3D Printed Barrel Slip Curvature Control
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Solution Overview
Problem
Conventional barrel slips used in well packers often experience premature setting and inconsistent grip on well casings due to geometric shape issues, leading to suboptimal engagement and uneven deployment of teeth, which affects the sealing and support of production tubing.
Innovation Solution
A barrel slip partially manufactured using additive manufacturing, such as 3D printing, allows for complex geometries and internal chambers that equalize stiffness and facilitate simultaneous or controlled deployment of slip anchors, reducing the likelihood of premature setting and improving grip consistency by optimizing the curvature and arrangement of teeth and wedges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional barrel slips with standard geometric shapes are used, then manufacturing is simpler, but premature setting occurs and grip consistency deteriorates
Solution Approach 1:
The patent applies local quality by varying the curvature radii at different locations of the barrel slip. Specifically, the curvature radius varies along the axial direction and circumferential direction, with different sections having different curvature characteristics. This localized variation in geometric properties ensures uniform stress distribution and simultaneous engagement of teeth with the casing, improving grip consistency without requiring overall geometric complexity
Solution Approach 2:
The patent implements parameter changes by modifying the curvature radius as a continuous variable along the barrel slip geometry. The curvature radius is not constant but changes according to specific mathematical functions or gradients, allowing optimization of stress distribution and deployment characteristics. This parameter variation approach transforms a simple geometric shape into one that provides consistent grip while maintaining manufacturability through controlled complexity
2Stability of the object's composition
If conventional barrel slips are used, then manufacturing process is simpler, but deployment uniformity deteriorates
Solution Approach 1:
The patent applies local quality by creating non-uniform curvature distribution in specific regions of the barrel slip. The curvature radius is tailored at different locations to control the expansion sequence and stress distribution during deployment. This localized geometric customization ensures that all teeth engage the casing simultaneously or in a controlled sequence, achieving uniform deployment while the overall structure remains manufacturable
Solution Approach 2:
The patent utilizes curvature principles by designing the barrel slip with varying radius of curvature instead of straight or constant-curvature surfaces. The curved geometry, with radii that change along axial and circumferential directions, naturally guides the deformation and expansion process during deployment. This curvature-based design ensures uniform radial expansion and simultaneous tooth engagement, improving deployment stability without requiring complex manufacturing processes
3Force
If conventional barrel slips with uniform geometry are used, then manufacturing is easier, but load distribution deteriorates
Solution Approach 1:
The patent applies local quality by distributing geometric variations strategically throughout the barrel slip structure. Different sections have different curvature characteristics tailored to their specific functional requirements - some areas have higher curvature for better tooth engagement, while other areas have lower curvature for structural support. This localized optimization of geometric properties achieves uniform load distribution across all teeth while maintaining overall structural integrity and reasonable manufacturability
Data Source
AI summary
A 3D printed barrel slip that includes a radially expandable barrel slip body that is movable from an unexpanded position to an expanded position; wherein the body has an outer surface that, when in the unexpanded position, defines a first radius; wherein the first radius is associated with a first curvature; and wherein, when in the expanded position, portion(s) of the outer surface has a second curvature that is less than the first radius. The body is an integrally formed single-component body that defines an external surface; and an internal chamber isolated from the external surface. The internal chambers affect the strength of portions of the body to control the timing of deployment of the barrel slip.