Downhole Slip Assembly with Offset Segments and Long Connector
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Solution Overview
Problem
Existing downhole slip assemblies prone to premature separation due to radial outward forces, causing premature setting of downhole tools in wellbores, as the segments break apart before reaching the desired location.
Innovation Solution
A slip assembly design featuring circumferentially offset segments coupled by a connector that extends from 50% to 100% of the segment length, made from materials like phenolic or magnesium, with a flat and recessed outer surface and curved inner surface, allowing controlled axial compression to break the connector and prevent premature separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If segments are coupled with a short connector, then ease of manufacture is improved, but reliability deteriorates due to premature separation under radial outward forces
Solution Approach 1:
The patent changes the key parameter of connector length from a short connector to a long connector extending 50-100% of the segment length. This parameter change fundamentally alters the mechanical behavior, providing sufficient structural support to prevent premature segment separation while maintaining manufacturability through standard casting processes.
Solution Approach 2:
The patent employs composite material construction by embedding high-strength steel rebar within the phenolic resin matrix of the connector. This composite approach allows the connector to withstand the radial outward forces and tensile stresses that would otherwise cause premature failure, thereby improving reliability without significantly complicating the manufacturing process.
2Reliability
If connector length is increased to 50-100% of segment length, then reliability is improved by preventing premature separation, but device complexity increases
Solution Approach 1:
The patent merges the connector and segments into a single integrated monolithic component formed by axial compression of a cast blank. This combining of previously separate parts (connector and segments) into one unified structure simplifies the overall device complexity while maintaining the improved reliability provided by the long connector design.
Solution Approach 2:
The patent optimizes the connector length parameter to fall within 50-100% of the segment length, which provides sufficient structural support to prevent premature separation. This optimized parameter range achieves the desired reliability improvement without excessive increase in device complexity, as the connector remains proportionate to the segment dimensions.
3Ease of operation
If segments break apart prematurely due to radial outward forces, then ease of operation is worsened by premature setting, but manufacturing precision is improved by allowing segment separation
Solution Approach 1:
The patent applies preliminary anti-action by designing the long connector with embedded steel rebar to counteract the radial outward forces before they can cause premature segment separation. This preventive design ensures that segments remain intact during deployment and only separate when the downhole tool reaches the desired location, thereby improving ease of operation without compromising manufacturing precision.
Data Source
AI summary
A slip assembly includes a first segment, a second segment that is circumferentially offset from the first segment, and a connector positioned circumferentially between the first and second segments. The connector couples the first and second segments together, and wherein a length of the connector is from about 50% to about 100% of a length of the first segment.