High pressure expandable packer

Abstract

A packer device includes a central packer mandrel and radially surrounding expansion mandrel that carries a suitable engagement profile for engaging the surrounding casing or other tubular member. A material chamber is defined between the expansion mandrel and the packer mandrel and is filled with a filler material. In currently preferred embodiments, the filler material comprises a pliable solid, a gel or colloid, or a liquid. A setting mechanism radially expands the expansion mandrel so that the engagement profile of the expansion mandrel is brought into engagement with the surrounding tubular.

1 . A packer device for use within a wellbore and comprising: 
 a central packer mandrel defining an axial flowbore;    an expansion mandrel radially surrounding the central packer mandrel to define a filler material chamber between the expansion mandrel and the central packer mandrel;    an engagement profile formed on a radial exterior surface of the expansion mandrel for forming a biting engagement with a surrounding tubular within the wellbore;    a filler material disposed within the filler material chamber; and    a setting mechanism for selectively radially expanding the expansion mandrel relative to the central packer mandrel by displacing the filler material.    
   
   
       2 . The packer device of  claim 1  wherein the filler material comprises elastomer.  
   
   
       3 . The packer device of  claim 1  wherein the filler material comprises a pliable solid material.  
   
   
       4 . The packer device of  claim 3  wherein the solid material comprises a plurality of pellets.  
   
   
       5 . The packer device of  claim 4  wherein the pellets are formed of TEFLON®.  
   
   
       6 . The packer device of  claim 3  wherein the solid material comprises a cylinder of elastomeric material.  
   
   
       7 . The packer device of  claim 1  wherein the filler material comprises a liquid.  
   
   
       8 . The packer device of  claim 7  wherein the liquid comprises water.  
   
   
       9 . The packer device of  claim 1  wherein the filler material comprises a gel.  
   
   
       10 . The packer device of  claim 1  wherein the setting mechanism comprises a piston having a displacement portion for displacing the filler material and expansion mandrel radially outwardly and bringing the engagement profile into engagement with a surrounding tubular.  
   
   
       11 . The packer device of  claim 10  wherein the setting mechanism further comprises a body lock ring for maintaining the packer device in a set position.  
   
   
       12 . A system for selectively setting a packer element in a wellbore, the system comprising: 
 a production tubing string;    a packer device incorporated into the tubing string; the packer device comprising:    a) a central packer mandrel defining an axial flowbore;    b) an expansion mandrel radially surrounding the central packer mandrel to define a filler material chamber between the expansion mandrel and the central packer mandrel;    c) a filler material disposed within the filler material chamber; and    d) a setting mechanism for selectively radially expanding the expansion mandrel relative to the central packer mandrel by displacing the filler material.    
   
   
       13 . The system of  claim 12  further comprising an engagement profile formed on a radial exterior surface of the expansion mandrel for forming a biting engagement with a surrounding tubular within the wellbore.  
   
   
       14 . The system of  claim 12  wherein the filler material is a material from the group consisting essentially of: a liquid, a gel, and a pliable solid.  
   
   
       15 . The system of  claim 12  wherein the filler material is a material from the group consisting of: a liquid, a gel, and a pliable solid.  
   
   
       16 . The system of  claim 12  wherein the setting mechanism comprises a piston having a displacement portion for displacing the filler material and expansion mandrel radially outwardly and bringing the engagement profile into engagement with a surrounding tubular.  
   
   
       17 . The system of  claim 12  wherein the setting mechanism further comprises a body lock ring for maintaining the packer device in a set position.  
   
   
       18 . A method of setting a packer device within a wellbore comprising the steps of: 
 1) disposing a packer device within a wellbore, the packer device having: 
 a) a central packer mandrel defining an axial flowbore;  
 b) an expansion mandrel radially surrounding the central packer mandrel to define a filler material chamber between the expansion mandrel and the central packer mandrel, the expansion mandrel having an engagement profile formed on a radial exterior surface of the expansion mandrel for forming a biting engagement with a surrounding tubular within the wellbore;  
 c) a filler material disposed within the filler material chamber; and  
   2) actuating a setting mechanism to displace the filler material and radially expand the expansion mandrel to secure the engagement profile with a surrounding tubular.    
   
   
       19 . The method of  claim 18  wherein the step of actuating a setting mechanism further comprises urging a piston having a displacement portion into the filler material to displace the filler material.  
   
   
       20 . The method of  claim 19  wherein the step of actuating a setting mechanism further comprises retaining the piston in a set position with a body lock ring.