Resilient Matrix Backup Ring for Frangible Components

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Solution Overview

Problem

Composite frac plugs in wellbore fracturing applications face premature breakage of frangible components, leading to reduced reliability and increased risk of stuck-in-hole events during shipping and deployment.

Innovation Solution

A backup ring with a resilient matrix material, such as silicone or rubber, is applied to fill slots between segments, providing additional support and preventing premature breakage, while allowing for normal expansion and setting during fracturing operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If frangible components are made breakable for controlled fracturing, then they can be easily removed after operation, but they break prematurely during shipping and deployment

Engineering Contradiction:

Improveease of removalVSAvoidpremature breakage

Core Design Contradiction:

Ease of repairVSReliability

Solution Approach 1:

A resilient matrix material is applied to the frangible backup ring segments before deployment. This matrix material acts as a cushioning protective layer that prevents premature breakage during shipping and deployment while allowing the segments to break apart as intended when exposed to fracturing fluid, thus resolving the contradiction between ease of removal and reliability

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If additional retainer rings are added to prevent breakage, then reliability improves, but device complexity increases

Engineering Contradiction:

Improveprevention of premature breakageVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the protective function with the existing backup ring segments by applying a resilient matrix material directly to them. This merges the protection function into the existing structure rather than adding separate retainer rings, thus improving reliability while avoiding increased device complexity

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If over-molded rubber is used to protect frangible components, then reliability improves, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveprotection during shippingVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of using over-molded rubber which requires complex multi-material molding processes, the patent applies a resilient matrix material that can be coated or bonded onto the frangible segments. This changes the manufacturing parameter from complex over-molding to simpler application processes, improving reliability while maintaining ease of manufacture

Inventive Principle:

Principle #35Parameter changes

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 solution enhances the reliability of downhole tools by preventing premature damage and reducing stuck-in-hole events, ensuring effective sealing and fracturing fluid distribution without requiring additional retainer rings or over-molded rubber.

Implementation Method 1

a resilient matrix material that at least partially fills each slot of the plurality of slots

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

wherein mating the backup ring with the end of the sealing element causes the resilient matrix material to at least partially fill each slot of the plurality of slots; and allowing the resilient matrix material to cure into a solid

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS11788375B2Resilient matrix suspension for frangible components

Publication Date: 2023.10.17 SCHLUMBERGER TECH CORP

AI summary

A backup ring includes a plurality of segments defined by a plurality of slots, wherein each segment is defined by a sequential pair of the plurality of slots, and a resilient matrix material that at least partially fills each slot of the plurality of slots.