Frac Plug Blocking Device for Instant Flow Reestablishment

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Solution Overview

Problem

Conventional frac plugs require complex and time-consuming operations for removal and do not allow instant reestablishment of communication if perforation guns fail to fire, leading to inefficiencies in frac fluid consumption and cost.

Innovation Solution

A downhole tool with an embedded blocking device that forms a seal and can be repositioned to allow bi-directional fluid flow, using a pressure differential to shear the device and enable communication without additional milling or waiting, allowing a single-run frac plug to create multiple seals and reestablish communication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional frac plugs are used with ball and seat mechanisms, then wellbore zonal isolation can be achieved, but the operations become complex and time-consuming for removal

Engineering Contradiction:

Improvewellbore zonal isolationVSAvoidremoval time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The blocking device is segmented into an object portion and an embedded blocking device portion that can be separated. The embedded blocking device can be disengaged from the object through fluid pressure, allowing the object to remain in place while the blocking device is removed or repositioned, significantly reducing removal time and complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The blocking device transitions from a static sealed position to a mobile state through fluid pressure. The embedded blocking device can be repositioned or disengaged by applying fluid pressure in a second direction, enabling dynamic control of the seal and eliminating the need for complex mechanical removal operations

Inventive Principle:

Principle #15Dynamics

2Reliability

If conventional frac plugs require additional balls and seats, then multiple seals can be created, but the device complexity increases

Engineering Contradiction:

Improveseal creationVSAvoidmechanical parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The embedded blocking device serves multiple functions: it forms a seal with the object, can be repositioned to allow communication, and can be disengaged for removal. This single integrated mechanism replaces the need for separate balls, seats, and complex mechanical components, reducing device complexity while maintaining seal reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The blocking device merges the sealing function and the communication control function into a single integrated component. The embedded blocking device works with the object to create seals, and fluid pressure controls its position to either block or allow communication, eliminating the need for separate mechanical sealing components

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If conventional frac plugs are used, then perforation guns can be fired, but there is no contingency operation if guns fail to fire requiring additional milling time

Engineering Contradiction:

Improvefrac operation efficiencyVSAvoidcontingency response time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The blocking device provides dynamic contingency control. If perforation guns fail to fire, fluid pressure can be applied to disengage the embedded blocking device from the object, instantly reestablishing communication through the tool without requiring milling operations or waiting for dissolvable materials to dissolve

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system provides self-service contingency operation through the embedded blocking device. The same fluid system used for normal operation can also disengage the blocking device if needed, eliminating the need for separate contingency mechanisms or additional intervention equipment

Inventive Principle:

Principle #25Self-service

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

Enables efficient, single-run frac plug operations with reduced fluid consumption and cost, allowing for instant reestablishment of communication and improved wellbore zonal isolation during stimulation treatments.

Implementation Method 1

A pressure differential across the blocking device may shear the embedded blocking device from the object

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Implementation Method 2

A pressure differential across the blocking device may shear the embedded blocking device from the object

Methodology Applied

Scientific EffectShear stress: Shear Stress

Data Source

PatentUS20260022621A1Methods and systems for selectively restricting fluid flowing through a downhole tool

Publication Date: 2026.01.22 VERTICE OIL TOOLS INC

AI summary

A bottom set frac plug including an object with an embedded blocking device, wherein the embedded blocking device is configured to form an initial seal across the object, allow communication through the object, be repositioned across the object to once again restrict communication through the object based on fluid flowing in a first direction, and be permanently disengaged from the object based on fluid flowing in a second direction.