Metal Sealing Ring for Downhole Tools
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Solution Overview
Problem
Downhole tools face issues with elastomeric sealing elements extruding during setting and under pressure differentials, leading to the need for additional backup components that introduce failure points.
Innovation Solution
A downhole tool design featuring a metal or composite sealing ring positioned around a tapered cone, where the slip assembly directly engages the sealing ring, expanding it radially outward into engagement with the surrounding tubular, eliminating the need for elastomeric seals and backup rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastomeric sealing elements are used, then the seal can be flexible and conform to the surrounding tubular, but the seal tends to extrude during setting and under pressure differentials
Solution Approach 1:
The patent changes the material parameter from elastomeric to metal, fundamentally altering the physical properties of the sealing element. This transformation provides both the necessary flexibility through controlled deformation and the extrusion resistance of metal, resolving the contradiction between adaptability and reliability.
Solution Approach 2:
The sealing ring is constructed as a composite structure with a metal body and embedded gripping elements (such as diamonds or carbide inserts). This composite approach combines the flexibility and strength of metal with the enhanced gripping capability of harder materials, preventing extrusion while maintaining seal effectiveness.
2Reliability
If backup members are added to prevent extrusion, then seal reliability improves, but device complexity increases due to additional components and failure points
Solution Approach 1:
The patent extracts and eliminates the backup member component entirely by integrating the extrusion prevention function directly into the sealing ring itself. The metal sealing ring with embedded gripping elements performs both sealing and extrusion resistance functions, reducing component count and eliminating the associated failure points.
Solution Approach 2:
The patent merges the functions of the sealing element and the backup member into a single integrated metal sealing ring. This consolidation eliminates the interface between separate components, reducing complexity while maintaining or improving reliability through the combined functionality.
3Reliability
If metal or composite sealing rings are used, then extrusion resistance and gripping force improve, but manufacturing complexity may increase
Solution Approach 1:
The patent applies local quality by embedding gripping elements (diamonds, carbide inserts) only in specific locations on the sealing ring where maximum extrusion resistance and gripping force are needed. This localized approach provides enhanced performance at critical points while keeping the overall manufacturing process simpler than creating a fully complex composite 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 metal or composite sealing ring resists extrusion and provides a strong, reliable seal with additional gripping force, reducing the risk of failure and eliminating the need for backup rings, enhancing the tool's holding capability and durability.
Implementation Method 1
The slips, which often have teeth, grit, buttons, or other marking structures, ride up the inclined surface of a cone during such compression, and are forced outwards into engagement with a surrounding tubular
Implementation Method 2
The seal is simultaneously expanded by such axial compression into engagement with the surrounding tubular, so as to isolate fluid communication axially across the tool
Implementation Method 3
a sealing ring positioned at least partially around the tapered outer surface of the cone... expands the sealing ring radially outward into engagement with the surrounding tubular
Data Source
AI summary
A downhole tool includes a cone having a tapered outer surface, a slip assembly positioned at least partially around the tapered outer surface of the cone, and a sealing ring positioned at least partially around the tapered outer surface of the cone. The slip assembly directly engages the sealing ring, such that the slip assembly is configured to transmit a setting force directly onto the sealing ring, which moves the sealing ring on the tapered outer surface of the cone and expands the sealing ring radially outward.