Lattice seal packer assembly and other downhole tools

Patent metadata

Field	Value
Publication number	US-10060217-B2
Application number	US-201515537062-A
Country	US
Kind code	B2
Filing date	Feb 17, 2015
Priority date	Feb 17, 2015
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

A downhole tool includes an elongated base pipe and a expandable element disposed on the base pipe and radially expandable from a first configuration to a second configuration. The expandable element includes a first lattice structure that includes a first plurality of connecting members; a second plurality of connecting members movable relative to the first plurality of connecting members to allow the expandable element to radially expand from the first configuration to the second configuration; and a plurality of cells, each of the cells being defined between at least two connecting members. Each of the connecting members from the at least two connecting members is from the first plurality of connecting members or from the second plurality of connecting members. In one or more exemplary embodiments, the first lattice structure is at least partially manufactured using an additive manufacturing process.

First claim

What is claimed is:

1. A downhole tool, comprising:
an elongated base pipe; and
an expandable element disposed on the base pipe and radially expandable from a first configuration to a second configuration;
wherein the expandable element comprises:
a first lattice structure comprising:
a first plurality of connecting members;
a second plurality of connecting members movable relative to the first plurality of connecting members to allow the expandable element to radially expand from the first configuration to the second configuration; and
a first plurality of cells, each of the cells in the first plurality of cells being defined between at least a connecting member from each of the first plurality of connecting members and the second plurality of connecting members; and

a second lattice structure that is different from the first lattice structure, wherein the second lattice structure comprises:
a third plurality of connecting members;
a fourth plurality of connecting members movable relative to the third plurality of connecting members to allow the expandable element to radially expand from the first configuration to the second configuration; and
a second plurality of cells, each of the cells in the second plurality of cells being defined between at least a connecting member from each of the third plurality of connecting members and the fourth plurality of connecting members;

wherein the second lattice structure is adjacent to the first lattice structure in a longitudinal or radial direction relative to the elongated base pipe;
wherein, when the expandable element is in the first configuration, one or more of the cells in the first plurality of cells defines a first volume;
wherein, when the expandable element is in the second configuration, one of more of the cells in the first plurality of cells defines a second volume that is greater than the first volume;
wherein the downhole tool is a packer assembly that is adapted to extend within a pre-existing structure, the pre-existing structure defining a circumferentially extending inner surface;
wherein the expandable element further comprises a swellable elastomer accommodated in one or more of the cells in the first plurality of cells, wherein the swellable elastomer is expandable from a third volume that corresponds to the first volume to a fourth volume that corresponds to the second volume; and
wherein, when the packer assembly extends within the pre-existing structure and the expandable element is in the second configuration, the swellable elastomer is adapted to expand to the fourth volume to sealingly engage the inner surface.

2. A downhole tool, comprising:
an elongated base pipe; and
an expandable element disposed on the base pipe and radially expandable from a first configuration to a second configuration;
wherein the expandable element comprises:
a first lattice structure comprising:
a first plurality of connecting members;
a second plurality of connecting members movable relative to the first plurality of connecting members to allow the expandable element to radially expand from the first configuration to the second configuration; and
a first plurality of cells, each of the cells in the first plurality of cells being defined between at least a connecting member from each of the first plurality of connecting members and the second plurality of connecting members; and

a second lattice structure that is different from the first lattice structure, wherein the second lattice structure comprises:
a third plurality of connecting members;
a fourth plurality of connecting members movable relative to the third plurality of connecting members to allow the expandable element to radially expand from the first configuration to the second configuration; and
a second plurality of cells, each of the cells in the second plurality of cells being defined between at least a connecting member from each of the third plurality of connecting members and the fourth plurality of connecting members;

wherein the second lattice structure is adjacent to the first lattice structure in a longitudinal or radial direction relative to the elongated base pipe;
wherein, when the expandable element is in the first configuration, one or more of the cells in the first plurality of cells defines a first volume;
wherein, when the expandable element is in the second configuration, one of more of the cells in the first plurality of cells defines a second volume that is greater than the first volume;
wherein the expandable element further comprises a swellable elastomer accommodated in one or more of the cells in the first plurality of cells, wherein the swellable elastomer is expandable from a third volume that corresponds to the first volume to a fourth volume that corresponds to the second volume; and
wherein the swellable elastomer is adapted to expand from the third volume to the fourth volume to cause the expandable element to radially expand from the first configuration to the second configuration.

3. The downhole tool of claim 2 , wherein the first lattice structure is at least partially manufactured using an additive manufacturing process.

4. The downhole tool of claim 2 ,
wherein the second lattice structure is adjacent to the first lattice structure in the radial direction relative to the elongated base pipe and defines an exterior skin of the expandable element, the exterior skin having a circumference; and
wherein the fourth plurality of connecting members are movable relative to the third plurality of connecting members to allow the circumference of the exterior surface to expand when the expandable element radially expands from the first configuration to the second configuration.

5. The downhole tool of claim 2 , wherein the first lattice comprises at least one of: a uniform lattice structure; a non-uniform lattice structure; and a conformal lattice.

6. The downhole tool of claim 2 , wherein the first lattice structure is composed of a metal.

7. The downhole tool of claim 2 , wherein the downhole tool is any one of: an expansion joint; a travel joint; an anchor; a screen filter; a seal bore; and a bridge plug.

8. A downhole tool, comprising:
an elongated base pipe; and
an expandable element disposed on the base pipe and radially expandable from a first configuration to a second configuration;
wherein the expandable element comprises:
a first lattice structure comprising:
a first plurality of connecting members;
a second plurality of connecting members movable relative to the first plurality of connecting members to allow the expandable element to radially expand from the first configuration to the second configuration; and
a first plurality of cells, each of the cells in the first plurality of cells being defined between at least a connecting member from each of the first plurality of connecting members and the second plurality of connecting members; and

a second lattice structure that is different from the first lattice structure, wherein the second lattice structure comprises:
a third plurality of connecting members;
a fourth plurality of connecting members movable relative to the third plurality of connecting members to allow the expandable element to radially expand from the first configuration to the second configuration; and
a second plurality of cells, each of the cells in the second plurality of cells being defined between at least a connecting member from each of the third plurality of connecting members and the fourth plurality of connecting members;

wherein the second lattice structure is adjacent to the first lattice structure in a longitudinal or radial direction relative to the elongated base pipe;
wherein, when the expandable element is in the

Assignees

• Halliburton Energy Services Inc

Inventors

• Murphree Zachary Ryan
• Fripp Michael Linley
• Frosell Thomas Jules
• Gano John Charles
• Zhong Xiaoguang Allan

Classifications

• E21B33/1208 Primary

  characterised by the construction of the sealing or packing means (E21B33/1277 takes precedence) · CPC title

• E21B33/122

  Multiple string packers · CPC title