Multi-Modulus Sealing Element With Localized Fiber Loading

Solution Overview

Problem

Wellbore seals in subterranean formations are prone to failure due to substantial pressure differentials, leading to time, money, and equipment losses, as well as potential harm to individuals. Current designs and materials for wellbore seals are limited in structure and material choice, which increases the risk of failure.

Innovation Solution

The development of sealing elements with regions of different Young's modulus, incorporating localized fiber loading, which includes a lower modulus region for flexibility and a higher modulus region for enhanced extrusion resistance and abrasion resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a wellbore seal is subjected to substantial pressure differentials, then the seal must provide adequate containment, but the seal is prone to failure due to extrusion and deformation

Engineering Contradiction:

Improveseal reliabilityVSAvoidresistance to extrusion and deformation

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The sealing element incorporates regions with different Young's modulus values within its structure. Specifically, it includes a first region with a first Young's modulus and a second region with a second Young's modulus that is different from the first. This allows different portions of the seal to have optimized properties for their specific functions - some regions provide flexibility for conforming to the borehole geometry, while other regions provide rigidity for resistance to extrusion and deformation under pressure differentials.

Inventive Principle:

Principle #3Local quality

2Reliability

If the sealing element structure and material choice are limited to minimize failure, then the chance of failure is reduced, but the design and manufacture flexibility is constrained

Engineering Contradiction:

Improvefailure resistanceVSAvoidstructure and material choice flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The sealing element is constructed as a composite structure with multiple regions having different Young's modulus values. This composite approach allows the seal to combine materials or material configurations that provide both flexibility and strength, enabling designers to select from a broader range of material combinations and structural arrangements to optimize performance while maintaining reliability.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If the sealing element is designed to expand under pressure, then it can conform to the borehole wall, but substantial deformation induces internal stress that increases failure risk

Engineering Contradiction:

Improveexpansion capabilityVSAvoidinternal stress resistance

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The sealing element incorporates regions with different Young's modulus values within its structure. Specifically, it includes a first region with a first Young's modulus and a second region with a second Young's modulus that is different from the first. This allows different portions of the seal to have optimized properties for their specific functions - some regions provide flexibility for conforming to the borehole geometry, while other regions provide rigidity for resistance to extrusion and deformation under pressure differentials.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250034964A1Sealing Element With Higher Modulus Region

Publication Date: 2025.01.30 HALLIBURTON ENERGY SERVICES INC

AI summary

A variety of methods and apparatus are disclosed, including, in one embodiment, downhole tool for use in a well, comprising: a tool mandrel; a sealing element disposed about the mandrel, wherein the sealing element comprises a lower modulus region and a higher modulus region.