Flexible Support Ring Assembly for Borehole Sealing
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Solution Overview
Problem
Existing borehole sealing technologies face challenges in maintaining effective isolation across irregular borehole shapes and varying operating conditions, particularly at high pressures and temperatures, where they struggle to ensure reliable sealing and prevent seal material extrusion.
Innovation Solution
A flexible support assembly featuring spring discs rotationally locked to a mandrel, with actuation rings and a corrugated member that uses axial force to pivot and radially expand, pushing sealing material into contact with the borehole wall while controlling extrusion through external peaks and valleys, allowing for high-pressure and high-temperature sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If axial force is applied to expand the sealing element radially, then sealing contact with the borehole wall is improved, but seal material extrusion increases
Solution Approach 1:
The patent applies local quality by providing extrusion barriers (stiff rings) at specific locations - the ends of the sealing element - rather than uniformly across the entire sealing element. This localized reinforcement prevents extrusion at critical points while maintaining the flexibility and sealing capability of the main sealing body.
Solution Approach 2:
The patent uses composite materials by combining a flexible sealing element with embedded stiff rings. The sealing element provides radial flexibility for conforming to the borehole wall, while the stiff rings provide axial rigidity to prevent extrusion. This composite structure resolves the contradiction between needing flexibility for sealing and rigidity for extrusion control.
2Adaptability or versatility
If the sealing element is made more flexible to conform to irregular borehole shapes, then adaptability to borehole geometry is improved, but resistance to high pressure differentials deteriorates
Solution Approach 1:
The patent combines flexible sealing material with embedded stiff rings to create a composite structure. The flexible material allows the sealing element to conform to irregular borehole shapes, while the stiff rings provide the structural strength needed to resist high pressure differentials without excessive deformation.
Solution Approach 2:
The patent segments the sealing element by embedding discrete stiff rings at intervals along its length. This segmentation allows the sealing element to maintain flexibility between the rings for conforming to irregular shapes, while the distributed rings provide cumulative strength to resist pressure differentials.
3Loss of substance
If embedded stiff rings are added to control seal element extrusion, then extrusion control is improved, but device complexity increases
Solution Approach 1:
The patent merges the sealing function and extrusion control function into a single integrated component. The stiff rings are embedded within the sealing element itself, combining the sealing material and extrusion barriers into one unified structure rather than requiring separate components for each function.
Solution Approach 2:
The patent creates a composite material structure where stiff rings are embedded within the flexible sealing element. This composite design provides both sealing and extrusion control functions in a single integrated component, avoiding the need for additional separate parts and reducing overall device complexity.
4Reliability
If the sealing element is designed for high expansion to reach irregular borehole surfaces, then sealing contact is improved, but the run-in dimension increases
Solution Approach 1:
The patent uses a corrugated or bellows-like structure with curved segments that can compress axially and expand radially. This curved geometry allows the sealing element to achieve significant radial expansion from a compact run-in configuration, reducing the axial length required during installation while maintaining the ability to conform to irregular borehole surfaces.
Solution Approach 2:
The patent employs a dynamic structure that transitions from a compressed state during run-in to an expanded state during operation. The corrugated design allows the sealing element to dynamically change its configuration - compact axially during installation, then expand radially to contact the borehole wall, achieving high expansion ratios without excessive run-in dimension.
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 provides enhanced sealing contact and extrusion control, accommodating irregular borehole shapes and high operating conditions, with the ability to handle temperatures up to 600F and achieve significant radial expansion, ensuring reliable isolation and reduced seal material extrusion.
Implementation Method 1
spring discs rotationally locked to a mandrel, with actuation rings and a corrugated member that uses axial force to pivot and radially expand
Implementation Method 2
uses axial force to pivot and radially expand, pushing sealing material into contact with the borehole wall
Data Source
Figure 1
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Figure 4~5
AI summary
Spring discs are rotationally locked to the mandrel are between pairs of actuation rings that feature a circumferential protrusion. On application of axial force release of a stored force from flexing, the protrusion engages a sloping portion of the spring disc and moves the sloping portion toward a more vertical orientation. Alternatively, a release of a stored force from flexing accomplishes the same result. Slots in the spring disc allow irregular growth to conform to surface irregularities of a surrounding surface. The discs can serve as anchors, centralizers or supports for a sealing element in a packer. Ends of fingers feature stiffeners to enhance strength. The discs can be stacked apart or together and oriented in the same or opposed directions. The can deliver an axial force when stacked and pushed toward flat and released.