Load-Aligned Filament Windings for Directional Strength
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Solution Overview
Problem
Conventional filament-reinforced composite materials used in downhole assemblies, such as frac plugs, often lack sufficient strength to withstand directional mechanical loads due to randomly oriented or parallel filament windings, leading to suboptimal performance under loading conditions.
Innovation Solution
A filament-reinforced composite material with load-aligned filament windings, where the filaments change orientation from being substantially parallel to the outer surface at one end to a defined angle or perpendicular at the opposing end, enhancing mechanical strength by optimizing filament orientation to match loading directions, and incorporating a cross-linked polymer matrix with prepregnated glass filaments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional parallel or random filament windings are used, then manufacturing is simpler, but strength under directional loading is insufficient
Solution Approach 1:
The filament winding process is segmented into different zones along the slip length, with each zone having filaments oriented at different angles. This allows the structure to be optimized for different loading conditions at different locations, achieving high strength under directional loading while maintaining manufacturing feasibility through systematic segmentation.
Solution Approach 2:
Different regions of the slip are given different filament orientations tailored to the local stress state. The filaments are oriented at angles that specifically match the principal stress directions at each location, creating local quality optimization that maximizes strength where needed without requiring complex orientation throughout the entire structure.
2Strength
If filaments are oriented perpendicular to loading direction, then strength under that specific load is maximized, but engagement with wellbore surface is compromised
Solution Approach 1:
The slip structure implements local quality by having filaments oriented at different angles in different regions. At the engagement surface, filaments are oriented to provide friction and mechanical interlocking with the wellbore, while in the load-bearing regions, filaments are oriented perpendicular to the loading direction to maximize strength. This spatial variation in filament orientation resolves the contradiction between engagement reliability and loading strength.
Solution Approach 2:
The slip is divided into functional segments: an engagement zone with filaments oriented for surface interaction and a load-bearing zone with filaments oriented for maximum strength. This segmentation allows each zone to be optimized for its specific function without compromising the other.
3Strength
If filament orientation is optimized for loading direction, then strength increases, but manufacturing complexity increases
Solution Approach 1:
The filament orientation is made dynamic rather than static, with the winding angle varying continuously or in steps along the length of the slip according to the local stress state. This dynamic orientation optimization achieves high strength to failure while the variation follows systematic patterns that can be implemented through controlled winding processes, maintaining manufacturing feasibility.
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 load-aligned filament windings significantly increase the strength-to-failure of composite slips by up to 300% compared to conventional materials, ensuring effective engagement and securing of downhole assemblies under directional loading, as demonstrated by increased psi ratings.
Implementation Method 1
a matrix phase comprising a cross-linked polymer
Implementation Method 2
the second orientation may be transverse to a loading direction experienced by the slip
Data Source
AI summary
A filament-reinforced composite material having with load-aligned filament windings enables improvement of mechanical properties for specific loading of parts made from the material. The orientation of the winding within the part may be changed depending on an orientation of an external load to the part. In one example, the part may be a slip in a frac plug or a bridge plug in a downhole application.