Flow Resistant Packing Element System for Composite Plug

Patent metadata

Field	Value
Publication number	US-2016061000-A1
Application number	US-201514827460-A
Country	US
Kind code	A1
Filing date	Aug 17, 2015
Priority date	Aug 30, 2014
Publication date	Mar 3, 2016
Grant date	—

Abstract

A downhole tool, such as a composite bridge plug, has a packing element disposed on a mandrel of the tool adjacent an activating element, such as a cone and slip arrangement. The packing element includes a packer and at least one backup ring. The packer is composed of packing material and is compressible on the downhole tool at least in part due to the activating element. The at least one backup ring limits extrusion of the packer. The at least one backup ring is molded into the packing material at one end of the packer adjacent the activating element. Preferably, each end of the packer has at least two backup rings molded therein, and slots in the adjacent backup rings are preferably offset at the ends.

First claim

What is claimed is:

1 . A downhole tool, comprising:
a packer positioning on the downhole tool, the packer being composed of packing material and being compressible on the downhole tool; and at least one element co-molded directly into the packing material at at least one end of the packer and at least partially limiting extrusion of the packing material axially past the at least one element beyond the at least one end of the packer.

2 . The tool of claim 1 , comprising:
a mandrel on which the packer positions; and an activating element disposed on the mandrel and compressing the packer.

3 . The tool of claim 1 , wherein the at least one element comprises at least one backup ring.

4 . The tool of claim 3 , wherein the at least one backup ring defines a plurality slots defined longitudinally therein and disposed about the at least one backup ring.

5 . The tool of claim 4 , wherein the at least one backup ring comprises at least two backup rings, the slots of the at least two backup rings being offset from one another.

6 . The tool of claim 3 , wherein at least a portion of the at least one end of the packer at least partially covers an exterior of the at least one backup ring.

7 . The tool of claim 6 , wherein the at least one backup ring comprises an endwall exposed beyond the packing material.

8 . The tool of claim 1 , wherein the at least one element comprises first and second backup rings co-molded into the packing material at opposing ends of the packer.

9 . The tool of claim 1 , wherein the at least one element comprises a first slip co-molded directly into the packing material at the at least one end of the packer.

10 . The tool of claim 9 , wherein the at least one element comprises a second slip co-molded directly into the packing material at an opposite end of the packer.

11 . The tool of claim 1 , wherein the at least one element comprises at least one first backup ring co-molded directly into the packing material at the at least one end of the packer; and wherein the tool further comprises:
a first cone disposed on the downhole tool adjacent the at least one first backup ring; and a first slip disposed on the downhole tool adjacent the first cone.

12 . The tool of claim 11 , further comprising a second slip co-molded directing into the packing material at an opposite end of the packer.

13 . The tool of claim 11 , wherein the at least one element comprises at least one second backup ring co-molded directly into the packing material at an opposite end of the packer; and wherein the system further comprises:
a second cone disposed on the downhole tool adjacent the at least one second backup ring; and a second slip disposed on the downhole tool adjacent the cone.

14 . A method of manufacturing a packing element for a downhole tool, the method comprising:
positioning at least one element in a mold; molding a packer of packing material in the mold; and adapting the at least one element to at least partially limit extrusion of the packing material axially past the at least one element beyond at least one end of the packer by co-molding the at least one element directly into the packing material at the at least one end of the packer.

15 . The method of claim 14 , wherein positioning the at least one element in the mold comprises positioning at least one backup ring in the mold with a plurality slots disposed longitudinally around a circumference of the at least one backup ring.

16 . The method of claim 15 , wherein positioning the at least one backup element in the mold comprises positioning at least two backup rings in the mold, the slots of the at least two backup rings being offset from one another.

17 . The method of claim 14 , wherein positioning the at least one backup element in the mold comprises positioning first and second backup rings in the mold; and wherein molding comprises molding the first and second backup rings directly into the packing material at opposing ends of the packer.

18 . The method of claim 14 , wherein molding the at least one element directly into the packing material at the at least one end of the packer comprises molding at least a portion of the at least one end of the packer at least partially covering an exterior of the at least one element.

19 . The method of claim 18 , wherein molding the at least one element directly into the packing material at the at least one end of the packer comprises exposing an endwall of the at least one element beyond the packing material.

20 . The method of claim 14 , wherein positioning the at least one element in the mold comprises positioning at least one slip in the mold.

21 . The method of claim 14 , wherein molding the at least one element directly into the packing material at the at least one end of the packer comprises preparing a surface of the at least one element by performing at least one of applying a bonding agent to the surface, performing surface treatment to the surface, and adding texture, holes, or roughness to the surface.

22 . The method of claim 21 , wherein preparing the surface of the at least one element comprises only partially preparing the surface for bonding with the packing material.

23 . The method of claim 14 , further comprising positioning the packer on a mandrel of the downhole tool.

24 . A downhole tool having a packer manufactured according to the method of claim 14 .

Assignees

• Weatherford Technology Holdings Llc

Inventors

• Rochen James A
• Young Jonathan A
• Mhaskar Nauman H

Classifications

• B29C45/14 Primary

  incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)} · CPC title

• B29K2027/18

  PTFE, i.e. polytetrafluoroethylene {, e.g. ePTFE, i.e. expanded polytetrafluoroethylene} · CPC title

• E21B33/1291 Primary

  anchor set by wedge or cam in combination with frictional effect, using so-called drag-blocks (E21B33/1295 takes precedence) · CPC title

• E21B33/1292

  with means for anchoring against downward and upward movement · CPC title

• E21B33/1216 Primary

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