COLLAPSIBLE SUPPORT RINGS FOR A DOWNHOLE SYSTEM

Abstract

A downhole system, such as a packer or a bridge plug, isolates zones in a wellbore. Each downhole system includes a mandrel, a sealing member, ring members, and support rings. Each support ring has an extended configuration to position the support ring between the respective ring member and sealing member during deployment and before installation and a collapsed configuration to prevent extrusion of the ring member and sealing member after installation. Ring caps can be added between the support rings and ring members for additional support.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

See Application Data Sheet.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

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INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR AS A TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB)

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STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a downhole tool for isolating zones in a wellbore. More particularly, the present invention relates to collapsible support rings for downhole systems to isolate zones in the wellbore. More particularly, the present invention relates to collapsible support rings compatible with a packer system or a millable bridge plug system.

2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98

Land formations have different zones. Some zones have mixtures of oil and gas, which can be extracted or produced. The zones may not be identical, such that the mixtures of oil and gas may be different in different zones. Still others zones may produce other fluids, such as water, which do not need to be produced. Some zones may produce no fluids at all. An oil and gas wellbore can pass through any number and combination of these zones in the land formation. In order to effectively extract the oil and gas, the zones with desirable mixtures of oil and gas, called production zones, are isolated from the other zones.

Open-hole completions are commonly used for producing oil and gas in a wellbore. Open-hole completions are particularly useful in slant-hole wells. In these wells, the wellbore may be deviated and run horizontally for thousands of feet through a producing zone. It is often desirable to provide annular isolators, or packers, along the length of the horizontal production tubing to allow selective production from, or isolation of, various portions of the producing zone. FIG. 1 shows a prior art liner system 410 with packers. The land formation 416 has a water-producing zone 420, a non-producing zone 421 below the water-producing zone 420, an oil-and-gas zone 422 below the non-producing zone 421, another water zone 423 below the oil-and-gas zone 422, and another oil-and-gas zone 424 below the water zone 423. The wellbore 450 extends vertically and diagonally through the water-producing zone 420. The wellbore 450 extends diagonally through the non-producing zone 421, the oil-and-gas zone 422, the other water zone 423, and a portion of the oil-and-gas zone 424. The wellbore 450 has a casing 414 on the walls of the wellbore 450 near the surface 412 of the land formation 416. FIG. 1 shows the wellbore 450 without casing 414 when turned diagonal or horizontal. The liner system includes packers 417 to isolate in the casing 414 and within the zones 421, 422, 423, 424. Each packer 417 includes a mandrel 411 placed in an interior 452 of the wellbore 450 and a sealing member activated at the desired location in the wellbore 450. Packers 417 provide annular seals, or barriers, between the liner and the wellbore wall to isolate various zones within the wellbore and along the liner.

Bridge plugs are alternative downhole components to isolate zones. Usually in a casing, a bridge plug generally includes a mandrel, a sealing member placed around the mandrel, ring members adjacent the end of the sealing member and around the mandrel, upper and lower slip devices at opposite ends of the mandrel, and respective upper and lower cone assemblies engaged to the upper and lower slip devices. FIG. 2A shows the prior art bridge plug system 10 with a mandrel 12, sealing member 14, and upper and lower slip devices 16 and 18 shown. The bridge plug is placed in the wellbore by a setting tool on a positioning assembly, such as wireline, coiled tubing or even the drill string itself. Once in position at the correct depth and orientation, the bridge plug is activated. The setting tool holds the mandrel 12 in place, while a ramming portion of the setting tool exerts pressure on the stack, which includes the sealing member 14 and the slip devices 11 and 18. The end can have a cap which prevents the stack from sliding off the mandrel 12, when the ramming portion of the setting tool hits the stack. Instead, the pressure of the ramming portion compresses the stack, forcing the sealing member 14 to radially extend outward to seal against the wellbore or case and to flatten to a smaller height along the mandrel. The slip devices 16 are toothed and are distended radially outward by the stack to dig into the wellbore walls, locking the sealed configuration of the stack. The lower slip device 18 holds position by the cap at the end, while the upper slip device 16 lowers and locks the seal of the spread sealing member 14. When the ramming portion has compressed and locked the stack, the end 20 proximal to the setting tool on the positioning assembly is sheared, separating the bridge plug from the setting tool and the positioning assembly. FIG. 2B shows the prior art bridge plug system 10 in an activated and set state. Pressure on the lower cone assembly against the lower slip device 18 at the distal end of the mandrel causes the lower slip device 16 to open and latch against the wellbore. Continuing pressure by the ram expands the sealing member 14 against the rings to form a seal against the walls of the wellbore. Pressure on the upper cone assembly causes the upper slip device 16 to also open and latch against the wellbore, setting the seal of the sealing member.

The activation of the bridge plug requires advancement for a more efficient and stable seal in the wellbore. The ramming portion provide the force needed to form the seal on the wellbore, and this force is directed by those stack structures, the sealing member, ring members, cone assemblies, and slip devices, of the bridge plug. The interactions between these stack structures are important for efficiency and consistency of the forming the seal and locking the seal on the wellbore. The pressure is exerted directly on the sealing member by ring members in some arrangements of the stack structures. The interface between the sealing member and the ring members of the prior art has a constant taper angle between the sealing member and the ring members. The amount of pressure against the sealing member does not vary as the pressure of the positioning assembly is exerted through the ring members. The expansion of the sealing member to the wall of the wellbore is steady, yet possibly insufficient for an adequate seal. The lack of a threshold amount of pressure for setting the seal may result in a sealing member that is not expanded enough to form a good seal or extrusion of the sealing member beyond the ring members due to too much pressure. The exerted pressure on the sealing member may also be too much, causing extrusion and degradation of the seal member. There is a need for resistance to excess pressure after the seal is formed.

Conventional materials of the millable bridge plug, like all downhole tools, must withstand the range of wellbore conditions, including high temperatures and/or high pressures. High temperatures are generally defined as downhole temperatures generally in the range of 200-450 degrees F.; and high pressures are generally defined as downhole pressures in the range of 7,500-15,000 psi. Other conditions include pH environments, generally ranging from less than 6.0 or more than 8.0. Conventional sealing elements have evolved to withstand these wellbore conditions so as to maintain effective seals and resist degradation.

Metallic components have the durability to withstand the wellbore conditions, including high temperatures and high pressures. However, these metallic components are difficult to remove. De-activating and retrieving the bridge plug to the surface is costly and complicated. Milling metallic components takes time, and there is a substantial risk of requiring multiple drilling elements due to the metallic components wearing or damaging a drilling element of a removal assembly.

Non-metallic components are substituted for metallic components as often as possible to avoid having so much metal to be milled for removal of the bridge plug. However, these non-metallic components still must effectively seal an annulus at high temperatures and high pressures. Composite materials are known to be used to make non-metallic components of the bridge plug. These composite materials combine constituent materials to form a composite material with physical properties of each composite material. For example, a polymer or epoxy can be reinforced by a continuous fiber such as glass, carbon, or aramid. The polymer is easily millable and withstands the wellbore conditions, while the fibers also withstand the wellbore conditions and resist degradation. Resin-coated glass is another known composite material with downhole tool applications. Composite materials have different constituent materials and different ways of combining constituent materials.

It is an object of the present invention to provide an embodiment of a downhole system for isolating zones in the wellbore.

It is an object of the present invention to provide an embodiment of a support accessory for a downhole system for isolating zones in the wellbore.

It is another object of the present invention to provide an embodiment of a collapsible support ring to prevent extrusion of the ring members and sealing member.

It is another object of the present invention to provide an embodiment of a collapsible support ring having different configurations when the downhole system is deployed and installed in a wellbore.

It is an object of the present invention to provide an embodiment of a packer system.

It is an object of the present invention to provide an embodiment of the packer system with support accessories for ring members and sealing member.

It is another object of the present invention to provide an embodiment of the packer system with support rings to prevent extrusion of the ring members and sealing member.

It is still another object of the present invention to provide an embodiment of the packer system with a metallic support ring.

It is another object of the present invention to provide an embodiment of the packer system with collapsible support rings.

It is still another object of the present invention to provide an embodiment of the packer system with support rings having different configurations when the packer system is deployed and installed in a wellbore.

It is an object of the present invention to provide an embodiment of a millable bridge plug system.

It is an object of the present invention to provide an embodiment of the millable bridge plug system with support accessories for stack structures, including support accessories for ring members and the sealing member.

It is another object of the present invention to provide an embodiment of the millable bridge plug system with support rings to prevent extrusion of the ring members and the sealing member.

It is still another object of the present invention to provide an embodiment of the millable bridge plug system with a metallic support ring.

It is another object of the present invention to provide an embodiment of the millable bridge plug system with collapsible support rings.

It is still another object of the present invention to provide an embodiment of the millable bridge plug system with support rings having different configurations when the bridge plug system is deployed and installed in a wellbore.

These and other objectives and advantages of the present invention will become apparent from a reading of the attached specifications and appended claims.

BRIEF SUMMARY OF THE INVENTION

A downhole system isolates zones of a formation in a wellbore. The downhole system has a mandrel, a sealing member, and ring members on each side of the sealing member. The sealing member and the ring members expand to seal against the wellbore. The expansion can be by chemical or mechanical means. The sealing member and the ring members form the seal that allows flow through the formation to be controlled. The downhole system can restrict flow between zones in the formation to the mandrel. Thus, valves, seats, and sleeves in the mandrel can control flow through the formation.

Embodiments of the present invention include a packer system and a millable bridge plug system. The packer system of the present invention further includes a plurality of support rings, in addition to the mandrel, sealing member, and ring members. The ring members are positioned between the sealing member and the support rings. The millable bridge plug system of the present invention further includes the plurality of support rings, in addition to the mandrel, sealing member, and ring members. In the embodiment of the millable bridge plug system, there is also a shearing means attached at an upper portion of the mandrel, a plurality of cone assemblies, a plurality of slip means for extending radially outward and engaging an inner surface of a surrounding borehole, and a cap means attached at a lower portion of the mandrel. The sealing member is still positioned around the mandrel between the upper portion and the lower portion, and the ring members are between the sealing member and the support rings. In particular, a first ring member is placed adjacent the upper end of the sealing member, and a second ring member is adjacent the lower end of the sealing member. A first cone assembly is proximate to the first ring member, and a second cone assembly is proximate to the second ring member. A first support ring is between the first cone assembly and the first ring member; and a second support ring is between the second cone assembly and the second ring member. The slip means extend radially outward and engage an inner surface of a surrounding borehole to lock the position of the bridge plug. A first slip means is mounted around the mandrel and engages the first cone assembly, and a second slip means is mounted around the mandrel and engages the second cone assembly.

Embodiments of the present invention for both packers and bridge plugs include support rings for each ring member, and each support ring is comprised of a peripheral side, a fold line, and an engagement side. Support rings can be made of metallic materials for the added strength. At the same time, the support ring of metal does not add a bulk of metal material for affecting the ability to mill the bridge plug system. Each support ring has an extended configuration for positioning the support ring when deployed and before installation of the system and a collapsed configuration for preventing extrusion of the ring members and sealing member after installation. Each peripheral side is folded flush to the engagement side along the fold line in the collapsed configuration. Each peripheral side is separated from the engagement side at an angle along the fold line in the extended configuration. When the fold line has a smaller diameter than the engagement side and peripheral side, the support ring folds outward, and the engagement side can be adjacent to the ring member in the extended configuration. When the fold line has a larger diameter than the engagement side and peripheral side, the support ring folds inward, and the edge of the engagement side is adjacent to the ring member in the extended configuration.

Alternative embodiments include a plurality of ring caps between respective support rings and ring members. The ring caps are additional support for the support ring and ring member to prevent extrusion. Each ring cap has a contour side and a support side. The contour side faces the ring member to prevent extrusion of the respective ring member and the sealing member. The engagement side faces the support ring to be in a sealed engagement with the support ring in the collapsed configuration. The profile of the inner surface of the contour side matches the profile of the respective ring member. There is flush engagement so that seals between the support rings and ring caps, between ring caps and ring members, and between ring members and the sealing member, are maintained, when the downhole system is installed.

The method of installing a downhole system comprises the steps of: placing a downhole system, such as the packer or bridge plug, in a wellbore, the wellbore having inner walls surrounding the packer or bridge plug, forming a seal against the inner walls, and fixing position of the packer or bridge plug. The step of forming a seal involves collapsing the support ring to seal against the ring member to prevent extrusion. When there are ring caps between the ring members and the support rings, the sealing engagement is set by the sequence of collapsing the support rings, engaging the ring caps, and collapsing the ring caps to seal the deforming ring members and sealing member.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 a schematic view of a prior art liner system with packer systems in a wellbore

FIG. 2A is a schematic view of a prior art bridge plug system, being placed in a wellbore.

FIG. 2B is another schematic view of the prior art bridge plug system, being locked in position within the wellbore.

FIG. 3A is a partial sectional view of an embodiment of the packer system of the present invention, when deployed in the wellbore.

FIG. 3B is a partial sectional view of the embodiment of FIG. 3A, when installed in the wellbore.

FIG. 4A is a partial sectional view of another embodiment of the packer system of the present invention, when deployed in the wellbore.

FIG. 4B is a partial sectional view of the embodiment of FIG. 4A, when installed in the wellbore.

FIG. 5 is a perspective view of an embodiment of the bridge plug system of the present invention.

FIG. 6 is an exploded perspective view of the embodiment of FIG. 5.

FIG. 7 is a cross-sectional view of an embodiment of the bridge plug system of the present invention along an axis of the bridge plug system, showing placement in the wellbore.

FIG. 8 is a cross-sectional view of an embodiment of the bridge plug system of the present invention along an axis of the bridge plug system, showing an activated configuration in the wellbore.

FIG. 9 is an isolated cross-sectional view of a sealing member, ring members, and an embodiment of support rings for both embodiments of the packer system and bridge plug system of the present invention.

FIG. 10 is an isolated cross-sectional view of FIG. 9, showing the compressed configuration corresponding to both embodiments of the downhole system installed in a wellbore.

FIG. 11 is an isolated cross-sectional view of a sealing member, ring members, and another embodiment of support rings for both embodiments of the packer system and bridge plug system of the present invention.

FIG. 12 is an isolated cross-sectional view of FIG. 11, showing the compressed configuration corresponding to both embodiments of the downhole system installed in a wellbore.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-12 show embodiments of a downhole system 100, 300 to isolate zones of a formation in a wellbore. The downhole system 100, 300 has a mandrel 112, 312, a sealing member 114, 314, ring members 116, 118, 316, 318 on each side of the sealing member, and support rings 160, 160′, 170, 170′. The sealing member and the ring members expand to seal against the wellbore. The expansion can be by chemical or mechanical means. The sealing member is any known sealing means for downhole systems. The sealing member and the ring members form the seal that allows flow through the formation to be controlled. The downhole system can restrict flow between zones in the formation to the mandrel. Thus, valves, seats, and sleeves in the mandrel can control flow through the formation.

FIGS. 9-12 show a plurality of support rings 160, 160′, 170, 170′. There are support rings 160, 160′, 170, 170′ for each ring member, 116, 118, 316, 118, so the system 100, 300 includes a set of two support rings: a first support ring 160, 170 and a second support ring 160′, 170′. In the embodiments of FIGS. 9-12, the first ring member 116, 316 is positioned between the sealing member 114, 314 and the first support ring 160, and the second ring member 118, 318 is positioned between the sealing member 114, 314 and the second support ring 160′. Each support ring 160, 160′, 170, 170′ is comprised of a peripheral side 162, 172 a fold line 164, 174 and an engagement side 166, 176. The fold line 164, 174 can be a crease or ridge between the peripheral side 162, 172 and the engagement side 166, 176. Each support ring 160, 160′, 170, 170′ has an extended configuration (FIGS. 9 and 11) and a collapsed configuration (FIGS. 10 and 12). Each peripheral side 162, 172 can be folded flush to the engagement side 166, 176 in the collapsed configuration along the fold line 164, 174 in FIGS. 10 and 12. Each peripheral side 162, 172 is separated from the engagement side 166, 176 at an angle along the fold line in the extended configuration in FIGS. 9 and 11.

The embodiment of FIGS. 9-10 include each support ring 160, 160′ having a fold line 164 with a smaller diameter than a diameter of the peripheral side 162 and the engagement side 166. Thus, the peripheral side 162 folds to the engagement side 166 outward from the fold line 164 in the collapsed configuration, as shown in FIG. 10. The engagement side 166 is adjacent a respective ring member both in the extended configuration and in the collapsed configuration. The engagement side 166 is cooperative with the respective ring member so as to position each support ring 160, 160′ relative to a respective ring member in the extended configuration in FIG. 9. The spacing and distance of the support ring 160 to the ring member 116, 316 is set by this extended configuration and the angle formed by the peripheral side 162, fold line 164, and engagement side 166.

In some embodiments, the engagement side 166 has a surface angled for abutting the respective ring member in the extended configuration. FIG. 9 shows the surface as V-shape of the peripheral side 162, fold line 164, and engagement side 166, with the engagement side 166 contacting the ring member 116, 316 on the angle or slant of the surface. The engagement side 166 is also cooperative with the respective ring member 116, 316 so as to prevent extrusion of the respective ring member 116, 316 and the sealing member 114, 314 in the collapsed configuration. FIG. 10 shows the surface as the closed V-shape of the peripheral side 162, fold line 164, and engagement side 166, with the engagement side 166 in sealing engagement to the respective ring member 116, 316 in the collapsed configuration.

The embodiment of FIGS. 11-12 include each support ring 170, 170′ having a fold line 174 with a larger diameter than a diameter of the peripheral side 172 and the engagement side 176. Thus, the peripheral side 172 folds to the engagement side 176 inward from the fold line 174 in the collapsed configuration, as shown in FIG. 12. The engagement side 176 is adjacent a respective ring member only in the collapsed configuration. The edge of the engagement side 176 can position each support ring 170, 170′ relative to a respective ring member in the extended configuration in FIG. 12. The spacing and distance of the support ring 170 to the ring member 116, 316 is set by this extended configuration and the entire width of the support ring 170, instead of just the angle formed by the peripheral side 172, fold line 174, and engagement side 176.

In some embodiments, the engagement side 176 is cooperative with the respective ring member 116, 316 so as to prevent extrusion of the respective ring member 116, 316 and the sealing member 114, 314 in the collapsed configuration. FIG. 12 shows the surface as the closed inward V-shape of the peripheral side 172, fold line 174, and engagement side 176, with the engagement side 176 in sealing engagement to the respective ring member 116, 316 in the collapsed configuration. The extended configuration has no sealing engagement in FIGS. 11-12. The support rings 170, 170′ are structural support and collapse, when the bridge plug system 100, 300 is installed.

FIGS. 9 and 11 also show embodiments with a plurality of ring caps 180, 180′, 190, 190′. Each set of ring caps 180, 180′, 190, 190′ is comprised of a first ring cap 180 positioned between the first ring member 116, 316 and the first support ring 160, and a second ring cap 180′ positioned between the second ring member 118, 318 and the second support ring 160′. Each ring cap 180, 180′, 190, 190′ is comprised of a contour side 182, 192 and a support side 184, 194. Each contour side 182, 192 is cooperative with the respective ring member 116, 316 so as to prevent extrusion of the respective ring member 116 and the sealing member 114, 314. In the embodiments with ring caps 180, 180′, 190, 190′, the support rings 160, 160′, 170, 170′ prevent extrusion through the ring caps 180, 180′, 190, 190′. The engagement sides 162, 172 engage the respective ring members 116, 316 by engaging the ring caps 180, 180′, 190, 190′. Each contour side 182, 192 has an inner surface for sealing engagement to the respective ring member, similar to the respective engagement sides 166, 176 for sealing engagement to the respective ring member. On the other side, each support side 184, 194 abuts at least a portion of a respective engagement side 166, 176 of a corresponding support ring 180, 190. The profile of the inner surface matches the profile of the respective ring member. There is flush engagement so that the seals are maintained between the support rings to ring caps to ring members to sealing member, when the bridge plug system 100 or packer assembly 300 is installed.

The collapsed configuration and the extended configuration for the embodiments with ring caps 180, 180′, 190, 190′, the respective engagement sides 166, 176 are cooperative with the respective ring cap 180, 190 so as to prevent extrusion of the respective ring member 116, 316 and the sealing member 114, 314 in the collapsed configuration. There is sealing engagement between the engagement side 166, 176 and the respective ring cap 180, 190, which is already in sealing engagement to the ring member 116, 316 in the collapsed configuration. The collapsed configuration with ring caps 180, 180′, 190, 190′ is very similar to the collapsed configuration without ring caps 180, 180′, 190, 190′, as FIGS. 10 and 12 show. FIG. 10 shows the ring caps 180 and 180′, and FIG. 12 shows the collapsed configuration without ring caps.

FIGS. 9 and 11 show the embodiments in the extended configuration with ring caps 180, 180′, 190, 190′. The support side 184 of the ring cap 180 faces and abuts the engagement side 166 in the extended configuration, when the respective ring cap 180 is between the respective ring member 116, 316 and the engagement side 166. FIG. 9 shows a cooperative relationship so as to prevent extrusion of the respective ring member and the sealing member in the collapsed configuration and so as to position the support ring 160 in the extended position. The sealing engagement is shown in FIG. 10 in the collapsed configuration. FIG. 12 shows again how the ring cap 190 engages the engagement side 176 of the first support ring 170 based on the width dimension of the first support ring 170. Only the edge of the engagement side 176 contacts the ring cap 190 or ring member 116, 316. FIG. 11 shows that the first support ring 170 may not touch the ring cap 190 in the extended configuration, but a sealing engagement and flush contact would occur, when the bridge plug system 100 or packer assembly 300 is installed.

Referring to FIGS. 3A and 3B, an embodiment of the downhole system is a packer system or packer assembly 300 includes a mandrel 312 having an outer surface and an inner surface, a sealing member 314 positioned around the outer surface of the mandrel, a plurality of ring members, 316, 318, a first support ring 160, and a second support ring 160′. The first support ring 160 and the second support ring 160′ are shown in a “cup up” configuration, similar to FIGS. 9-10. There can also be stop means 320, 322 attached to the mandrel 312. The stop means 320, 322 can be positioned according to the chemical or mechanical trigger of the packer assembly 300. FIGS. 3A and 3B show the stop means 320, 322 as slips anchoring the packer assembly 300. Downhole pressure may actuate the slips, which can cause the compression of the sealing member 314. There is a first ring member 316 adjacent an upper end of the sealing member and a second ring member 318 adjacent a lower end of the sealing member 314. The first ring member 316 is positioned between the sealing member 314 and the first support ring 160, and the second ring member 318 is positioned between the sealing member 314 and the second support ring 160′, according to FIGS. 9-10. The sealing member 314 is positioned around the mandrel 312. The sealing member 314 is generally symmetrical to start and is comprised of a deformable material. The sealing member 314 and ring members 316, 318 can be swellable materials reactive to chemical triggers or other mechanically activated swelling to seal against the casing or wellbore.

In another embodiment, FIGS. 4A and 4B show the same packer assembly 300 including a mandrel 312 having an outer surface and an inner surface, a sealing member 314 positioned around the outer surface of the mandrel, a plurality of ring members, 316, 318, a first support ring 170, and a second support ring 170′. The first support ring 170 and the second support ring 170′ are shown in a “cup down” configuration, similar to FIGS. 11-12. There can also be stop means 320, 322 attached to the mandrel 312. The stop means 320, 322 are still positioned according to the chemical or mechanical trigger of the packer assembly 300. FIGS. 4A and 4B also show the stop means 320, 322 as slips anchoring the packer assembly 300. There is a first ring member 316 adjacent an upper end of the sealing member and a second ring member 318 adjacent a lower end of the sealing member 314. In this embodiment, the first ring member 316 is positioned between the sealing member 314 and the first support ring 170, and the second ring member 318 is positioned between the sealing member 314 and the second support ring 170′, according to FIGS. 11-12. The embodiment of FIGS. 4A-4B have the analogous sealing member 314 positioned around the mandrel 312 and comprised of a deformable material. The sealing member 314 and ring members 316, 318 are still swellable materials reactive to chemical triggers or other mechanically activated swelling to seal against the casing or wellbore.

In FIGS. 5-8, an embodiment of the downhole system is a millable bridge plug system 100 of the present invention is shown. The bridge plug system 100 includes a mandrel 112, a sealing member 114, and a plurality of ring members, 116, 118, a plurality of cone assemblies 120, 122, and a plurality of slip means 124, 126. The sealing member or sealing member 114, ring members 116, 118, cone assemblies 120, 122 and the slip means 124, 126 are stack structures mounted on the mandrel 112, sharing a common radial axis of alignment. FIGS. 5-8 also show a shearing means 128, and a cap means 130. The bridge plug system 100 is placed within a wellbore or borehole of a well by a setting tool. The wellbore or the borehole could have a casing or not, and the orientation of the wellbore is variable. FIG. 7 shows an embodiment with a casing 132. The bridge plug system 100 can be used in all ranges from generally vertical to generally horizontal orientations. As previously described, the millable bridge plug system 100 is used to isolate zones within the wellbore, separating sections of the wellbore for production or isolation. The system 100 is millable or drillable, such that a removal assembly, such as a milling unit on a drill string, can be used to grind through the system 100. All of the components of the system 100 are destroyed so that the isolated zone of the wellbore is no longer isolated.

Embodiments of the bridge plug system 100 include the mandrel 112 of the bridge plug system 100 as a generally tubular member formed of a material to withstand the heat and pressure of the borehole conditions. The mandrel 112 is also millable. The mandrel 112 may have a bridge 134 or a ball valve, which seals the zone above the system 100 from the zone below the system 100. The sealing member 114 is positioned around the mandrel 112. The sealing member 114 has an upper end 136 and lower end 138 as shown in FIGS. 7 and 8. The sealing member 114 is generally symmetrical to start and is comprised of a deformable material.

FIGS. 9-12 also show detailed views of the sealing member 114, 314 and the ring members 116, 118, 316, 118 for different embodiments of the present invention as a packer system 300 or a bridge plug system 100. There is a first ring member 116, 316 adjacent the upper end 136, 336 of the sealing member 114, 314 and a second ring member 118 adjacent the lower end 138 of the sealing member 114, 314. The ring members 116, 118, 316, 118 surround the sealing member 114, 314 and surround the mandrel 112. The ring members 116, 118, 316, 118 contact the sealing member 114, 314 and can exert pressure on the sealing member 114, 314. In an activated state, the system 100, 300 has the sealing member 114, 314 compressed to radially extend to contact the wellbore or casing 132 or expanded to seal the wellbore by other means. The ring members 116, 118, 316, 118 directly contact the sealing member 114, 314. The seal created by the sealing member 114, 314 isolates the zones of the wellbore.

In some embodiments, the upper end 136, 336 of the sealing member 114, 314 has a first means 140, 340 for resisting pressure by the first ring member 116, 316 when in contact with the first ring member 116, 316. The lower end 138, 338 of the sealing member 114, 314 has a second means 142, 342 for resisting pressure by the second ring member 118, 318 when in contact with the second ring member 118, 318. In one embodiment, the first means 140, 340 for resisting pressure is comprised of a surface interface with a curvature, and the second means 142, 342 for resisting pressure is also comprised of a surface interface with a curvature. The pressures exerted by the ring members 116, 118, 316, 118 on the upper end 136, 336 and the lower end 138, 338 of the sealing member 114, 314 can cause deformation of the sealing member 114, 314 related to the first means 140, 340 and the second means 142, 342. The deformation of the sealing member 114, 314 allows a greater surface area of the sealing member 114, 314 to seal against the wellbore or casing. There is a more even spread of the sealing member 114, 314. A portion of the ring members 116, 118, 316, 118 may also spread to the wellbore for additional seal.

The bridge plug system 100 also includes the plurality of cone assemblies, 120, 122. FIGS. 5-8 show a first cone assembly 120 proximate to the first ring member 116 and a second cone assembly 122 proximate to the second ring member 118. As shown in exploded view of FIG. 5, the first ring member 116 is mounted on the mandrel 112 between the first cone assembly 120 and the sealing member 114. Similarly, the second ring member 118 is mounted on the mandrel 112 between the second cone assembly 122 and the sealing member 114. The cone assemblies 120, 122 contact the ring members 116, 118 through the respective peripheral sides 162, 172 of the support rings 160, 160′, 170, 170′ and can exert pressure on the ring members 116, 118 through the support rings 160, 160′, 170, 170′. In an activated state, the system 100 has pressure of the cone assemblies 120, 122 pushing through the support rings 160, 160′, 170, 170′, and ring members 116, 118 to the sealing member 114.

FIGS. 5-8 also show the plurality of slip means 124, 126 for extending radially outward and engaging an inner surface of a surrounding borehole. The slip means 124, 126 lock the position of the system 100 by fixedly engaging the casing 132 or other structure on the inner surface of the borehole. The slips dig into the casing 132 to anchor the millable bridge plug system 100. Pressure can be exerted on the system 100 to create the seal with the sealing member 114, once the slip means 124, 126 are active. There is a first slip means 124 mounted around the mandrel 112 and engaging the first cone assembly 120 and a second slip means 126 mounted around the mandrel 112 and engaging the second cone assembly 122.

FIGS. 5-8 also shows the shearing means 128 and the cap means 130. The shearing means 128 is attached to an upper portion of the mandrel 112 in FIGS. 5-8. The positioning assembly with the setting tool handles the system 100 by the mandrel 112 for placement in the wellbore. The pressure from the ramming portion of the setting tool sets and locks the bridge plug system 100. When the correct location is reached and the wellbore is sealed, the shearing means 128 is separated from the setting tool on the positioning assembly. The shearing means 128 can be comprised of a millable material and have the form of a shaft. The cap means 130 is shown as a tubular body at the end of the system 100. The cap means 130 can also be comprised of a millable material. The cap means 130 engage a shearing means of an adjacent bridge plug system further down the wellbore. In some embodiments, the cap means 130 can interlock with the adjacent shearing means of the next bridge plug system. As the bridge plug system 100 is milled, the cap means 130 may fall loose down the wellbore 132 to reach the next bridge plug system.

The method of installing includes placing a downhole system 100, 300 in a wellbore having inner walls surrounding the downhole system 100, 300. The downhole system 100, 300 of FIGS. 1-12 comprises a mandrel 112, 312 having an outer surface and an inner surface; a sealing member 114, 314 positioned around the outer surface of the mandrel; a plurality of ring members, 116, 118, 316, 318, the plurality of ring members being comprised of a first ring member 116, 316 adjacent an upper end of the sealing means and a second ring member 118, 318 adjacent a lower end of the sealing member; and a plurality of support rings 160, 160′, 170, 170′ the plurality of support rings being comprised of a first support ring 160, 170 and a second support ring 160′, 170′, the first ring member being positioned between the sealing means and the first support ring, the second ring member being positioned between the sealing means and the second support ring.

Each support ring 160,160′, 170, 170′ is comprised of a peripheral side 162, 172 a fold line 164, 174 and an engagement side 166, 176 the fold line being between the peripheral side and the engagement side. Each support ring has an extended configuration and a collapsed configuration, the peripheral side being folded flush to the engagement side in the collapsed configuration along the fold line, the peripheral side being separated from the engagement side at an angle along the fold line in the extended configuration.

The method of installing further comprises forming a seal by extending the sealing member to the inner walls, the ring members being cooperative with the sealing member. The extending can be mechanical, such as compressing the sealing member and ring members. The extending can also be chemical, such as dispensing a chemical additive into the wellbore or mandrel to react with the sealing member or ring members or both. The composition of the sealing member or ring members or both can be compatible with the chemical additive for a controlled extending. The support rings seal against the ring members in the method of installing also.

Another step of the method of installing includes the step of collapsing the support rings from the extended configuration to the collapsed configuration so as to maintain the seal; and locking the downhole system within the wellbore. The locking can be done by stop means 320, 322 for the packer system 300 or the cone assemblies 120, 122 and the slip means 124, 126 for the bridge plug system 100. 20.

When the downhole system 100, 300 further comprises a plurality of ring caps 180, 180′, 190, 190′, the plurality of ring caps can be comprised of a first ring cap 180, 190 and a second ring cap 180′, 190′. The first ring cap is positioned between the first ring member and the first support ring, and the second ring cap is positioned between the second ring member and the second support ring. With the ring caps, the step of collapsing the support rings further comprises the steps of: engaging the ring caps with the support rings; and collapsing the ring caps on the ring members

According the FIGS. 3-4, installing the packer assembly 300 comprises the steps of placing a packer assembly 300 in a wellbore, activating the seal on the wellbore, and sealing the system 300 in position within the wellbore. With the packer assembly 300 of the present invention, packer assembly 300 is deployed the wellbore having inner walls with or without casing. At the proper depth and location, the sealing member 314 is activated by a chemical or mechanical trigger, causing the sealing member 314 to form the seal against the wellbore. The chemical trigger may be a chemical agent released in the wellbore to react with the material composition of the sealing member 314 so as to cause the sealing member 314 to swell. The mandrel 312 is held in place as sealing member 314 is activated. The ring members 316, 318 may also be activated by a chemical or mechanical trigger, causing the ring members 316, 318 to assist the sealing member 314 to form the seal against the wellbore. The ring members 316, 318 may swell and seal at a different rate than the sealing member 314. In some instances, the ring members 316, 318 push the sealing member 314 to expand, the support rings 160, 160′ seal the ring members 316, 318. The step of sealing includes the support rings 160, 160′ sealing to the ring members 116, 118, which includes collapsing the support rings 160, 160′ from the extended configuration to the collapsed configuration. When the packer assembly 300 includes ring caps 180, 180′, the step of collapsing the support rings 160, 160′ includes engaging the ring caps 180, 180′ with the support rings 160, 160′ and then collapsing those ring caps 180, 180′ on the respective ring member 316, 318.

According to FIGS. 5-8, the embodiment of the method of installing a millable bridge plug system 100 comprises the steps of placing a bridge plug system 100 in a wellbore, forming the seal on the wellbore, and locking the system 100 in position within the wellbore. With the millable bridge plug system 100 of the present invention, system 100 is lowered into the wellbore having inner walls, such as a casing 130, using a setting tool on a positioning assembly. The mandrel is held in place as the stack structures 114, 116, 118, 120, 122, 124, and 126 are hammered by a ram portion of the setting tool. Pressure on the bridge plug system 110 forms a seal, when the sealing member 114 is compressed to radially extend outward to seal against the inner walls of the borehole. The ring members 116, 118 push the sealing member 114 to expand, the support rings 160, 160′ seal said ring members 116, 118, and the cone assemblies 120, 122 push the ring members 116, 118 through the support rings 160, 160′. The cone assemblies 120, 122 also push the slip means 124, 126 to extend radially outward to fixedly engage the inner walls, locking the system 100 in position within the wellbore. At least one slip means 124, 126 is activated, so that stack structures are locked in the sealed position. The exerted pressure through the system 100 is controlled by the sealing member 114 in conjunction with the ring members 116, 118. The step of sealing the support rings 160, 160′ to said ring members 116, 118 includes collapsing the support rings 160, 160′ from the extended configuration to the collapsed configuration. When the system 100 include ring caps 180, 180′, the step of collapsing the support rings 160, 160′ includes engaging the ring caps 180, 180′ with the support rings 160, 160′ and then collapsing those ring caps 180, 180′ on the respective ring member 116, 118.

The present invention is a downhole system for isolating zones in the wellbore. The collapsible support rings are accessories to improve the seal by the known sealing member and ring members of the conventional packers and bridge plugs. The collapsible support rings have different configurations when deployed and installed in a wellbore. There is an extended configuration for being deployed, and a collapsed configuration for being installed. The support rings and ring caps improve the sealing engagement of the ring members and sealing member. The downhole system can be a packer assembly to prevent extrusion of the ring members and sealing member or a millable bridge plug system with support rings and ring caps as support accessories for the stack structures. For the bridge plug in particular, when installed and compressed under pressure, the composite material or other deformable material compositions are prevented from extruding. The seal to the wellbore is more stable without the ring member or sealing member leaking around the cone assemblies because of the support rings with or without ring caps.

In some embodiments, the support ring can be metallic so that the system has the added strength of metallic components. Furthermore, as just a support ring, there is no bulk of metal material, which would reduce the ability to remove the packer or to mill the bridge plug system for removal. The versions of metallic rings can give added strength for support with impact on the overall removing of the packer and milling of the bridge plug for removal. The support rings of the present invention are also collapsible with the two configurations: extended and collapsed. The sealing engagement can be deployed at the proper time, and the method of installing can include sealing the ring member with the collapsed configuration before the ring member and sealing member are fully deformed. A more stable seal can be formed against the wellbore. The ring caps further support the sealing engagement of the support rings to the ring member. With the collapsing of the support ring, the sealing engagement to the ring member is stabilized with the ring cap between the support ring and ring member. The ring cap prevents any premature deformation from affecting the collapsing and sealing engagement of the support ring.

The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated structures, construction and method can be made without departing from the true spirit of the invention.

Claims

1. A downhole system, comprising:

a mandrel having an outer surface and an inner surface;

a sealing member positioned around said outer surface of said mandrel;

a plurality of ring members, said plurality of ring members being comprised of a first ring member adjacent an upper end of said sealing means and a second ring member adjacent a lower end of said sealing member; and

a plurality of support rings, said plurality of support rings being comprised of a first support ring and a second support ring, said first ring member being positioned between said sealing means and said first support ring, said second ring member being positioned between said sealing means and said second support ring.

2. The downhole system, according to claim 1,

wherein each support ring is comprised of a peripheral side, a fold line, and an engagement side, said fold line being between said peripheral side and said engagement side, and

wherein each support ring has an extended configuration and a collapsed configuration, said peripheral side being folded flush to said engagement side in said collapsed configuration along said fold line, said peripheral side being separated from said engagement side at an angle along said fold line in said extended configuration.

3. The downhole system, according to claim 2,

wherein said fold line has a smaller diameter than said peripheral side and said engagement side, said peripheral side being folded to said engagement side outward from said fold line in said collapsed configuration,

wherein said engagement side is adjacent a respective ring member in said extended configuration and in said collapsed configuration, and

wherein said engagement side is cooperative with said respective ring member so as to position each support ring relative to a respective ring member in said extended configuration.

4. The downhole system, according to claim 3, said engagement side having a surface angled in abutment to said respective ring member in said extended configuration.

5. The downhole system, according to claim 3, said engagement side being cooperative with said respective ring member so as to prevent extrusion of said respective ring member and said sealing member in said collapsed configuration, said engagement side having a surface for sealing engagement to said respective ring member in said collapsed configuration.

6. The downhole system, according to claim 2,

wherein said fold line has a larger diameter than said peripheral side and said engagement side, said peripheral side being folded to said engagement side inward to said fold line in said collapsed configuration,

wherein said engagement side is adjacent a respective ring member in said collapsed configuration only,

wherein said engagement side is cooperative with said respective ring member so as to prevent extrusion of said respective ring member and said sealing member in said collapsed configuration, and

wherein said engagement side has a surface for sealing engagement to said respective ring member in said collapsed configuration.

7. The downhole system, according to claim 1, further comprising:

a plurality of ring caps, said plurality of ring caps being comprised of a first ring cap and a second ring cap, said first ring cap being positioned between said first ring member and said first support ring, said second ring cap being positioned between said second ring member and said second support ring,

wherein each support ring is comprised of a peripheral side, a fold line, and an engagement side, said fold line being between said peripheral side and said engagement side, and

wherein each support ring has an extended configuration and a collapsed configuration, said peripheral side being folded flush to said engagement side in said collapsed configuration along said fold line, said peripheral side being separated from said engagement side at an angle along said fold line in said extended configuration.

8. The downhole system, according to claim 7,

wherein said fold line has a smaller diameter than said peripheral side and said engagement side, said peripheral side being folded to said engagement side outward from said fold line in said collapsed configuration,

wherein said engagement side is adjacent a respective ring cap, said respective ring cap being adjacent a respective ring member in said extended configuration and in said collapsed configuration, said respective ring cap facing said engagement side in said extended configuration, when said respective ring cap is between said respective ring member and said engagement side, and

wherein said engagement side is cooperative with said respective ring cap so as to position each support ring relative to a respective ring member in said extended configuration.

9. The downhole system, according to claim 8, said engagement side having a surface angled in abutment to said respective ring cap in said extended configuration.

10. The downhole system, according to claim 8, said engagement side being cooperative with said respective ring cap so as to prevent extrusion of said respective ring member and said sealing member in said collapsed configuration, said engagement side having a surface for sealing engagement to said respective ring cap in said collapsed configuration.

11. The downhole system, according to claim 7,

wherein said fold line has a larger diameter than said peripheral side and said engagement side, said peripheral side being folded to said engagement side inward to said fold line in said collapsed configuration,

wherein said engagement side is adjacent a respective ring cap, said respective ring cap being adjacent a respective ring member in said collapsed configuration only, said respective ring cap facing said engagement side in said collapsed configuration, when said respective ring cap is between said respective ring member and said engagement side

wherein said engagement side is cooperative with said respective ring cap so as to prevent extrusion of said respective ring member and said sealing member in said collapsed configuration, and

wherein said engagement side has a surface for sealing engagement to said respective ring cap in said collapsed configuration.

12. The downhole system, according to claim 7,

wherein each ring cap is comprised of a contour side and a support side, and

wherein said contour side is cooperative with a respective ring member so as to prevent extrusion of said respective ring member and said sealing member.

13. The downhole system, according to claim 12, said contour side having an inner surface for sealing engagement to said respective ring member.

14. The downhole system, according to claim 12, said support side abutting at least a portion of a respective engagement side of a corresponding support ring.

15. A downhole system, comprising:

a mandrel having an outer surface and an inner surface, said mandrel having an upper portion and a lower portion, said mandrel being comprised of a shearing means attached at said upper portion of said mandrel, and an interlocking means between said shearing means and said lower portion;

a sealing member positioned around said outer surface of said mandrel and around said mandrel between said upper portion and said lower portion;

a plurality of ring members, said plurality of ring members being comprised of a first ring member adjacent an upper end of said sealing means and a second ring member adjacent a lower end of said sealing member;

a plurality of support rings, said plurality of support rings being comprised of a first support ring and a second support ring, said first ring member being positioned between said sealing means and said first support ring, said second ring member being positioned between said sealing means and said second support ring;

a plurality of cone assemblies, a first cone assembly proximate to said first support ring and a second cone assembly proximate to said second support ring, said first support ring being between said first cone assembly and said first ring member, said second support ring being between said second cone assembly and said second ring member; and

a plurality of slip means for extending radially outward and engaging an inner surface of a surrounding borehole, a first slip means mounted around said mandrel and engaging said first cone assembly and a second slip means mounted around said mandrel and engaging said second cone assembly.

16. The downhole system, according to claim 15,

wherein each support ring is comprised of a peripheral side, a fold line, and an engagement side, said fold line being between said peripheral side and said engagement side,

wherein each support ring has an extended configuration and a collapsed configuration, said peripheral side being folded flush to said engagement side in said collapsed configuration along said fold line, said peripheral side being separated from said engagement side at an angle along said fold line in said extended configuration,

wherein said fold line has a smaller diameter than said peripheral side and said engagement side, said peripheral side being folded to said engagement side outward from said fold line in said collapsed configuration,

wherein said engagement side is adjacent a respective ring member in said extended configuration and in said collapsed configuration, and

wherein said engagement side is cooperative with said respective ring member so as to position each support ring relative to a respective ring member in said extended configuration.

17. The downhole system, according to claim 15,

wherein each support ring is comprised of a peripheral side, a fold line, and an engagement side, said fold line being between said peripheral side and said engagement side,

wherein each support ring has an extended configuration and a collapsed configuration, said peripheral side being folded flush to said engagement side in said collapsed configuration along said fold line, said peripheral side being separated from said engagement side at an angle along said fold line in said extended configuration,

wherein said fold line has a larger diameter than said peripheral side and said engagement side 176, said peripheral side being folded to said engagement side inward to said fold line in said collapsed configuration,

wherein said engagement side is adjacent a respective ring member in said collapsed configuration only,

wherein said engagement side is cooperative with said respective ring member so as to prevent extrusion of said respective ring member and said sealing member in said collapsed configuration, and

wherein said engagement side has a surface for sealing engagement to said respective ring member in said collapsed configuration.

18. The downhole system, according to claim 15, further comprising:

a plurality of ring caps, said plurality of ring caps being comprised of a first ring cap, and a second ring cap, said first ring cap being positioned between said first ring member and said first support ring, said second ring cap being positioned between said second ring member and said second support ring,

wherein each support ring is comprised of a peripheral side, a fold line, and an engagement side, said fold line being between said peripheral side and said engagement side, and

wherein each support ring has an extended configuration and a collapsed configuration, said peripheral side being folded flush to said engagement side in said collapsed configuration along said fold line, said peripheral side being separated from said engagement side at an angle along said fold line in said extended configuration.

19. A method of installing a downhole system, the method comprising the steps of:

placing a downhole system in a wellbore, said wellbore having inner walls surrounding said downhole system, said downhole system comprising: a mandrel having an outer surface and an inner surface; a sealing member positioned around said outer surface of said mandrel; a plurality of ring members, said plurality of ring members being comprised of a first ring member adjacent an upper end of said sealing means and a second ring member adjacent a lower end of said sealing member; and a plurality of support rings, said plurality of support rings being comprised of a first support ring and a second support ring, said first ring member being positioned between said sealing means and said first support ring, said second ring member being positioned between said sealing means and said second support ring,

wherein each support ring is comprised of a peripheral side, a fold line, and an engagement side, said fold line being between said peripheral side and said engagement side, and

wherein each support ring has an extended configuration and a collapsed configuration, said peripheral side being folded flush to said engagement side in said collapsed configuration along said fold line, said peripheral side being separated from said engagement side at an angle along said fold line in said extended configuration; forming a seal by extending said sealing member to said inner walls, said ring members being cooperative with said sealing member, said support rings sealing against said ring members; collapsing said support rings from said extended configuration to said collapsed configuration so as to maintain said seal; and locking said downhole system within said wellbore.

20. The method of installing, according to claim 19,

wherein said downhole system further comprises a plurality of ring caps, said plurality of ring caps being comprised of a first ring cap and a second ring cap, said first ring cap being positioned between said first ring member and said first support ring, said second ring cap being positioned between said second ring member and said second support ring, and

wherein the step of collapsing said support rings further comprises the steps of: engaging said ring caps with said support rings; and collapsing said ring caps on said ring members.