Downhole tool with anti-extrusion device

Patent metadata

Field	Value
Publication number	US-10408011-B2
Application number	US-201715618823-A
Country	US
Kind code	B2
Filing date	Jun 9, 2017
Priority date	Oct 31, 2014
Publication date	Sep 10, 2019
Grant date	Sep 10, 2019

Abstract

A downhole tool including a mandrel, a sealing element, a cone, a plurality of fingers, and a slip. The sealing element may be positioned around the mandrel. The sealing element is configured to expand radially-outward from a contracted state to an expanded state. The cone may be positioned around the mandrel and proximate to the sealing element. The plurality of fingers may be positioned at least partially around the mandrel. The fingers may be axially-aligned with at least a portion of the sealing element. The fingers are coupled to a base and configured to break away from the base at a weak point when the sealing element expands into the expanded state. The slip may be positioned around the mandrel and proximate to the cone. The slip may include a tapered inner surface configured to slide along a tapered outer surface of the cone.

First claim

What is claimed is:

1. A downhole tool, comprising:
a sealing element configured to expand outward to seal with a surrounding tubular;
slips; and
a cone positioned at least partially adjacent to the sealing element and the slips, wherein the cone comprises a base and a plurality of fingers that extend from the base and overlap an end of the sealing element,
wherein a weak point is defined by the cone,
wherein the sealing element expanding causes at least a portion of each finger of the plurality of fingers to breaks away from the base at the weak point, and
wherein the base comprises a tapered outer surface that is configured to force the slips radially outward as the slips slide axially along the tapered outer surface.

2. The downhole tool of claim 1 , wherein the weak point is defined by a recess that extends circumferentially around the base, located where the plurality of fingers meet the base.

3. The downhole tool of claim 1 , wherein the base, the plurality of fingers, or both define a recess extending circumferentially entirely around the base and radially therein that provides the weak point.

4. The downhole tool of claim 3 , wherein the plurality of fingers define slots therebetween that extend from a distal end of the plurality of fingers to the base.

5. The downhole tool of claim 1 , wherein the at least a portion of each finger of the plurality of fingers is displaced radially outwards from the base after breaking away from the cone at the weak point.

6. The downhole tool of claim 1 , wherein, after breaking away, at least one of the plurality of fingers is configured to be entrained radially between at least a portion of the sealing element and the surrounding tubular.

7. The downhole tool of claim 1 , further comprising a generally-cylindrical mandrel, wherein the sealing element and the cone are positioned around the mandrel, and wherein the sealing element expands radially outwards from the mandrel.

8. The downhole tool of claim 7 , wherein the slips are positioned around the mandrel, and wherein the slips each include a tapered inner surface configured to slide along the tapered outer surface of the base of the cone, so as to expand the slips radially outwards and into engagement with the surrounding tubular.

9. The downhole tool of claim 7 , wherein at least one of the plurality of fingers includes a tapered inner surface that increases in diameter moving in a direction parallel to a central longitudinal axis of the mandrel and toward the sealing element.

10. The downhole tool of claim 1 , further comprising a ring positioned at least partially between the sealing element and the plurality of fingers.

11. The downhole tool of claim 10 , wherein the ring is configured to prevent the sealing element from extruding between the plurality of fingers.

12. The downhole tool of claim 10 , wherein the ring is configured to expand radially-outward by expanding the sealing element radially-outward.

13. The downhole tool of claim 1 , wherein the slips do not slide against the fingers.

14. The downhole tool of claim 1 , wherein the slips are configured to engage the surrounding tubular while engaging the tapered outer surface of the base of the cone, such that the slips apply a compressive force on the base in reaction to engaging the surrounding tubular.

15. A cone for a setting assembly in a downhole tool, the cone comprising:
a tapered section that is configured to wedge between a mandrel and slips of the downhole tool, for expanding the slips by moving the slips axially with respect to the cone;
a base coupled to or integral with the tapered section, wherein the base comprises a tapered outer surface that is configured to force the slips radially outward as the slips slide axially along the tapered outer surface; and
a plurality of fingers extending axially from the base,
wherein the cone defines a weak point that is configured to break upon application of a predetermined force,
wherein, when the cone breaks at the weak point, at least a portion of each of the plurality of fingers are separated from the base, and
wherein the plurality of fingers are configured to be positioned at least partially around an end of a sealing element, such that outward expansion of the sealing element causes the plurality of fingers to break away from the base at the weak point.

16. The cone of claim 15 , wherein the base is integral with or coupled to the plurality of fingers prior to the plurality of fingers breaking away from the base.

17. The cone of claim 15 , wherein at least one of the plurality of fingers includes a tapered inner surface that increases in diameter moving in a direction away from the base, and wherein the tapered inner surface is configured to engage an outer surface of the sealing element.

18. The cone of claim 15 , wherein the plurality of fingers are configured to be entrained between at least a portion of the sealing element and a surrounding tubular when the sealing element expands.

19. A method for actuating a downhole tool in a wellbore, comprising:
running the downhole tool into the wellbore, wherein the downhole tool comprises:
a sealing element configured to expand outward to seal with a surrounding tubular;
slips; and
a cone positioned at least partially adjacent to the sealing element and the slips, wherein the cone comprises a base that defines a tapered outer surface, and a plurality of fingers that extend from the base and overlap an end of the sealing element, wherein a weak point is defined by the cone; and

applying an axial compression force to the sealing element and the slips, wherein the compression force causes the sealing element to expand radially-outward from a contracted state to an expanded state, wherein the sealing element expanding causes the plurality of fingers to break away from the cone at the weak point and move radially outward with respect to the cone, and wherein the compression force causes the slips to slide along the tapered outer surface of the base, so as to expand the slips outward into engagement with a surrounding tubular by engagement with the tapered outer surface of the base.

20. The method of claim 19 , wherein the cone defines a recess extending radially outward from an inner diameter thereof, such that the weak point is formed in the cone.

21. The method of claim 19 , wherein the sealing element expanding radially outwards entrains at least one of the plurality of fingers at least partially between the sealing element, the base, and the surrounding tubular.

22. The method of claim 19 , wherein the downhole tool further comprises a ring positioned between the sealing element and the plurality of fingers, wherein the sealing element expanding causes the ring to expand, and wherein the ring is configured to prevent the sealing element from extruding axially between circumferentially-adjacent fingers of the plurality of fingers.

Assignees

• Team Oil Tools Lp
• Innovex Downhole Solutions Inc

Inventors

• Harris Michael J

Classifications

• E21B33/1216 Primary

  Anti-extrusion means, e.g. means to prevent cold flow of rubber packing · CPC title