3D Curved Anti-Extrusion Ring for Downhole Packer
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Solution Overview
Problem
Existing single-set anti-extrusion rings for non-retrievable downhole pressure isolation packers, such as frac plugs, face challenges in maintaining sealing contact under extreme fluid temperatures and pressures, leading to packer element extrusion, and require complex and costly interlocking parts for effective operation.
Innovation Solution
A single-set anti-extrusion ring with 3-dimensionally curved mating ring segment faces and a fracture ring that fractures to expand, preventing extrusion by eliminating straight paths for pressurized elastomeric material, and utilizing an elastomeric O-ring for stabilization and backup sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex interlocking parts are used in anti-extrusion rings, then extrusion inhibition effectiveness is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent applies curved surfaces to the mating faces of ring segments, replacing traditional flat or complex interlocking geometries. The curved surfaces naturally guide the ring segments into proper alignment during expansion, providing effective extrusion inhibition through the continuous curved contact surfaces that distribute stresses and prevent gap formation, while simplifying the overall part design and reducing manufacturing complexity
Solution Approach 2:
The anti-extrusion ring is divided into multiple ring segments that can be manufactured separately and assembled. Each segment has simplified geometry with curved mating surfaces, allowing for easier manufacturing and assembly compared to a single complex interlocking structure. The segments work together through their curved surfaces to provide the same extrusion inhibition function
2Reliability
If traditional anti-extrusion rings are used, then packer element sealing is maintained, but gaps may form between ring segments under pressure, reducing sealing effectiveness
Solution Approach 1:
The curved mating surfaces of the ring segments provide continuous contact that naturally maintains alignment under pressure. The curvature ensures that as the ring expands, the segments follow the curved path, preventing gap formation and maintaining stable alignment throughout the pressure cycle, thereby preserving sealing effectiveness
Data Source
AI summary
A single-set anti-extrusion ring has a plurality of ring segments with a mating face on each end. Each mating face has a 3-dimensionally curved topology and the first mating face is a mirror image of the second mating face so the ring segments fit together to form and anti-extrusion ring without gaps in an unexpanded condition, and no straight path through the anti-extrusion ring in an expanded condition.