Abstract: An extrusion ring has a base from which multiple segmented rows of rings integrally extend. Gaps in one row are offset from the adjacent row to cover any gaps. The rows gain strength from a common base that also prevents relative rotation among the rows. The overlapping rings are additively manufactured with breakable restraints in some or all the gaps that fail during the setting such as in shear. Faster running in rates can be realized as each ring row has hoop strength due to the ties in the gap or gaps that are incorporated into the additive manufacturing process to make the assembly. Residual stresses in each ring from the additive manufacturing process are resisted from the ties in the gaps. Ties between overlapping rows are also contemplated.

Abstract: A sealing element is flanked by wedge-shaped extrusion ring assemblies. The extrusion rings are continuous for 360 degrees and are slotted from the outside dimension and alternatively from the inside dimension to allow the diameter to increase to the surround tubular or open hole. The extrusion rings climb a ramp on an adjacent pedestal ring on the way out to the borehole wall. Depending on the dimension of the gap to be spanned the extrusion ring slides a variable distance up the pedestal ring ramp. An optional anchor ring is initially forced up an opposite ramp of the pedestal ring. If the sealing gap is short the anchor ring can be eliminated. For larger gaps the anchor ring moves out far enough toward the borehole wall to contact the extrusion ring located on an opposing ramp of the pedestal ring so that reaction forces are directed to keep the anchor ring wedged in position for support of the extrusion ring assembly.

Abstract: An extrusion ring has a base from which multiple segmented rows of rings integrally extend. Gaps in one row are offset from the adjacent row to cover any gaps. The rows gain strength from a common base that also prevents relative rotation among the rows. The overlapping rings are additively manufactured with breakable restraints in some or all the gaps that fail during the setting such as in shear. Faster running in rates can be realized as each ring row has hoop strength due to the ties in the gap or gaps that are incorporated into the additive manufacturing process to make the assembly. Residual stresses in each ring from the additive manufacturing process are resisted from the ties in the gaps. Ties between overlapping rows are also contemplated.

Abstract: A seal backup including: a ring-like body, the body including: a first portion of the body having a first generally zig-zag construction, the first generally zig-zag construction facilitative of radial expansion of the first portion; a second portion of the body having a second generally zig-zag construction, the second generally zig-zag construction facilitative of radial expansion of the second portion; a parting feature disposed between the first portion of the body and the second portion of the body facilitative of relative movement between the first portion of the body and the second portion of the body.

Abstract: An extrusion ring has a base from which multiple segmented rows of rings integrally extend. Gaps in one row are offset from the adjacent row to cover any gaps. The rows gain strength from a common base that also prevents relative rotation among the rows. The overlapping rings are additively manufactured with breakable restraints in some or all the gaps that fail during the setting such as in shear. Faster running in rates can be realized as each ring row has hoop strength due to the ties in the gap or gaps that are incorporated into the additive manufacturing process to make the assembly. Residual stresses in each ring from the additive manufacturing process are resisted from the ties in the gaps. Ties between overlapping rows are also contemplated.

Abstract: A backup or extrusion barrier ring assembly has multiple rows of rings in segments that have circumferentially offset slots. The rings are rotationally locked to each other to maintain the circumferential offset of the slots that allow the rings to be more flexible in the setting process. The rings as a unit can be mounted to relatively rotate on a supporting mandrel. The rings are mounted to allow them to move axially during setting either in tandem or axially relatively to each other. The axial run in heights of rings decline from innermost to outermost so that when set the heights approach each other to minimize or eliminate sharp ends against the seal. Alternatively, the height difference can be such as to allow ends to bend over an adjacent end further out radially so that free ends bend toward the surrounding tubular and avoid the seal.

Abstract: An extrusion ring has a base from which multiple segmented rows of rings integrally extend. Gaps in one row are offset from the adjacent row to cover any gaps. The rows gain strength from a common base that also prevents relative rotation among the rows. The overlapping rings are additively manufactured with breakable restraints in some or all the gaps that fail during the setting such as in shear. Faster running in rates can be realized as each ring row has hoop strength due to the ties in the gap or gaps that are incorporated into the additive manufacturing process to make the assembly. Residual stresses in each ring from the additive manufacturing process are resisted from the ties in the gaps. Ties between overlapping rows are also contemplated.

Abstract: A seal backup including: a ring-like body, the body including: a first portion of the body having a first generally zig-zag construction, the first generally zig-zag construction facilitative of radial expansion of the first portion; a second portion of the body having a second generally zig-zag construction, the second generally zig-zag construction facilitative of radial expansion of the second portion; a parting feature disposed between the first portion of the body and the second portion of the body facilitative of relative movement between the first portion of the body and the second portion of the body.

Abstract: Alternating l-shaped side slots are cut into opposed sides of a backup ring and are circumferentially offset and alternately extend from the inside and outside dimension. An oval shaped opening connects adjacent circumferentially offset slots so that on ring expansion the inside and outside diameters increase as the openings are sheared at one end to place a barrier in opened side slot to prevent extrusion of the adjacent sealing element.

Abstract: An extrusion ring has a base from which multiple segmented rows of rings integrally extend. Gaps in one row are offset from the adjacent row to cover any gaps. The rows gain strength from a common base that also presents relative rotation among the rows.

Abstract: In one aspect, a seal apparatus for use with a mandrel is disclosed that in one non-limiting embodiment contains a seal housing disposed about the mandrel, wherein the seal housing is spaced apart from the mandrel to form a seal gap, a seal member disposed between the seal housing and the mandrel, wherein the seal member is bonded to the seal housing and the seal member is formed from a first material, and a seal support disposed between the seal housing and the mandrel, wherein the seal support is formed from a second material, wherein the second material is stiffer than the first material, and the seal support extends across the seal gap in response to an energizing force applied to the seal support.

Abstract: A unique backup ring against ends of a sealing element features axial slots extending part way along a cylindrical segment of the backup ring. The slots end in rounded openings to relieve stress and a part of the cylindrical shape of the backup ring is solid. The slotted end of the cylindrical portion is tapered in section toward the end overlapping the sealing element. The face of the backup ring away from the sealing element is tapered and rides on an adjacent tapered surface away from the mandrel during the setting. The tapered seal end of the backup ring bends to reach the surrounding tubular before the balance of the cylindrical portion reaches the surrounding tubular. Extrusion along the mandrel is stopped by a mandrel seal on an adjacent wedge ring. The mandrel end of the backup ring has a peripheral stiffener to lend rigidity.

Abstract: A sealing element is flanked by wedge-shaped extrusion ring assemblies. The extrusion rings are continuous for 360 degrees and are slotted from the outside dimension and alternatively from the inside dimension to allow the diameter to increase to the surround tubular or open hole. The extrusion rings climb a ramp on an adjacent pedestal ring on the way out to the borehole wall. Depending on the dimension of the gap to be spanned the extrusion ring slides a variable distance up the pedestal ring ramp. An optional anchor ring is initially forced up an opposite ramp of the pedestal ring. If the sealing gap is short the anchor ring can be eliminated. For larger gaps the anchor ring moves out far enough toward the borehole wall to contact the extrusion ring located on an opposing ramp of the pedestal ring so that reaction forces are directed to keep the anchor ring wedged in position for support of the extrusion ring assembly.