Prior art

I have analyzed US patent 12110780 (US12110780B2) and its cited prior art. The patent focuses on novel systems and methods for magnetic ranging while drilling, aiming to eliminate the need for wireline deployment for excitation or detection, a drawback of previous methods.

The most relevant prior art references, as explicitly discussed and contrasted within the background and detailed description of US12110780B2 itself, are detailed below. These references highlight the technological landscape that US12110780B2 seeks to improve upon.

Most Relevant Prior Art for US12110780B2

1. U.S. Pat. No. 4,372,398 (US4372398A)

• Full Citation: US4372398A - Method of determining the location of a deep-well casing by magnetic field sensing.
• Publication/Filing Date: Publication: 1983-02-08; Priority: 1980-11-04.
• Brief Description: This patent describes a magnetic ranging method typically deployed via wireline. It involves lowering a common assembly into a drilling well that contains an electrode and a receiver. Electrical power is transmitted down the wireline, delivered into the formation, and the injected current collects on a nearby target well casing, creating a magnetic field. This magnetic field is then detected by the receiver to calculate a bearing and distance to the target well.
• Potential Anticipation (35 U.S.C. § 102): US4372398A potentially anticipates the fundamental concept of active magnetic ranging where an electrical current is induced on a target well's casing to generate a detectable magnetic field for proximity determination. However, it does not anticipate the specific "while drilling" apparatus and method of US12110780B2. The distinguishing features of US12110780B2, such as the use of an internal wire within the drill pipe with a rigid or continuous electrical connection for power delivery while drilling, and the specific configuration of gap subs to control current injection without wireline deployment, are not taught by US4372398A. Thus, while the general principle of inducing and detecting magnetic fields for ranging is present, the specific structural and operational limitations of claims 1, 9, 18 (e.g., "at least one section of drill pipe," "wire inside the at least one section of drill pipe," "rigid connection that maintains its rigid connection as the at least one section of drill pipe is drilling"), and the method of claim 19 (e.g., "connecting a power supply to at least one section of drill pipe using at least one wire that is located inside the at least one section of drill pipe... is a rigid connection") are not anticipated.

2. U.S. Pat. No. 8,695,730 (US8695730B2)

• Full Citation: US8695730B2 - System and method for drilling multilateral wells using magnetic ranging while drilling.
• Publication/Filing Date: Publication: 2014-04-15; Priority: 2008-04-10.
• Brief Description: This patent describes a system and method for magnetic ranging while drilling that incorporates a current source within the drilling assembly, separated by an electrically insulative gap sub. However, US12110780B2 critiques this approach, stating that "the effective circuit for current flow is localized about the drilling assembly," which "severely limits the along well current flow path of the target well tubular, and therefore sufficient signal for a ranging determination is often not achievable."
• Potential Anticipation (35 U.S.C. § 102): US8695730B2 potentially anticipates the general concept of "magnetic ranging while drilling" and the use of an "electrically insulative gap sub" in a drilling assembly to influence current flow for ranging. This could bear on elements of claims 1, 9, and 18 related to a "first electrically insulated member" and the method steps in claims 19 and 21. However, US12110780B2 distinguishes itself by providing a system that effectively accumulates current on the target well casing to create a sufficient magnetic ranging signal. The specific internal wiring configuration with rigid/continuous connections within the drill pipe, as detailed in US12110780B2's claims (e.g., "rigid connection that maintains its rigid connection as the at least one section of drill pipe is drilling" in claim 1; "continuous electrical connection while the at least one section of drill pipe is drilling" in claim 18), appears to be a key differentiation from US8695730B2's localized current flow, which is described as inadequate for effective ranging.

3. U.S. Pat. No. 9,759,060 (US9759060B2)

• Full Citation: US9759060B2 - Proximity detection system for deep wells.
• Publication/Filing Date: Publication: 2017-09-12; Priority: 2008-12-22.
• Brief Description: This patent describes an approach that uses a wireline electrode deployed inside the drill pipe of the drilling assembly for target well excitation. US12110780B2 notes that this method "still involves the cessation of drilling for extended periods of time while wireline is deployed concentrically in the drill string," and also carries risks of mechanical and hydraulic sticking.
• Potential Anticipation (35 U.S.C. § 102): US9759060B2 addresses the challenge of ranging without withdrawing the entire drill string. It uses a "wireline electrode deployed inside the drill pipe," which could anticipate the concept of current delivery through the drill pipe while remaining partially deployed. However, it still relies on wireline deployment, necessitating a cessation of drilling for measurements. This directly contrasts with US12110780B2's objective to "eliminate entirely the need for any sort of wireline deployment" and its claims specifying a rigid, continuous connection of a wire permanently installed within the drill pipe that maintains its connection while drilling. Therefore, it does not anticipate the specific structural and functional characteristics related to continuous drilling, rigid internal connections, and the elimination of wireline deployment found in claims 1, 9, 18, and 19 of US12110780B2.

4. U.S. Patent Application Publication No. 2019/0119990 A1 (US20190119990A1)

• Full Citation: US20190119990A1 - Wired pipe and method for making.
• Publication/Filing Date: Publication: 2019-04-25; Priority: 2015-10-19.
• Brief Description: This application describes a "radially expansive conductive element" used to line the interior of an industry standard drill pipe, insulated from the drill pipe body and drilling fluid by an electrically insulative epoxy coating. US12110780B2 cites this as "One solution" for creating an insulated path for electrical current within the drill pipe.
• Potential Anticipation (35 U.S.C. § 102): US20190119990A1 directly teaches the construction of a wired drill pipe with an insulated internal conductive element. This reference would likely anticipate the structural elements within US12110780B2's claims related to "at least one section of drill pipe" and "at least one wire inside the at least one section of drill pipe" where the wire is insulated to carry current (as described in the descriptive portions of US12110780B2, e.g., FIGS. 9A-9C). However, it does not, by itself, teach the entire magnetic ranging system or method. It lacks the power supply connection for ranging, the specific "rigid connection" or "continuous electrical connection while drilling" requirement for such a wire in the context of ranging, the use of electrically insulative gap subs to control current exit into the formation for ranging, the sensor for detecting a magnetic ranging signal, or the overall method steps for magnetic ranging and adjusting drilling operations. Therefore, while providing a key component technology, it does not anticipate the complete apparatus or method claims of US12110780B2.