CABLE RETENTION SYSTEM AND METHOD OF MANUFACTURE FOR INFLATABLE PACKER

Description

RELATED APPLICATIONS

The present application claims priority to and benefit of U.S. Provisional patent application No. 63/726,829, filed Dec. 2, 2024, which is hereby incorporated by reference for all purposes as if set forth herein in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to downhole tools, and more specifically to a cable retention system and method of manufacture for an inflatable packer.

BACKGROUND OF THE INVENTION

Downhole tools can improve the productivity of a gas or oil well but have numerous disadvantages.

SUMMARY OF THE INVENTION

A downhole tool, such as an inflatable packer, is disclosed. The downhole tool includes a first metal end stage that has a plurality of tabs and a second metal end stage that has a plurality of tabs. A cable is disposed between the first metal end stage and the second metal end stage, wherein the cable is successively wrapped around each of the plurality of tabs to form a structure between the first metal end stage and the second metal end stage.

Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings may be to scale, but emphasis is placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, and in which:

FIG. 1 is a diagram of an inflatable packer 100, in accordance with an example embodiment of the present disclosure;

FIG. 2 is a diagram of an end assembly, in accordance with an example embodiment of the present disclosure;

FIG. 3 is a diagram of a second end assembly, in accordance with an example embodiment of the present disclosure;

FIG. 4 is a diagram of an end collar, in accordance with an example embodiment of present disclosure;

FIG. 5 is a diagram of an end collar, in accordance with an example embodiment of the present disclosure;

FIG. 6 is a diagram of cable winding, in accordance with an example embodiment of the present disclosure;

FIG. 7 is a diagram of a casing mold enclosing an inflatable packer, in accordance with an example embodiment of the present disclosure;

FIG. 8 is a diagram of a casing mold removed from an inflatable packer, in accordance with an example embodiment of the present disclosure; and

FIG. 9 is a diagram of a manufacturing process for manufacturing an inflatable packer, in accordance with an example embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures may be to scale, and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness.

The present application claims priority to and benefit of U.S. Provisional patent application No. 63/726,829, filed Dec. 2, 2024, which is hereby incorporated by reference for all purposes as if set forth herein in its entirety.

Inflatable packers can be fabricated using two end collars, with steel slats disposed between the end collars to provide reinforcement and to separate an inner bladder from an outer cover. Steel slats can provide sufficient rigidity to support the inflatable element but lack the flexibility to conform to non-uniform well conditions. A mesh or cable could alternatively be used in place of steel slats but known attachment methods for mesh and cable material does not provide enough strength to withstand the pressure requirements of the inflatable element.

The present disclosure relates to a cable retention system and method of manufacture that allows a single cable to be threaded between two end collars. The disclosed system and method of manufacture advantageously avoids any need for attaching a cable to an end collar, such that the strength of the cable is no longer reliant on the attachment method of the cable (such as epoxy). Instead, the cable is formed into segments by winding it around steel tabs on each end collar, which allows the inflatable packer to use the benefit of the cable's flexibility and ability to conform to non-uniform hole conditions, while not reducing the strength.

FIG. 1 is a diagram of an inflatable packer 100, in accordance with an example embodiment of the present disclosure. Inflatable packer 100 can be fabricated from metal, rigid polymers, composite materials or other suitable materials.

Inflatable packer 100 includes end collar 102, end collar 104, cable 106, threads 108, tabs 110, threads 112 and tabs 114. End collar 102 and end collar 104 can be machined from steel pipe, using computer numerical control machining, stamping, forging, casting, injection molding, 3D printing or in other suitable manners. End collar 102 and end collar 104 can be fabricated separately and then assembled with cable 106 to form inflatable packer 100. In one example embodiment, embodiment, end collar 102 and end collar 104 can be placed on a mandrel and cable 106 can be wound around tabs 110 of end collar 102 and tabs 114 of end collar 104 in a continuous manner, such as by using a robotic device or in other suitable manners. A single continuous length of cable 106 can be used, multiple lengths of cable can be used with or without connectors, or other suitable embodiments can also or alternatively be used. In this example embodiment, end collar 102 and end collar 104 can be rotated on the mandrel as the cable is wound or other suitable processes can also alternatively be used. In this manner, the manufacturing process can ensure that threads 108 and threads 112 are not damaged during the cable winding process.

FIG. 2 is a diagram of an end assembly 200, in accordance with an example embodiment of the present disclosure. End assembly 200 includes outer threads 202, which are machined into end collar 102 at an outer diameter portion. Inner threads 204 are likewise machined into an inner diameter portion of end collar 102. End surface 206 or other suitable surfaces can be formed on end collar 102, and inner surface 208 can be an inner surface of end collar 102. Seal 210 and seal 212 are provided to form a seal between end collar 102 and a casing pipe or other suitable materials. Tab 214 is typical of a plurality of tabs that are disposed with an even radial spacing around the circumference of end collar 102, and cable 106 is wound around tabs 214. As shown in FIG. 2, cable portion 216 is wound around tab 214, and a similar configuration is used for cable 106 as it is wound around other tabs. In this manner, one end of inflatable packer 100 can be formed on a mandrel or in other suitable manners while a second end is also being formed.

FIG. 3 is a diagram of a second end assembly 300, in accordance with an example embodiment of the present disclosure. Second end assembly 300 includes end collar 104 and inner threads 302, outer threads 304, seal 306, seal 308, seal 310, seal 312, tab 314, and cable turn 316. As previously discussed, cable turn 316 is typical of all cable turns of second end assembly 300 and can be formed from a single length of cable or in other suitable manners. Cable 106 can be formed around tab 314 by a robotic device or in other suitable manners, such as by placing end collar 104 on a mandrel that is the same as or that is coordinated with the mandrel holding and collar 102, and by turning end collar 104 as cable 106 is wound around tab 314 and other tabs. In this manner, the inner threads 302, outer threads 304, and seals 306, 308, 310, and 312 will not be damaged during the manufacturing process.

FIG. 4 is a diagram 400 of end collar 102, in accordance with an example embodiment of present disclosure. In addition to other noted elements, diagram 400 includes inner tabs 402, which are disposed around the circumference of end collar 102. Likewise, outer surface 404 is positioned in the area that is contained under cable 106 after it is wound around in inner tabs 402 and tabs 214. In this manner, multiple layers of cable can be provided to increase the strength of inflatable packer 100.

FIG. 5 is a diagram 500 of end collar 104, in accordance with an example embodiment of the present disclosure. In addition to other components previously discussed, diagram 500 includes inner tabs 502, outer surface 504, end surface 506, inner surface 508, inner seal 510 and end surface 512. Inner tabs 502 and tabs 314 can be used to form two layers of cable windings to increase the strength of and maintain structural stability of inflatable packer 100. Inner seal 510 can be used to form a seal between the inflatable packer 100 and other well string components.

FIG. 6 is a diagram of cable winding 600, in accordance with an example embodiment of the present disclosure. Cable winding 600 includes first edge 602, second edge 604, turns 608 and turns 610. In one example embodiment, cable winding 600 can be formed prior to installation on inflatable packer 100. In another example environment, cable winding 600 can be formed with end collar 102 and end collar 104 disposed on a mandrel or in other suitable manners.

FIG. 7 is a diagram of a casing mold enclosing an inflatable packer, in accordance with an example embodiment of the present disclosure. The casing mold includes a top mold half 710 and a bottom mold half 712, which are disposed around an inflatable packer that has been placed onto mandrel 702. End collars 704 and 706 cover the cable windings that form a substructure for a molded casing. Press plug 708 is secured to mandrel 702 with threads or other suitable fasteners.

FIG. 8 is a diagram of a casing mold removed from an inflatable packer, in accordance with an example embodiment of the present disclosure. The casing mold includes a top mold half 710 and a bottom mold half 712, which are removed from an inflatable packer that has been placed onto mandrel 702. End collars 704 and 706 cover the cable windings that form a substructure for a molded casing 802. Press plug 708 is secured to mandrel 702 with threads or other suitable fasteners.

FIG. 9 is a diagram of a manufacturing process 900 for manufacturing an inflatable packer, in accordance with an example embodiment of the present disclosure. Process 900 can be implemented using a programmable process controller, an inflatable packer manufacturing system, a cable handling system, one or more robotic systems, metal machining systems and in other suitable manners.

Process 900 begins at 902, where end stages are placed on a mandrel. In one example embodiment, the mandrel can be a manufacturing mandrel for use in initial manufacturing processes, such as winding cable. The end stages can be manually placed on the mandrel, can be placed using a robotic device, or can be placed in other suitable manners. The process then proceeds to 904.

At 904, the location of tabs on the end stages is indexed. In one example embodiment, the tabs can be indexed by manually aligning the tabs on a first end stage with the tabs on a second end stage. In another example embodiment, the tabs can be indexed using a programmable controller, where an assumed location of a first tab is aligned with a robotic cable winding system. Indexing can also or alternatively be implemented using a robotic vision system or other suitable robotic sensors. The process then proceeds to 906.

At 906, a cable is attached to an end stage. In one example embodiment, the cable can be secured using a set screw or other suitable mechanical attachment device to a predetermined location on a first end stage. Other suitable attachment mechanisms can also or alternatively be used. The process then proceeds to 908.

At 908, a first layer of cable is wound around tabs of the end stages. In one example embodiment, the end stages can include multiple layers of tabs, and the first layer of tabs at the smallest radius can be wound with the cable first, with successive layers of tabs wound after each preceding layer has been wrapped. The cable can be wound manually, a robotic device or system can be used to wrap the cable, or other suitable systems and processes can also or alternatively be used. For example, if a robotic device or system is used, a combination of servo motors can be used to control the feed of the cable and the placement of a cable setting tool, to successively wrap the cable around each tab on successive end stages. A robotic vision system can be used to confirm a location of each tab, programmable coordinates can be used to control the location of the cable setting tool, or other suitable systems and processes can also or alternatively be used. The process then proceeds to 910.

At 910, the end stages and first layer of cable are wrapped with Kevlar or other suitable protective materials. In one example embodiment, each end stage can be wrapped with Kevlar that extends for a predetermined distance over the first layer of cable and which then terminates, to protect the ends of the first layer of cable during a shell molding process or subsequent manufacturing processes. Other suitable processes can also or alternatively be used. The process then proceeds to 912.

At 912, it is determined whether an additional layer of cable should be wrapped. In one example embodiment, end stages can include multiple layers of tabs, and the determination can be made manually, by analyzing image data with a robotic sensor, by using programmable coordinates for a robotic controller or in other suitable manners. If it is determined that an additional layer should be wrapped, the algorithm proceeds to 914 where the next layer of cable is wrapped, such as using the processes discussed and described above or in other suitable manners. The additional layers of cable can be aligned with the first layer as shown in FIG. 3, can be offset at an angle from the first layer, or other suitable configurations can also or alternatively be used. In one example embodiment, the angle between the cables in the first layer and the cables in the second layer can be 30 degrees, where the angle between the cables as shown in FIG. 3 is 0 degrees. The algorithm then returns to 912. Likewise, if it is determined that no more layers of cable need to be wrapped at 912, the algorithm proceeds to 916.

At 916, a shell is formed around the end stages and cable windings. In one example embodiment, a mold can be placed over the assembled end stages and cable windings, the shell can be fabricated from polyurethane, plastics, composites, elastomers, or other suitable materials, such as by extrusion molding, injection molding, machining, other suitable processes, or a suitable combination of processes. The combination of the cables and shell provides a light weight inflatable packer with improved mechanical properties.

In one example embodiment, a downhole tool is disclosed that includes a first metal end stage having a plurality of first tabs, a second metal end stage having a plurality of second tabs; and a cable disposed between the first metal end stage and the second metal end stage, wherein the cable is successively wrapped around each of the plurality of first tabs and the plurality of second tabs.

In another example embodiment, the plurality of first tabs of the first metal end stage are located around a circumference of the first metal end stage.

In another example embodiment, the plurality of first tabs of the first metal end stage have a uniform size and shape.

In another example embodiment, the plurality of first tabs of the first metal end stage have a uniform size and shape and are located around a circumference of the first metal end stage.

In another example embodiment, the plurality of tabs of the first metal end stage have a uniform size and shape and are located around a circumference of the first metal end stage with a uniform spacing.

In another example embodiment, the plurality of first tabs of the first metal end stage comprises a first row of metal tabs and a second row of metal tabs.

In another example embodiment, the plurality of first tabs of the first metal end stage comprises a first row of metal tabs having a first circumference and a second row of metal tabs having a second circumference that is different from the first circumference.

In another example embodiment, the plurality of first tabs of the first metal end stage are located around a circumference of the first metal end stage and the plurality of second tabs of the second metal end stage are located around a circumference of the first metal end stage.

In another example embodiment, the plurality of first tabs of the first metal end stage and the plurality of second tabs of the second metal end stage have a uniform size and shape.

In another example embodiment, the plurality of first tabs of the first metal end stage have a uniform size and shape and are located around a circumference of the first metal end stage and the plurality of second tabs of the second metal end stage have a uniform size and shape and are located around a circumference of the second metal end stage.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.”

As used herein, “hardware” can include a combination of discrete components, an integrated circuit, an application-specific integrated circuit, a field programmable gate array, or other suitable hardware. As used herein, “software” can include one or more objects, agents, threads, lines of code, subroutines, separate software applications, two or more lines of code or other suitable software structures operating in two or more software applications, on one or more processors (where a processor includes one or more microcomputers or other suitable data processing units, memory devices, input-output devices, displays, data input devices such as a keyboard or a mouse, peripherals such as printers and speakers, associated drivers, control cards, power sources, network devices, docking station devices, or other suitable devices operating under control of software systems in conjunction with the processor or other devices), or other suitable software structures. In one exemplary embodiment, software can include one or more lines of code or other suitable software structures operating in a general-purpose software application, such as an operating system, and one or more lines of code or other suitable software structures operating in a specific purpose software application. As used herein, the term “couple” and its cognate terms, such as “couples” and “coupled,” can include a physical connection (such as a copper conductor), a virtual connection (such as through randomly assigned memory locations of a data memory device), a logical connection (such as through logical gates of a semiconducting device), other suitable connections, or a suitable combination of such connections. The term “data” can refer to a suitable structure for using, conveying or storing data, such as a data field, a data buffer, a data message having the data value and sender/receiver address data, a control message having the data value and one or more operators that cause the receiving system or component to perform a function using the data, or other suitable hardware or software components for the electronic processing of data.

In general, a software system is a system that operates on a processor to perform predetermined functions in response to predetermined data fields. A software system is typically created as an algorithmic source code by a human programmer, and the source code algorithm is then compiled into a machine language algorithm with the source code algorithm functions, and linked to the specific input/output devices, dynamic link libraries and other specific hardware and software components of a processor, which converts the processor from a general-purpose processor into a specific purpose processor. This well-known process for implementing an algorithm using a processor should require no explanation for one of even rudimentary skill in the art. For example, a system can be defined by the function it performs and the data fields that it performs the function on. As used herein, a NAME system, where NAME is typically the name of the general function that is performed by the system, refers to a software system that is configured to operate on a processor and to perform the disclosed function on the disclosed data fields. A system can receive one or more data inputs, such as data fields, user-entered data, control data in response to a user prompt or other suitable data, and can determine an action to take based on an algorithm, such as to proceed to a next algorithmic step if data is received, to repeat a prompt if data is not received, to perform a mathematical operation on two data fields, to sort or display data fields or to perform other suitable well-known algorithmic functions. Unless a specific algorithm is disclosed, then any suitable algorithm that would be known to one of skill in the art for performing the function using the associated data fields is contemplated as falling within the scope of the disclosure. For example, a message system that generates a message that includes a sender address field, a recipient address field and a message field would encompass software operating on a processor that can obtain the sender address field, recipient address field and message field from a suitable system or device of the processor, such as a buffer device or buffer system, can assemble the sender address field, recipient address field and message field into a suitable electronic message format (such as an electronic mail message, a TCP/IP message or any other suitable message format that has a sender address field, a recipient address field and message field), and can transmit the electronic message using electronic messaging systems and devices of the processor over a communications medium, such as a network. One of ordinary skill in the art would be able to provide the specific coding for a specific application based on the foregoing disclosure, which is intended to set forth exemplary embodiments of the present disclosure, and not to provide a tutorial for someone having less than ordinary skill in the art, such as someone who is unfamiliar with programming or processors in a suitable programming language. A specific algorithm for performing a function can be provided in a flow chart form or in other suitable formats, where the data fields and associated functions can be set forth in an exemplary order of operations, where the order can be rearranged as suitable and is not intended to be limiting unless explicitly stated to be limiting.

It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.