Elastomeric Sealing Element with Rigid Particles for Extrusion Resistance

Solution Overview

Problem

Sealing elements in downhole fluid recovery operations are prone to extrusion due to varying pressures, which existing technologies fail to adequately address, especially in low-precision nested structures where metal barriers can break and leave the packer unprotected.

Innovation Solution

Incorporating a plurality of rigid particles with sizes greater than 100 microns into an elastomeric matrix to create interstitial spaces, increasing the resistance to extrusion by requiring higher forces to move the matrix material through these smaller spaces, and using materials like stainless steel and inconel for enhanced resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal barriers are used to support the sealing element, then extrusion resistance is improved, but the barriers are susceptible to breaking due to low precision in nested structures

Engineering Contradiction:

Improveextrusion resistanceVSAvoidbarrier integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The sealing element uses a composite material consisting of an elastomeric matrix with embedded rigid incorporants (such as metal particles or fibers). This composite structure combines the flexibility and conformability of elastomer with the extrusion resistance of rigid materials, eliminating the need for separate metal barriers that could break.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The rigid incorporants are distributed throughout the elastomeric matrix to provide localized reinforcement specifically where extrusion resistance is needed, while maintaining the overall flexibility and sealing capability of the elastomeric material.

Inventive Principle:

Principle #3Local quality

2Strength

If the gap beyond the barrier is reduced, then extrusion resistance is improved, but the gap cannot be sufficiently reduced due to low precision in nested structures

Engineering Contradiction:

Improveextrusion resistanceVSAvoidgap control precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The invention changes the fundamental parameter of extrusion resistance from being dependent on geometric gap control (which requires high manufacturing precision) to being dependent on material properties (the composite structure of elastomer with rigid incorporants). This allows effective extrusion resistance without requiring precise gap control.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If elastomeric material is used for the sealing element, then sealing capability is improved, but extrusion resistance deteriorates under dramatically differing pressures

Engineering Contradiction:

Improvesealing capabilityVSAvoidextrusion resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The sealing element uses a composite material consisting of an elastomeric matrix with embedded rigid incorporants (such as metal particles or fibers). This composite structure combines the flexibility and conformability of elastomer with the extrusion resistance of rigid materials, eliminating the need for separate metal barriers that could break.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The rigid incorporants are distributed throughout the elastomeric matrix to provide localized reinforcement specifically where extrusion resistance is needed, while maintaining the overall flexibility and sealing capability of the elastomeric material.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8490979B2Method for reducing extrusion of sealing elements

Publication Date: 2013.07.23 BAKER HUGHES CO

AI summary

A sealing element includes an elastomeric matrix; a plurality of incorporants embedded in the matrix.