Abstract: A component of a slip assembly is formed by rolling sheet molding compound into a rolled charge. The rolled charge is positioned in a compression molding press and compressed to produce a molded element. The molded element is removed from the compression molding press and can be machined for use as the component of the slip assembly. The component can be a slip segment or can be a cylindrical body for the slip segment. The compound layers in the molded component can be oriented in a number of different orientations in the component and can increase the overall strength of the component.

Abstract: A downhole tool, such as a fracture plug used during a fracture operation, installs in a downhole tubular, such as casing. The tool has a mandrel with a sealing element disposed thereon between uphole and downhole ends. Slip assemblies on the mandrel can be moved to engage the downhole tubular. When the tool is used as a bridge plug, the uphole assembly supports the sealing element compressed, and the downhole assembly supports fluid pressure downhole of the tool. The slip assemblies have inserts composed of at least two materials that are different from one another and are geometrically separate from one another. In addition or as an alternative, the slip assemblies can be composed of at least two different materials that are geometrically separate from one another.

Abstract: A component of a slip assembly is formed by rolling sheet molding compound into a rolled charge. The rolled charge is positioned in a compression molding press and compressed to produce a molded element. The molded element is removed from the compression molding press and can be machined for use as the component of the slip assembly. The component can be a slip segment or can be a cylindrical body for the slip segment. The compound layers in the molded component can be oriented in a number of different orientations in the component and can increase the overall strength of the component.

Abstract: A component of a slip assembly is formed by rolling sheet molding compound into a rolled charge. The rolled charge is positioned in a compression molding press and compressed to produce a molded element. The molded element is removed from the compression molding press and can be machined for use as the component of the slip assembly. The component can be a slip segment or can be a cylindrical body for the slip segment. The compound layers in the molded component can be oriented in a number of different orientations in the component and can increase the overall strength of the component.

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.

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.

Abstract: A downhole tool, such as a fracture plug used during a fracture operation, installs in a downhole tubular, such as casing. The tool has a mandrel with a sealing element disposed thereon between uphole and downhole ends. Slip assemblies on the mandrel can be moved to engage the downhole tubular. When the tool is used as a bridge plug, the uphole assembly supports the sealing element compressed, and the downhole assembly supports fluid pressure downhole of the tool. The slip assemblies have inserts composed of at least two materials that are different from one another and are geometrically separate from one another. In addition or as an alternative, the slip assemblies can be composed of at least two different materials that are geometrically separate from one another.

Abstract: A component of a slip assembly is formed by rolling sheet molding compound into a rolled charge. The rolled charge is positioned in a compression molding press and compressed to produce a molded element. The molded element is removed from the compression molding press and can be machined for use as the component of the slip assembly. The component can be a slip segment or can be a cylindrical body for the slip segment. The compound layers in the molded component can be oriented in a number of different orientations in the component and can increase the overall strength of the component.

Abstract: A single piece composite slip component is disclosed, making it easier and more feasible for milling up a composite plug after use. Moreover, because the composite slip component is one piece during deployment, and not in segments like conventional slip segments, it can better withstand the high speeds and higher fluid velocities and pressures downhole.

Abstract: A slip assembly for a downhole tool, such as a bridge plug, has a slip body composed of independent segments. The segments are affixed together along their longitudinal sides by a bond, which can be composed of thermoplastic or thermoset resins, an elastomer, epoxy adhesives, bonding agent manufactured using ceramic, metallic agent, or a combination of these. The surface area over which the bonding agent is applied can be controlled for a particular implementation. Thus, more or less of the longitudinal sides of the segments can be bonded to other segments. This provides greater control of the required force to break the bond itself, which can be tailored as desired.