Composite Slip Segment Spiral Fiber Orientation

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Solution Overview

Problem

Conventional composite slip segments used in downhole tools have high compressive strength but low shear and tensile strength due to fiber orientation, and metallic slips can cause issues during milling operations in horizontal wells.

Innovation Solution

The use of a 'jelly roll' or multidimensional charge pattern in the molding process to create a spiral fiber orientation in composite slip segments, enhancing mechanical properties such as compression, tension, and shear strength, and incorporating metallic inserts for gripping the casing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metallic slips are used, then structural strength is high, but they cause problems during mill-up operations in horizontal wells

Engineering Contradiction:

Improvestructural strengthVSAvoidmilling operation difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent employs composite slip segments designed as disposable components that can be easily milled or broken down during mill-up operations. The composite material structure allows for cleaner, easier removal compared to metallic slips, accepting that the slips will be discarded after single use in exchange for simplified milling operations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the material parameters from metallic to composite construction, fundamentally altering the mechanical properties and removability characteristics. The composite material has different milling characteristics than metal, enabling easier removal in horizontal well applications where mill-up operations are required.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If composite slip segments with linear fiber orientation are used, then manufacturing is simple, but mechanical properties in all directions are not optimized

Engineering Contradiction:

Improvemolding simplicityVSAvoidmulti-directional mechanical properties

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent moves from simple linear fiber alignment to a three-dimensional randomized fiber distribution during the molding process. While this adds complexity to the molding operation, it remains relatively simple compared to other composite manufacturing methods, while dramatically improving multi-directional mechanical properties.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10087707B2Molded composite slip of sheet molded compound for downhole tool

Publication Date: 2018.10.02 WEATHERFORD TECHNOLOGY HOLDINGS LLC

AI summary

A component of a slip assembly is formed by rolling sheet molding compound into a rolled charge. The rolled charge is positioned in a compression molding press and compressed to produce a molded element. The molded element is removed from the compression molding press and can be machined for use as the component of the slip assembly. The component can be a slip segment or can be a cylindrical body for the slip segment. The compound layers in the molded component can be oriented in a number of different orientations in the component and can increase the overall strength of the component.