Downhole tool and method of forming the same

Patent metadata

Field	Value
Publication number	US-10378303-B2
Application number	US-201514639581-A
Country	US
Kind code	B2
Filing date	Mar 5, 2015
Priority date	Mar 5, 2015
Publication date	Aug 13, 2019
Grant date	Aug 13, 2019

Abstract

A downhole tool, including at least one body defining a surface, the at least one body having a plurality of cavities sealed from an outside of the at least one body by the surface. A plurality of the plurality of cavities being in fluidic communication with others of the plurality of cavities through a plurality of openings. A method of forming a downhole tool.

First claim

What is claimed is:

1. A downhole plug, comprising at least one body defining a surface of the downhole plug, the at least one body having a plurality of cavities sealed from an outside of the at least one body by the surface, a plurality of the plurality of cavities being in fluidic communication with others of the plurality of cavities through a plurality of openings.

2. The downhole plug of claim 1 , wherein the at least one body is formed by an additive manufacturing process.

3. The downhole plug of claim 2 , wherein the additive manufacturing process adheres together particles of a material that forms the at least one body and some of the particles of the material are left unadhered within the plurality of cavities.

4. The downhole plug of claim 3 , wherein the unadhered particles of the material provide structural support to the surface.

5. The downhole plug of claim 1 , wherein the plurality of cavities are set to an effective density of the at least one body by setting ratios of volumes of the plurality of cavities relative to that of a balance of the at least one body.

6. The downhole plug of claim 1 , wherein the at least one body comprises polymer, metal, ceramic or combinations of two or more of the foregoing.

7. The downhole plug of claim 1 , wherein the downhole plug comprises a ball.

8. The downhole plug of claim 1 , wherein the at least one body is disintegratable in a target fluid.

9. The downhole plug of claim 8 , wherein the plurality of cavities control exposure of surface area of the at least one body to the target fluid after the surface has been breached.

10. The downhole plug of claim 8 , further comprising a plurality of webs that separate the plurality of cavities from one another.

11. The downhole plug of claim 1 , wherein the plurality of cavities form concentric spheres in the at least one body.

12. The downhole plug of claim 1 , wherein the plurality of cavities are positioned below the surface to allow the surface to deform under loads applied to the surface.

13. The downhole plug of claim 12 , wherein a volume of the plurality of cavities decrease as the surface is deformed.

14. The downhole plug of claim 12 , wherein deformation of the surface is elastic deformation.

15. The downhole plug of claim 14 , wherein deformation of the surface allows the surface to seal to other members under less loading than if the surface were not allowed to deform.

16. The downhole plug of claim 1 , wherein the at least one body comprises, a first body and a second body, the first body defining the surface and the second body being sealingly encapsulated within the first body.

17. The downhole plug of claim 16 , wherein the first body and the second body are originally attached to one another but can be detached in response to loads imparted on the first body.

18. The downhole plug of claim 16 , wherein the second body includes a structure supportive to the first body should the first body deform sufficiently to make contact with the second body.

19. The downhole tool of claim 1 , wherein the downhole plug is pumpable within a downhole environment.

20. The downhole plug of claim 5 , wherein the effective density of the at least one body is set at least in part by employing more than one material during fabrication thereof of the at least one body.

21. A method of forming a downhole plug, comprising:
creating a three-dimensional computer model of the downhole plug of claim 1 ; and
forming the downhole plug with an additive manufacturing process from the three-dimensional computer model.

22. The method of forming a downhole plug of claim 21 , further comprising forming the downhole plug one layer at a time.

23. The method of forming a downhole plug of claim 21 , further comprising positioning the plurality of cavities near to the surface to allow the surface to deform.

Assignees

• Hayter Steven R
• Gilmour Daniel A
• Baker Hughes A Ge Co Llc

Inventors

• Hayter Steven R
• Gilmour Daniel A

Classifications

• B33Y80/00

  Products made by additive manufacturing · CPC title

• G05B2219/35134

  3-D cad-cam · CPC title

• E21B33/12 Primary

  Packers; Plugs (used for cementing E21B33/134, E21B33/16) · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• G05B19/4099

  Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing · CPC title