Backup Ring Extending Tab Closes Mandrel Extrusion Gaps
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Solution Overview
Problem
Existing packer sealing element designs, particularly those using backup rings, face issues with axial extrusion along a mandrel due to the difficulty and expense of producing and maintaining the wedge ring, which can become displaced and ineffective during the setting process.
Innovation Solution
A backup ring assembly with a base ring and a thin-walled, tapered extending ring that uses the pressure from the sealing element to push the extending ring firmly against the mandrel, closing extrusion gaps through plastic deformation and flexibility, ensuring a secure seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wedge ring is used to prevent extrusion between the mandrel and backup ring, then extrusion control is improved, but manufacturing cost and installation difficulty increase significantly
Solution Approach 1:
The patent integrates the extrusion barrier function directly into the backup ring structure by forming a tapered extending ring as an integral part of the backup ring. This eliminates the need for a separate wedge ring component, simplifying installation while maintaining extrusion control through the tapered geometry that guides the sealing element.
Solution Approach 2:
The patent replaces the expensive PEEK wedge ring with a simpler, more cost-effective backup ring design that achieves the same extrusion control function through its tapered extending structure, reducing material costs and manufacturing complexity.
2Reliability
If a wedge ring is used to prevent extrusion, then extrusion control is improved, but the wedge ring can become displaced and ineffective during setting
Solution Approach 1:
By integrating the extrusion barrier as an integral tapered extending ring of the backup ring, the design eliminates the risk of displacement that plagues separate wedge rings. The unified structure ensures the extrusion control feature remains in its correct position throughout the setting process.
Solution Approach 2:
The tapered extending ring is pre-formed as part of the backup ring structure, establishing the extrusion barrier in the correct position before the setting process begins. This preliminary positioning prevents displacement during operation.
3Reliability
If a separate abutting ring is integrated to close extrusion gap, then sealing effectiveness is improved, but device complexity increases
Solution Approach 1:
The patent merges the abutting ring function into the backup ring by forming a tapered extending ring as an integral structure. This single integrated component performs both the backup ring support function and the abutting ring extrusion closure function, improving sealing effectiveness without increasing overall device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents axial extrusion by utilizing the sealing element's pressure to maintain the extending ring's position against the mandrel, enhancing the seal's effectiveness and durability while reducing production costs and installation complexities.
Implementation Method 1
the pressure internally in the seal material helps to apply a force in a direction toward the mandrel
Implementation Method 2
The base ring has a thin walled tapered extending ring out of the base ring and into the direction of the sealing element
Implementation Method 3
The base ring has a thin walled tapered extending ring... The flexibility of the extending ring helps push the extending ring toward the mandrel outer surface
Data Source
AI summary
A backup ring assembly has a base ring to support the plastically deformed extrusion barrier when the packer sealing element is set. The base ring has a thin walled tapered extending ring out of the base ring and into the direction of the sealing element. The sealing element fills the annular gap volume between an upper taper on the extending ring and the body of the backup ring such that on setting the pressure internally in the seal material helps to apply a force in a direction toward the mandrel and for the full circumference of the mandrel. This force and the flexibility of the extending ring helps push the extending ring toward the mandrel outer surface to close extrusion gaps between the mandrel and the base ring of the backup ring assembly.