no. 10/571017, attorney docket no. 25791.306.04, filed on 3/3/06; (181) U.S. National State patent application serial no. 10/571086, attorney docket no. 25791.307.04, filed on 3/6/06; and (182) U.S. National State patent application serial no. 10/571085, attorney docket no. 25791.308.07, filed on 3/6/06, (183) U.S. utility patent application serial number 10/938788, attorney docket number 25791.330, filed on 9/10/04, (184) U.S. utility patent application serial number 10/938225, attorney docket number 25791.331 , filed on 9/10/04, (185) U.S. utility patent application serial number 10/952288, attorney docket number 25791.332, filed on 9/28/04, (186) U.S. utility patent application serial number 10/952416, attorney docket number 25791.333, filed on 9/28/04, (187) U.S. utility patent application serial number 10/950749, attorney docket number 25791.334, filed on-9/27/04, (188)U.S. utility patent application serial number 10/950869, attorney docket number 25791.335, filed on 9/27/04; (189) U.S. provisional patent application serial number 60/761324, attorney docket number 25791.340, filed on 1/23/06, (190) U.S. provisional patent application serial number 60/754556, attorney docket number 25791.342, filed on 12/28/05, (191) U.S. utility patent application serial number 11/380051 , attorney docket number 25791.388, filed on 4/25/06, (192) U.S. utility patent application serial number 11/380055, attorney docket number 25791.389, filed on 4/25/06, (193) U.S. utility patent application serial number 10/522039, attorney docket number 25791.106.05, filed on 3/10/2006; (194) U.S. provisional patent application serial number 60/746,813, attorney docket number 25791.259, filed on 5/9/2006; (195) U.S. utility patent application serial number 11/456584, attorney docket number 25791.403, filed on 7/11/2006; and (196) U.S. utility patent application serial number 11/456587, attorney docket number 25791.404, filed on 7/11/2006; (197) PCT Patent Application No. PCT/US2006/009886, attorney docket no. 25791.32.02 filed on 3/21/2006; and (198) PCT Patent Application No. PCT/US2006/010674, attorney docket no. 25791.337.02 filed on 3/21/2006, the disclosures of which are incorporated herein by reference.
[0046] In the event that the coupled casing sections are expanded in accordance with one or more of the techniques disclosed in one or more of the patent applications cited above, the surface-to-surface air tight metallic seal provided by the sleeves 40, 86 and 94 holds the sections together during the expansion process and increases the collapse strength of the casing sections. Also, the sleeves 40, 86 and 94 prevent, or at least reduce, crack propagation during the radial expansion and plastic deformation and provide fluid-tight, metai-to-metal seals between the interior surface of the sleeves and the exterior surfaces of the casing sections to prevent fluidic materials from passing through the threaded connections. Furthermore, following the radial expansion and plastic deformation of the casing sections, the sleeves 40, 86 and 94 are maintained in circumferential tension and the casing sections are maintained in circumferential compression, thus permitting axial and/or torque loads to be transmitted through the sleeves.
[0047] It is understood that, in the embodiment of Figs. 9 and 10, the thickness of the layer 126 or the layers 126a, 126b, 126c and 126d is calculated in order to fill the above gap before and after the radial expansion and plastic deformation of the casing sections 114 and 116 in accordance with one or more of the above techniques.
Variations
[0048] It is understood that variations may be made in the foregoing without departing from the scope of the invention. Examples of some of the variations are as follows:
• The lengths of the sleeves 40, 86 and 94 can vary.
• In the embodiment of Fig. 7, the ridge rings 88a, 88b, and 88c can be formed on the casing section 82 rather than the casing section 80 and can take shapes and sizes other than that shown and described.
• In the embodiment of Fig. 10, the number and thicknesses of the layers disposed in the gap between the threads can vary.
• The sleeve 40 of the embodiment of Fig. 4-6, the sleeve 86 of the embodiment of Fig. 7, and/or the sleeve 94 of the embodiment of Fig. 8 can be used in one or more of the embodiments of Figs. 9-12.
• The magnetic impulse energy apparatus 50 of the embodiments of Figs. 6 and 8 can be used in one or more of the embodiments of Figs. 7, and 9-12. [0049] Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure, In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.

Claims

ClaimsWhat is claimed is:
1. A well bore casing for insertion in a well bore, the casing comprising: a first casing section; a second casing section coupled to the first casing section; and a sleeve extending in a coaxial relationship with the coupled sections and in an overlapping relation to at least a portion of the sections, the sleeve adapted to melt in response to the application of energy to the sleeve and flow around the joint between the coupled sections to produce a surface-to-surface air tight metallic seal.
2. The casing of claim 1 further comprising threads provided on the first casing section, and threads provided on the second casing section that engage the threads on the first casing section to couple the sections, and wherein the melted sleeve flows around at least a portion of the threaded sections.
3. The casing of claim 1 , wherein the sleeve extends around the casing sections, and wherein the energy causes the sleeve to collapse against the sections before it melts.
4. The casing of claim 1 , wherein the sleeve extends within the casing sections and wherein the energy causes the sleeve to expand against the casing sections before it melts.
5. The casing of claim 1 wherein a portion of the first casing section is coupled to a portion of the second casing section, and wherein at least a portion of the sleeve extends in an overlapping relation to the coupled portions of the casing sections.
6. The casing of claim 1 wherein a channel is defined between the casing sections and wherein a portion of the melted sleeve flows into the channel.
7. The casing of claim 1 further comprising an apparatus disposed proximate to the casing sections for producing the energy in the form of a magnetic impulse.
8. The casing of claim 1 wherein the diameter of an end portion of one casing section is less that that of the remaining portion of the one casing, and wherein the diameter of an end portion of the other casing section is greater than that of the remaining portion of the other casing section and interlocks with the end portion of the one casing section to couple the sections.
9. The casing of claim 8 further comprising at least one raised ridge ring extending radially from the end portion of one casing section and into a groove formed in the end portion of the other casing section.
10. A well bore casing for insertion in a well bore, the casing comprising: a first casing section having a threaded portion; a second casing section having a threaded portion threadedly engaging the threaded portion of the first casing section to couple the sections; a space defined between the coupled threaded portions; and an insert disposed in the space for providing a seal between the coupled threaded portions.
11. The casing of claim 10, wherein the insert comprises a metallic material
12. The casing of claim 10 wherein the insert comprises a first layer having a first modulus of elasticity; and at least one additional layer having a second modulus of elasticity that is different from the first modulus of elasticity.
13. The casing of claim 12, wherein one of the layers comprises copper; and wherein the other layer comprises cadmium.
14. The casing of claim 12, wherein the modulus of elasticities of the layers are less than the modulus of elasticities of the casing sections.
15. The casing of claim 12 wherein one of the layers provides a fluidic seal; and wherein the other layer provides a micro fluidic seal.
16. The casing of claim 10 further comprising a sleeve extending in a coaxial relationship with the casing sections and in an overlapping relation to at least a portion of the threaded portions of the sections; the sleeve adapted to melt in response to the application of external energy to the sleeve and flow around the joint between the threaded portions to produce a surface-to-surface air tight metallic seal over the threaded portions.
17. A well bore casing for insertion in a well bore, the casing comprising: a first casing section having a tapered end portion; and a second casing section having a flared end portion extending over the tapered end portion; and a material extending between the tapered end portion and the flared end portion to couple the casing sections.
18. The casing of claim 17 wherein the material flashes in response to it increasing in temperature caused by rotation of at least one casing section.
19. The casing of claim 17 further threads formed on the tapered end portion, and threads formed on the flared end portion and in engagement with the threads on the tapered end portion.
20. A method of forming a well bore casing for insertion in a well bore, the method comprising: coupling a first casing section to a second casing section; positioning a sleeve extending in an overlapping relation to at least a portion of the sections; and melting the sleeve so that it flows around the joint between the coupled sections to produce a surface-to-surface air tight metallic seal.
21. The method of claim 20 wherein the step of coupling comprises placing the sections in a threaded engagement, and flowing the melted sleeve around at least a portion of the threaded sections.
22. The method of claim 20, wherein the sleeve extends around the casing sections, and further comprising collapsing the sleeve against the sections before the step of melting.
23. The method of claim 20, wherein the sleeve extends within the casing sections and further comprising expanding the sleeve against the sections before the step of melting.
24. The method of claim 20 wherein a portion of the first casing section is coupled to a portion of the second casing section, and wherein at least a portion of the sleeve extends in an overlapping relation to the coupled portions of the casing sections.
25. The method of claim 20 further comprising forming a channel between the casing sections, and wherein a portion of the melted sleeve flows into the channel.
26. The method of claim 20 further comprising applying energy, in the form of a magnetic impulse, to the sleeve to melt it.
27. The method of claim 20 wherein the diameter of an end portion of one casing section is less that that of the remaining portion of the one casing, and the diameter of an end portion of the other casing section is greater than that of the remaining portion of the other casing section, and wherein the step of coupling comprises interlocking the end portions.
28. The method of claim 20 further comprising inserting at least one raised ridge ring extending radially from the end portion of one casing section and into a groove formed in the end portion of the other casing section.
29. The method of claim 20 further comprising the step of expanding the casing sections radially outwardly towards the wall of the well bore.
30. A method of forming a well bore casing, the method casing comprising: providing threads on a portion of a first casing section; providing threads on a portion of a second casing section; engaging the threads on the first casing section portion with the threads on the second casing section portion to couple the sections; the threads being sized so as to form a gap between the engaged threads; and disposing an insert in the gap for providing a seal between the engaged threads.
31. The method of claim 30 wherein the insert is a metallic material.
32. The method of claim 30 wherein the insert is formed by a first layer having a first modulus of elasticity; and at least one additional layer having a second modulus of elasticity that is different from the first modulus of elasticity.
33. The method of claim 32 wherein one of the layers is copper; and wherein the other layer is cadmium.
34. The method of claim 32 wherein the modulus of elasticities of the layers are less than the modulus of elasticities of the casing sections.
35. The method of claim 32 wherein one of the layers provides a fluidic seal; and wherein the other layer provides a micro fluidic seal.
36. The method of claim 30 further comprising disposing a sleeve in a coaxial relationship with the casing sections and in an overlapping relation to at least a portion of the threads; and melting the sleeve so that it flows around the joint between the threaded portions to produce a surface-to-surface air tight metallic seal over the threaded portions.
37. The method of claim 36 wherein the step of melting comprises applying energy to the sleeve.
38. The method of claim 36 wherein the step of melting comprises applying magnetic impulses to the sleeve.
39. The method of claim 30 further comprising the step of expanding the casing sections radially outwardly towards the wall of the well bore.
40. A method of forming a well bore casing, the casing comprising: positioning a tapered end portion of a first casing section over a flared end portion of a second casing section; and providing a material between the end portions; and increasing the temperature of the material to flash the material and couple the sections.
41. The method of claim 40 further comprising rotating at least one of the casing sections to increase the temperature of the material and flash the material.
42. The method of claim 40 wherein threads are formed on the tapered end portion and threads are formed on the flared end portion, and further comprising engaging the threads.
43. The method of claim 40 further comprising the step of expanding the casing sections radially outwardly towards the wall of the well bore.
PCT/US2007/080280 2006-10-03 2007-10-03 Wellbore casing and method of forming same WO2008042945A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US11/538,228 US20070169939A1 (en) 2002-08-23 2006-10-03 Wellbore casing and method of forming same
US11/538,228 2006-10-03

Publications (2)

Publication Number Publication Date
WO2008042945A2 true WO2008042945A2 (en) 2008-04-10
WO2008042945A3 WO2008042945A3 (en) 2008-11-27

Family

ID=39269181

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2007/080280 WO2008042945A2 (en) 2006-10-03 2007-10-03 Wellbore casing and method of forming same

Country Status (2)

Country Link
US (1) US20070169939A1 (en)
WO (1) WO2008042945A2 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004081346A2 (en) 2003-03-11 2004-09-23 Enventure Global Technology Apparatus for radially expanding and plastically deforming a tubular member
WO2011127096A1 (en) * 2010-04-05 2011-10-13 Advanced Joining Technologies, Inc. Riser components and methods for making the same
US10279421B2 (en) 2013-10-31 2019-05-07 Halliburton Energy Services, Inc. Wellbore servicing assemblies and methods of using the same
US20200332604A1 (en) * 2019-04-22 2020-10-22 Oil States Industries, Inc. Expandable connection for expandable tubulars

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4096913A (en) * 1977-01-10 1978-06-27 Baker International Corporation Hydraulically set liner hanger and running tool with backup mechanical setting means
WO2004018823A2 (en) * 2002-08-23 2004-03-04 Enventure Global Technology Interposed joint sealing layer method of forming a wellbore casing
US6705395B2 (en) * 1999-02-26 2004-03-16 Shell Oil Company Wellbore casing
US6892819B2 (en) * 1998-12-07 2005-05-17 Shell Oil Company Forming a wellbore casing while simultaneously drilling a wellbore

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4096913A (en) * 1977-01-10 1978-06-27 Baker International Corporation Hydraulically set liner hanger and running tool with backup mechanical setting means
US6892819B2 (en) * 1998-12-07 2005-05-17 Shell Oil Company Forming a wellbore casing while simultaneously drilling a wellbore
US6705395B2 (en) * 1999-02-26 2004-03-16 Shell Oil Company Wellbore casing
WO2004018823A2 (en) * 2002-08-23 2004-03-04 Enventure Global Technology Interposed joint sealing layer method of forming a wellbore casing

Also Published As

Publication number Publication date
WO2008042945A3 (en) 2008-11-27
US20070169939A1 (en) 2007-07-26

Similar Documents

Publication Publication Date Title
US7424918B2 (en) Interposed joint sealing layer method of forming a wellbore casing
EP2815164B1 (en) Pipe, pipe connection and pipeline system
EP1268115B1 (en) Method of joining metal oilfield tubulars and well provided therewith
US20100230958A1 (en) Method and Apparatus for coupling Expandable Tubular Members
EP1967690B1 (en) High-strength sealed connection for expandable tubulars
US7377326B2 (en) Magnetic impulse applied sleeve method of forming a wellbore casing
US8205680B2 (en) Expandable connection
US20170314371A1 (en) Couplings for expandable tubular
US20040145184A1 (en) Helically wound expandable tubular insert
GB2429481A (en) Expandable pipe joint with strengthening sleeve
WO2008042945A2 (en) Wellbore casing and method of forming same
US20100225107A1 (en) Gas Tight Tubular Joint or Connection
US8454057B2 (en) Threaded end connector attachment for an end of a tube
JPS5884693A (en) Explosive type pipe expanding apparatus and method
GB2442636A (en) Expandable tubular connection with metallurgical bond created during expansion
GB2442635A (en) Tapered tubular capable of forming a metallurgical bond
GB2442637A (en) Expandable connection with dual material melted insert

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 07843731

Country of ref document: EP

Kind code of ref document: A2

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 07843731

Country of ref document: EP

Kind code of ref document: A2