Monolithic Composite Slip Insert for Downhole Anchoring
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Solution Overview
Problem
Composite materials used in downhole tools struggle to anchor effectively under high pressure due to insufficient biting force into metal casings, and the addition of harder materials like carbide or ceramic buttons complicates manufacturing and increases costs.
Innovation Solution
The design incorporates inserts with a base, first and second buttons, and a connecting member that are formed from a single monolithic piece, embedded within the slip segments, allowing for enhanced engagement with the tubular surface and improved anchoring force without the need for additional harder materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If carbide or ceramic buttons are bonded to composite slips to improve anchoring force, then the biting force into metal casing is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the button and connecting member into a single monolithic insert made of composite material, eliminating the need to bond separate carbide or ceramic buttons to the slip. This integration maintains anchoring functionality while simplifying the overall device structure and reducing assembly complexity.
Solution Approach 2:
The patent changes the material parameter from requiring harder materials (carbide/ceramic) to using a specially formulated composite material that achieves sufficient anchoring force through its structural design and monolithic construction, rather than relying on material hardness alone.
2Force
If carbide or ceramic buttons are bonded to composite slips to improve anchoring force, then the biting force into metal casing is improved, but the manufacturing cost increases
Solution Approach 1:
The insert is formed as a single monolithic piece combining the button and connecting member, which simplifies manufacturing by eliminating multiple bonding operations and reducing the need for expensive carbide or ceramic materials. The composite material can be formed more cost-effectively while maintaining anchoring performance.
Solution Approach 2:
The patent uses a composite material that can be formed economically through molding processes, replacing expensive carbide or ceramic buttons. The design accepts that the insert may be consumed or damaged during operation, but the lower material and manufacturing costs provide economic benefit.
3Force
If buttons are made larger to improve anchoring capability, then the biting force is improved, but the difficulty of milling the buttons increases
Solution Approach 1:
The patent changes the manufacturing method from mechanical milling to molding or forming processes. This allows larger button dimensions to be achieved more easily, as the monolithic insert can be formed in a mold rather than milled from solid material, significantly reducing manufacturing difficulty for larger sizes.
4Ease of operation
If composite material is used for slips to ease milling out, then the ease of operation is improved, but the anchoring force into metal casing is insufficient
Solution Approach 1:
The patent applies local quality by creating a monolithic insert with specific structural features (button and connecting member) that concentrate the anchoring function in a localized area. The composite material maintains its milling advantages while the insert's design provides enhanced anchoring capability through its geometry and integration with the slip.
Solution Approach 2:
The patent uses composite material for the monolithic insert that combines the advantages of ease of milling with improved anchoring characteristics. The composite can be formulated and structured to provide both machinability and sufficient biting force into the casing.
Data Source
AI summary
An insert for a slip of a downhole tool including a base, a first button, a second button, and a connecting member. The first and second buttons extend from the base and are configured to engage an inner diameter surface of a tubular. The connecting member extends from the base and is positioned between the first button and the second button.