Expandable Downhole Seal with Hardened Inserts
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Solution Overview
Problem
Existing downhole tool designs, such as packers and bridge plugs, face limitations in resisting high differential pressures, as the metal-to-metal contact and elastomer seal combination is insufficient for maintaining grip and seal integrity under elevated pressure conditions.
Innovation Solution
A sealing and gripping element featuring radially extending rings with hardened inserts, where the rings and inserts penetrate the surrounding tubular upon expansion, creating a metal-to-metal seal and enhanced grip, while the sealing material is designed to flex and cover the ribs for initial contact and resist extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If radially extending rings are used to create metal-to-metal contact with the surrounding tubular, then grip capability is improved, but the ability to resist differential pressure is insufficient beyond a predetermined level
Solution Approach 1:
The invention combines elastomer sealing material with hardened inserts to create a composite gripping element. The elastomer provides sealing and compliance, while the hardened inserts provide enhanced penetration and grip capability under high differential pressures. This composite structure resolves the contradiction by integrating materials with complementary properties that simultaneously address both grip capability and pressure resistance.
Solution Approach 2:
The gripping element features localized hardened inserts positioned within the elastomer material. These inserts are strategically placed to penetrate the surrounding tubular and provide enhanced grip where needed, while the surrounding elastomer maintains sealing and flexibility. This local quality approach allows different regions of the same component to perform different functions, resolving the contradiction between grip and pressure resistance.
2Adaptability or versatility
If the ring is made thin to reduce resistance to expansion, then expandability is improved, but structural strength to support the sealing element is compromised
Solution Approach 1:
The ring structure combines a thin expandable base ring with embedded hardened inserts. The thin base ring provides low resistance to expansion and high adaptability, while the hardened inserts provide the necessary structural strength to support the sealing element during run-in and upon expansion. This composite structure resolves the contradiction by distributing structural requirements across different materials.
Solution Approach 2:
The hardened inserts are pre-positioned within the elastomer material before expansion. During run-in, these pre-positioned inserts provide immediate structural support and penetration capability. Upon expansion, the inserts are already in place to enhance grip, eliminating the need for a thicker base ring and maintaining both expandability and strength.
3Reliability
If hardened inserts are added to enhance grip under high differential pressures, then pressure resistance is improved, but device complexity increases
Solution Approach 1:
The invention merges the sealing function (elastomer) and the gripping function (hardened inserts) into a single integrated element. The hardened inserts are embedded within the elastomer material, creating a unified component that performs both sealing and high-pressure gripping functions simultaneously. This merging approach resolves the contradiction by combining multiple functions into one element rather than adding separate components.
Solution Approach 2:
The gripping element with embedded hardened inserts serves multiple functions: sealing against the surrounding tubular, providing structural support during run-in, and enhancing grip under high differential pressures. This multi-functional design resolves the contradiction by making a single component versatile enough to handle both normal and high-pressure conditions without requiring additional separate elements.
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 solution effectively maintains seal integrity and enhances grip under high differential pressures, preventing the tool from being dislodged, even when subjected to pressures that would break loose earlier designs.
Implementation Method 1
The force to do this can come from hydraulic pressure acting on a piston to create relative movement to compress the sealing element driving it out against the surrounding tubular
Implementation Method 2
Expansion of the underlying ring brings the sealing material into contact with the surrounding tubular. It also forces the radially extending rings through the sealing material and into contact with the surrounding tubular
Implementation Method 3
Upon expansion of the underlying base ring, the inserts break through the sealing material and penetrate the surrounding tubular to enhance grip when high differential pressures are encountered
Implementation Method 4
The force to do this can come from hydraulic pressure acting on a piston to create relative movement to compress the sealing element
Data Source
AI summary
A sealing and gripping element for an expandable downhole tool features a ring supporting a sealing material with radially extending rings into the sealing material during run in. Expansion of the underlying ring brings the sealing material into contact with the surrounding tubular. It also forces the radially extending rings through the sealing material and into contact with the surrounding tubular. As a result the tips of the extending rings are blunted to create metal to metal seals on the surrounding tubular. Hardened inserts are also located within the sealing material for run in. Upon expansion of the underlying base ring, the inserts break through the sealing material and penetrate the surrounding tubular to enhance grip when high differential pressures are encountered.