Expandable Seal With High Yield Steel Setting Sleeve
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Solution Overview
Problem
Existing expandable seals/anchors face limitations in grip force due to small carbide buttons and soft material used for the setting sleeve, which attenuates the anchoring force transmission and requires excessive force to expand, potentially damaging the surrounding tubular.
Innovation Solution
The use of high yield steel for the setting sleeve with a weakened leading end and surface treatment, featuring a plurality of fingers with axial slots that flex easily and engage or penetrate the tubular wall, along with a travel stop mechanism to control expansion force and prevent excessive radial movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If soft material is used for the setting sleeve to reduce the required pushing force, then the force needed to expand the seal assembly is reduced, but the ability to transmit anchoring force to the mandrel is attenuated
Solution Approach 1:
The setting sleeve employs different material properties in different regions: the body is made of high yield steel for strong anchoring force transmission, while the leading end features a weakened section with reduced cross-sectional area or material density to require less pushing force during expansion
Solution Approach 2:
The setting sleeve is divided into functionally distinct segments: a body portion for structural strength and force transmission, and a leading end portion with weakened characteristics for easier expansion initiation
2Shape
If carbide buttons are made small to fit the seal design, then the seal structure is compact, but the grip force on the assembly is limited
Solution Approach 1:
The seal assembly combines carbide buttons (for penetration and anchoring) with a rubber or elastomeric body material (for flexibility and sealing), creating a composite structure that achieves both compactness and adequate grip force through the combination of hard and soft materials
Solution Approach 2:
The carbide buttons are designed with rounded or spherical shapes rather than sharp edges, allowing them to penetrate and grip the tubular wall effectively while maintaining a compact overall seal structure
3Reliability
If the setting sleeve outer dimension is increased to avoid engaging the surrounding tubular wall, then the seal assembly can be set properly, but the anchoring force transmission to the mandrel is reduced
Solution Approach 1:
The setting sleeve has different dimensional characteristics at different locations: the body maintains sufficient outer dimension for strong anchoring force transmission, while the leading end has reduced dimension to prevent premature engagement with the tubular wall during the setting process
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 the anchoring and sealing capability by transmitting anchoring forces effectively through high yield steel and reduces the required force to set the assembly, preventing damage to the surrounding tubular while ensuring secure locking.
Implementation Method 1
a plurality of fingers with axially oriented slots starting from a leading end allowing fingers to flex as they ride up the ramp on the mandrel
Implementation Method 2
The surface treatment can be wickers, hard particles or a roughening of the exterior surface in some other way. As a result the set position of the anchor/seal assembly is further locked in with the setting sleeve exterior surface wither abutting or penetrating the wall of the surrounding tubular
Data Source
AI summary
An expandable anchor/seal is pushed up a ramp until making contact with the surrounding tubular as or after the anchor/seal contacts the same tubular. The setting sleeve is made from high yield steel that has a weakened leading end to reduce the force required to push the leading end and the anchor/seal and an outer surface treatment at a leading end that engages or penetrates the wall of the surrounding tubular. Preferably a plurality of fingers are formed with axially oriented slots starting from a leading end allowing fingers to flex as they ride up the ramp on the mandrel for setting the anchor/seal and locking that set with the setting sleeve exterior surface configuration that can abut or penetrate the surrounding tubular.