Downhole tool with an expandable sleeve, grit material, and button inserts

Patent metadata

Field	Value
Publication number	US-10989016-B2
Application number	US-201816117089-A
Country	US
Kind code	B2
Filing date	Aug 30, 2018
Priority date	Aug 30, 2018
Publication date	Apr 27, 2021
Grant date	Apr 27, 2021

Abstract

A downhole tool includes an expandable sleeve having an outer surface. The expandable sleeve is configured to expand radially outwards without fracturing apart. The tool also includes a plurality of button inserts positioned at least partially in the expandable sleeve and extending outward past the outer surface by a first distance, so as to engage a surrounding tubular when the expandable sleeve is expanded. The tool further includes a first band of grit material on the outer surface, adjacent to at least one row of the plurality of button inserts. The first band of grit material extends outward from the outer surface by at least the first distance, to shield the plurality of button inserts during run-in of the downhole tool.

First claim

What is claimed is:

1. A downhole tool, comprising:
an expandable sleeve having an outer surface, wherein the expandable sleeve is configured to expand radially outwards without fracturing apart;
a plurality of button inserts positioned at least partially in the expandable sleeve and extending outward past the outer surface by a first distance, wherein the plurality of button inserts are configured to engage a surrounding tubular when the expandable sleeve is expanded;
a first band of grit material on the outer surface, adjacent to at least one row of the plurality of button inserts, wherein the first band of grit material extends outward from the outer surface by at least the first distance, wherein the first band of grit material is configured to prevent the plurality of button inserts from contacting the surrounding tubular in a run-in configuration of the downhole tool, and wherein the plurality of button inserts are configured to contact the surrounding tubular in a first set configuration of the downhole tool due to expansion of the expandable sleeve; and
a second band of grit material on the outer surface, wherein the plurality of button inserts are positioned axially between the first and second bands of grit material.

2. The downhole tool of claim 1 , wherein the second band extends outward from the outer surface by a second distance that is greater than the first distance.

3. The downhole tool of claim 1 , further comprising a first cone positioned in the expandable sleeve, wherein the first cone is configured to slide axially with respect to the expandable sleeve to expand an upper portion of the expandable sleeve.

4. The downhole tool of claim 3 , wherein the first cone comprises a bore extending therethrough and a valve seat, the valve seat being configured to receive an obstructing member that is configured to obstruct the bore and substantially prevent fluid flow in at least one direction through the expandable sleeve.

5. The downhole tool of claim 4 , further comprising a second cone positioned in the expandable sleeve, wherein the second cone is configured to slide axially with respect to the expandable sleeve, and toward the first cone to expand a lower portion of the expandable sleeve.

6. The downhole tool of claim 5 , wherein the second cone comprises a bore and a plurality of grooves extending outward from the bore, the grooves being configured to engage complementary ridges of a setting tool.

7. The downhole tool of claim 5 , wherein:
in the run-in configuration of the downhole tool, the first and second cones are positioned at or near to respective axial ends of the expandable sleeve;
in the first set configuration of the downhole tool, the first and second cones are closer together than in the run-in configuration, wherein the first and second cones are each configured to be moved by a first axial distance toward one another within the expandable sleeve to actuate the downhole tool from the run-in configuration to the first set configuration; and
in a second set configuration of the downhole tool, the first and second cones are closer together than in the first set configuration, wherein the first cone is configured to be moved toward the second cone, and the second cone is configured to be held stationary, to actuate the downhole tool from the first set configuration to the second set configuration.

8. The downhole tool of claim 7 , wherein the plurality of button inserts comprises a first row of button inserts, a second row of button inserts, and a third row of button inserts, the first, second, and third rows of button inserts being axially offset from one another such that the second row is axially between the first and third rows.

9. The downhole tool of claim 8 , wherein the first row of button inserts is positioned uphole of the second row of button inserts, and the second row of button inserts is positioned uphole of the third row of button inserts, and wherein in the first set configuration, the first row of button inserts and the third row of button inserts are configured to be pressed outward into engagement with the surrounding tubular to a greater extent than the second row of button inserts.

10. The downhole tool of claim 9 , wherein, in the second set configuration, the first, second, and third rows of button inserts are configured to be pressed outward into engagement with the surrounding tubular.

11. The downhole tool of claim 8 , wherein the first band of grit material is positioned between an uphole axial end of the expandable sleeve and the first row of button inserts, wherein the second band of grit material is positioned between the second row of button inserts and the third row of button inserts, and wherein the downhole tool further comprises a third band of grit material positioned between the third row of button inserts and a downhole axial end of the expandable sleeve.

12. The downhole tool of claim 5 , wherein the expandable sleeve comprises an upper section that is configured to be pressed outward by the first cone, and a lower section that is configured to be pressed outward by the second cone, wherein the plurality of button inserts are positioned in the upper section and the lower section, and wherein the plurality of button inserts in the upper section are oriented at the same angle as the plurality of button inserts in the lower section.

13. The downhole tool of claim 1 , wherein the plurality of button inserts are oriented at an angle relative to straight radial, such that an edge of the plurality of button inserts is configured to engage the surrounding tubular when pressed radially outwards.

14. The downhole tool of claim 1 , further comprising a ring-shaped area that is free from grit material and positioned on the outer surface axially between the first and second bands.

15. The downhole tool of claim 14 , wherein at least some of the plurality of button inserts are positioned in the ring-shaped area that is free from grit material.

16. The downhole tool of claim 1 , further comprising:
a third band of grit material on the outer surface, wherein the second band of grit material is positioned axially between the first and third bands of grit material;
a first ring-shaped area that is free from grit material and positioned on the outer surface axially between the first and second bands; and
a second ring-shaped area that is free from grit material and positioned on the outer surface axially between the second and third bands.

17. The downhole tool of claim 16 , wherein at least some of the plurality of button inserts are positioned in the first ring-shaped area, the second ring-shaped area, or both.

18. The downhole tool of claim 16 , wherein the plurality of button inserts comprises:
a first button insert in the first ring-shaped area; and
a second button insert in the second ring-shaped area.

19. The downhole tool of claim 1 , wherein the first band of grit material extends outward from the outer surface by a second distance that is greater than the first distance, and wherein the second band of grit material extends outward from the outer surface by the first distance.

20. The downhole tool of claim 1 , further comprising a third band of grit material on the outer surface, wherein the third band of grit material is positioned axially between the first band of grit material and the plurality of button inserts.

21. The downhole tool of claim 20 , wherein the first band of grit material extends outward from the outer surface by a secon

Assignees

• Innovex Downhole Solutions Inc

Inventors

• Tonti Nick
• Kellner Justin
• Martin Carl

Classifications

• E21B33/1285

  by fluid pressure · CPC title

• E21B33/1293 Primary

  with means for anchoring against downward and upward movement (E21B33/1291, E21B33/1295 take precedence) · CPC title

• E21B43/108 Primary

  Expandable screens or perforated liners · CPC title