Deployable Spacer Sealing Assembly for Open-Hole Expansion Gaps

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Solution Overview

Problem

Sealing elements in sealing assemblies face challenges in open-hole conditions with significant expansion gaps, leading to buckling, loss of axial stiffness, and inadequate load transfer, resulting in insufficient deployment and extrusion over backup shoes.

Innovation Solution

Incorporation of a deployable spacer between sealing elements to control deployment and enhance axial stiffness, ensuring full deployment of backup shoes with minimal risk of extrusion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sealing elements are allowed to radially expand in open-hole conditions with significant expansion gaps, then sealing capability is improved, but axial stiffness is lost and buckling occurs

Engineering Contradiction:

Improvesealing capabilityVSAvoidaxial stiffness

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The sealing element is divided into multiple segments separated by spacers. This segmentation allows each segment to expand radially for sealing while the spacers maintain axial stiffness and prevent buckling of individual segments. The spacers act as structural supports that distribute loads and maintain the mechanical integrity of the sealing element package.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Deployable spacers are introduced as intermediary elements between sealing element segments. These spacers serve as mediators that transfer axial loads while controlling radial expansion. The spacers prevent direct buckling of sealing elements by providing intermediate support structures that maintain axial stiffness during the expansion process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If sealing elements expand radially to seal against casing, then sealing effectiveness is improved, but deployment control becomes inadequate and extrusion occurs

Engineering Contradiction:

Improvesealing effectivenessVSAvoiddeployment control

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The spacers are designed to be deployable, transitioning from a retracted state during conveyance to an expanded state during setting. This dynamic behavior allows the system to adapt: during conveyance, spacers are retracted to minimize profile; during expansion, spacers deploy to control the radial expansion of sealing elements and prevent extrusion, providing deployment control at the appropriate moment.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The spacers are positioned and pre-configured between sealing element segments before deployment. This preliminary positioning ensures that when expansion is initiated, the spacers are already in place to control the expansion process and guide the sealing elements toward proper engagement with the casing, preventing uncontrolled deployment and extrusion.

Inventive Principle:

Principle #10Preliminary action

3Force

If sealing elements are compressed axially to expand radially, then sealing force is improved, but load transfer becomes insufficient and backup shoes are inadequately deployed

Engineering Contradiction:

Improvesealing forceVSAvoidload transfer

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The spacers act as intermediary load transfer elements between the sealing element segments and the backup shoes. They receive axial compression forces and distribute them through the sealing element package, ensuring adequate load transfer to the backup shoes for proper deployment while maintaining the axial stiffness needed for effective sealing force generation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

By segmenting the sealing element with spacers, the load transfer path is distributed across multiple points rather than concentrated in a single element. This segmentation allows progressive engagement of sealing segments and backup shoes, ensuring adequate load transfer throughout the expansion process and preventing insufficient deployment.

Inventive Principle:

Principle #1Segmentation

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 deployable spacer ensures orderly deployment and effective load transfer to backup shoes, preventing extrusion and ensuring a reliable seal by maintaining axial stiffness throughout the expansion process.

Implementation Method 1

enhance axial stiffness, ensuring full deployment of backup shoes with minimal risk of extrusion

Methodology Applied

Scientific EffectAxial stiffness:

Implementation Method 2

the sealing elements radially expand, thereby sealing against the mandrel and the casing and/or wellbore

Methodology Applied

Scientific EffectRadial expansion:

Implementation Method 3

the first and second collar sleeves are configured to axially translate relative to one another along the mandrel to move the sealing element between a radially retracted state a radially expanded state

Methodology Applied

Scientific EffectAxial translation:

Data Source

PatentUS12553308B2Sealing assembly employing a deployable spacer

Publication Date: 2026.02.17 HALLIBURTON ENERGY SERVICES INC

AI summary

A sealing assembly, a well system, and a method. The sealing assembly, in one aspect, includes a mandrel, and a sealing element positioned about the mandrel. The sealing element, in this aspect, includes a first sealing element portion and a second sealing element portion, and a deployable spacer positioned between the first sealing element portion and the second sealing element portion. The sealing assembly, according to this aspect, further includes a first collar sleeve coupled proximate a first end of the sealing element, and a second collar sleeve coupled proximate a second end of the sealing element.