Frustoconical Downhole Expansion Tool with Segmented Voids
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Solution Overview
Problem
Existing open tip downhole expansion tools face a trade-off between ease of setting and durability, with thinner materials setting easily but failing quickly and thicker materials being difficult to set but more durable.
Innovation Solution
A frustoconical member with radially outer and inner zones featuring voids that provide low setting pressure and high resistance to deformation, with the voids positioned along the axial length to maximize flexibility during setting and resistance after setting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a thinner material tool is used, then ease of setting is improved, but durability and resistance to deformation deteriorate
Solution Approach 1:
The tool body is segmented into multiple zones with different void structures. The first void extends through the entire thickness while the second void is partial, creating differentiated structural zones that provide both flexibility for setting and strength for durability.
Solution Approach 2:
Different regions of the tool have different void configurations - the first void provides overall flexibility while the second void in the radial zone provides localized strength. This local differentiation allows the tool to exhibit both ease of setting and high durability in different areas.
2Strength
If a thicker material tool is used, then durability and resistance to deformation are improved, but ease of setting deteriorates
Solution Approach 1:
The thick material is segmented into functional zones through strategically placed voids. The first void providing full thickness penetration and the second void in the radial zone create regions of varying material density that balance flexibility and strength.
Solution Approach 2:
The tool employs local quality variation through different void configurations in different regions, allowing the thicker material to provide durability where needed while maintaining ease of setting in other areas through the first void structure.
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 tool achieves easy setting with high resistance to failure, outperforming prior art tools in maintaining position under pressure, as demonstrated by graphs showing improved rubber pressure versus radial and axial deflection performance.
Implementation Method 1
the outer and inner voids each causing the frustoconical member to present a first resistance to deformation when the voids are open and a higher resistance to deformation of the frustoconical member when the voids are collapsed
Data Source
AI summary
An open tip downhole expansion tool including a frustoconical member having a base at a diametrically smaller portion of the frustoconical member and a tip at a diametrically larger portion of the frustoconical member, the member having a radially outer zone and a radially inner zone and having an axial length extending from the base to the tip; an outer void in a material of the member along a length of the radially outer zone; and an inner void in a material of the member along a length of the radially inner zone, the outer and inner voids being located at different positions along the axial length of the frustoconical member, the outer and inner voids each causing the frustoconical member to present a first resistance to deformation when the voids are open and a higher resistance to deformation of the frustoconical member when the voids are collapsed.