Expandable Liner Hanger Foam-Based Rib Engagement

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Solution Overview

Problem

Existing expandable liner hangers (ELH) face issues with voids between ribs and casing ID during expansion, leading to limited engagement and reduced rib engagement due to fluid expansion or thermal cycles, which affects deployment in extended reach wells.

Innovation Solution

Incorporation of a closed cell foam member with air pockets between ribs, which collapses under pressure or mechanical load to increase fluid volume, allowing unrestricted rib expansion and mitigating engagement reduction during thermal cycles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a non-compressible fluid fills the void between ELH ribs and casing ID, then rib engagement is limited during expansion, but if a compressible fluid is used, then rib engagement is unrestrained initially but reduces during thermal cycles

Engineering Contradiction:

Improverib engagementVSAvoidthermal cycle resistance

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the physical state and compressibility parameters of the fluid in the void space. By using a compressible fluid that can change its volume under pressure, the system adapts to both expansion phases (allowing full rib engagement) and thermal cycles (absorbing expansion without losing engagement), thus resolving the contradiction between initial engagement and thermal stability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The compressible fluid acts as an intermediary between the rigid ribs and the casing ID. It mediates the interaction by providing a compliant interface that allows controlled deformation, enabling the ribs to maintain engagement with the casing while accommodating thermal expansions and contractions of the surrounding structures

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If an elastomer is used to fill the void, then no fluid is trapped, but full engagement of ribs to casing ID is restricted

Engineering Contradiction:

Improvefluid trapping preventionVSAvoidrib engagement precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent employs a porous or foam-like material that allows fluid communication while providing structural support. This material enables the ribs to expand fully against the casing ID while still preventing fluid trapping, as the porous structure permits fluid to pass through rather than being enclosed by a solid elastomer barrier

Inventive Principle:

Principle #31Porous materials

3Volume of moving object

If the foam member collapses under pressure, then fluid volume increases allowing unrestricted rib expansion, but the foam occupies space that could be used for fluid volume

Engineering Contradiction:

Improvefluid volumeVSAvoidvoid space utilization

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The foam member is designed to be dynamic rather than static - it collapses under pressure during the setting operation, transforming from a space-occupying solid to a compressed state that releases fluid volume. This dynamic behavior allows the system to optimize both void space utilization during deployment and fluid volume availability during expansion

Inventive Principle:

Principle #15Dynamics

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

Enhances rib engagement and deployment in extended reach wells by increasing fluid volume and reducing effective weight, while maintaining grip during mechanical loading and pressure fluctuations.

Implementation Method 1

The foam member when exposed to either increased pressure from adjacent fluid or to mechanical load from the expansion process, collapses, and crushes the air pockets thereby reducing the volume of the foam member

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

connecting some or all of the air pockets to the outside void

Methodology Applied

Scientific EffectPressure-driven flow: Pressure Gradient

Implementation Method 3

The mechanism also mitigates any pressure increase in the fluid volume through thermal expansion

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12435603B2Enhanced expandable liner hanger rib engagement mechanism

Publication Date: 2025.10.07 HALLIBURTON ENERGY SERVICES INC

AI summary

Systems and methods of the present disclosure relate to downhole tools including expandable liner hangers that used a foam member to increase fluid volume in voids defined by the hanger and the casing. A system comprises a downhole tool comprising a tubular body, ribs extending along a circumference of the tubular body, and at least one foam member disposed on the tubular body and between the ribs. The system also includes a conduit. The downhole tool is disposed in the conduit. A void is defined by the tubular body, the ribs, and the conduit, and the foam member is disposed in the void.