Expandable Annular Isolator Swage Expansion Seal Fixation

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Solution Overview

Problem

Existing packer designs fail to effectively expand the tubular's drift dimension while maintaining adequate sealing and preventing extrusion under differential pressures, as they either rely on external energizing or limited segment expansion, which does not ensure full tubular expansion and seal alignment.

Innovation Solution

A tubular with an exterior sealing element in a recess is expanded by a swage, causing extending members initially embedded in the seal to move outward and penetrate the surrounding tubular, acting as extrusion barriers and aids in fixation, while increasing the tubular's drift dimension and ensuring proper seal alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the tubular is expanded to increase drift dimension, then the seal alignment and extrusion barrier performance improve, but the seal material may extrude under differential pressure during expansion

Engineering Contradiction:

Improvedrift dimensionVSAvoidseal extrusion

Core Design Contradiction:

Volume of moving objectVSObject-generated harmful factors

Solution Approach 1:

The spikes are pre-positioned in the seal material before expansion, ready to penetrate and create extrusion barriers at the critical locations where the seal will contact the surrounding tubular during expansion

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The spikes are designed to resist seal extrusion by penetrating the seal material and creating barriers that prevent the seal from being forced outward under differential pressure during the expansion process

Inventive Principle:

Principle #9Preliminary anti-action

2Reliability

If extending members penetrate the seal to engage the surrounding tubular, then extrusion barrier function improves, but the seal integrity may be compromised

Engineering Contradiction:

Improveextrusion barrier functionVSAvoidseal integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The spikes are pre-positioned within the seal material in a controlled manner, allowing them to penetrate and create extrusion barriers while maintaining seal integrity through proper design and placement

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The spikes are strategically positioned at specific locations within the seal where extrusion barriers are most needed, providing localized penetration that creates effective barriers without compromising overall seal integrity

Inventive Principle:

Principle #3Local quality

3Volume of moving object

If the tubular is expanded uniformly, then the drift dimension increases, but the seal may not align properly with the surrounding tubular

Engineering Contradiction:

Improvedrift dimensionVSAvoidseal alignment

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The spikes are pre-positioned to align with the surrounding tubular before expansion, ensuring that when the tubular expands, the seals and spikes will be properly aligned with the tubular wall at the expanded diameter

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The expansion process changes the dimensional parameters of the tubular and embedded components, causing the spikes to move radially outward and the seals to expand into alignment with the surrounding tubular at the new drift dimension

Inventive Principle:

Principle #35Parameter changes

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

This solution ensures effective sealing and fixation by increasing the tubular's drift dimension, allowing the seal to maintain differential pressure and penetrate the surrounding tubular, enhancing the seal's performance and stability under expansion.

Implementation Method 1

A swage passes through the tubular to increase its drift dimension from a location above the seal to below the seal

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

Extending members that are initially embedded in the seal while extending from the tubular wall that defines the recess move out during the expansion to engage the surrounding tubular to act as extrusion barriers and to aid in the fixation of the seal while being able to penetrate the wall of the surrounding tubular

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS9243468B2Expandable annular isolator

Publication Date: 2016.01.26 BAKER HUGHES CO

AI summary

A tubular has an exterior sealing element disposed in a recess. A swage passes through the tubular to increase its drift dimension from a location above the seal to below the seal. The interior projection that initially defined the exterior wall recess where the seal is located is expanded to the new drift dimension of the balance of the tubular. Extending members that are initially embedded in the seal while extending from the tubular wall that defines the recess move out during the expansion to engage the surrounding tubular to act as extrusion barriers and to aid in the fixation of the seal while being able to penetrate the wall of the surrounding tubular in so doing.