Bonded Segmented Slips

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.

What is claimed is: 
     
         1 . A downhole apparatus, comprising:
 a plurality of segments being independent from one another and being disposed side-by-side about the downhole apparatus, each side of the segments bonded by bonding material to the side of an adjacent one of the segments,   wherein the segments separate from one another at the bonded sides when expanded outward from the downhole apparatus.   
     
     
         2 . The apparatus of  claim 1 , wherein at least a portion of each of the segments is bonded by bonding material to a component of the downhole apparatus. 
     
     
         3 . The apparatus of  claim 1 , further comprising a cone disposed on the downhole apparatus adjacent one end of the segments, the cone and the segments being moveable relative to one another to expand the segments radially outward from the downhole apparatus. 
     
     
         4 . The apparatus of  claim 3 , further comprising a mandrel of the downhole tool about which the cone and the segments are positioned. 
     
     
         5 . The apparatus of  claim 1 , wherein the bonding material is selected from the group consisting of a thermoplastic resin, a thermoset resin, an elastomer, an epoxy adhesive, a bonding agent manufactured using ceramic agent, a bonding agent manufactured using a metallic agent, a bonding agent manufactured using a graphite agent, and a bonding agent manufactured using a combination of ceramic and metallic agents. 
     
     
         6 . A method of forming a slip assembly on a downhole tool, the method comprising:
 forming a plurality of independent segments;   positioning the segments side-by-side about the downhole tool; and   bonding each side of the segments with bonding material to the side of an adjacent one of the segments.   
     
     
         7 . The method of  claim 6 , further comprising bonding at least a portion of each of the segments with bonding material to a component of the downhole apparatus. 
     
     
         8 . The method of  claim 6 , wherein the bonding material is selected from the group consisting of a thermoplastic resin, a thermoset resin, an elastomer, an epoxy adhesive, a bonding agent manufactured using ceramic agent, a bonding agent manufactured using a metallic agent, and a bonding agent manufactured using a combination of ceramic and metallic agents. 
     
     
         9 . The method of  claim 6 , wherein bonding each side of the segments with bonding material to the side of the adjacent one of the segments comprises applying bonding material to the adjacent sides of the segments before or after positioning the segments side-by-side about the mandrel. 
     
     
         10 . A downhole apparatus, comprising:
 a plurality of segments being independent from one another and being disposed side-by-side about the downhole apparatus,   at least one retaining element disposed about the segments and holding the segments adjacent the downhole apparatus, the at least one retaining element having one or more components with ends affixed together by bonding material,   wherein the bonded ends of the one or more components separate from one another when the segments expand outward from the downhole apparatus.   
     
     
         11 . The apparatus of  claim 10 , wherein each segment comprises a surface disposed between the sides of the segment and facing outward away from the downhole apparatus, the surface defining a slot in which the retaining element disposes. 
     
     
         12 . The apparatus of  claim 10 , wherein the one or more components of the retaining element each comprise at least a portion of a ring composed of a non-metallic material. 
     
     
         13 . The apparatus of  claim 10 , wherein at least a portion of each of the segments is bonded by bonding material to a component of the downhole apparatus. 
     
     
         14 . The apparatus of  claim 10 , wherein sides of the segments are bonded by bonding material to the sides of adjacent ones of the segments. 
     
     
         15 . The apparatus of  claim 10 , further comprising a cone disposed on the downhole apparatus adjacent one end of the segments, the cone and the segments being moveable relative to one another to expand the segments radially outward from the downhole apparatus. 
     
     
         16 . The apparatus of  claim 15 , further comprising a mandrel of the downhole tool about which the cone and the segments are positioned. 
     
     
         17 . The apparatus of  claim 10 , wherein the bonding material is selected from the group consisting of a thermoplastic resin, a thermoset resin, an elastomer, an epoxy adhesive, a bonding agent manufactured using ceramic agent, a bonding agent manufactured using a metallic agent, and a bonding agent manufactured using a combination of ceramic and metallic agents. 
     
     
         18 . A downhole apparatus, comprising:
 a component of the downhole apparatus;   a plurality of segments being independent from one another and being disposed side-by-side about the downhole apparatus, at least a portion of each of the segments bonded by bonding material to the component of the downhole appartaus,   wherein the segments separate from one another and separate at the bonded portions when expanded outward from the downhole apparatus.   
     
     
         19 . The apparatus of  claim 18 , wherein the component of the downhole apparatus comprises a cone disposed on the downhole apparatus, the portion of each of the segments bonded by bonding material to the cone, the segments separating from one another and separating at the bonded portions when expanded outward from the downhole apparatus by the cone. 
     
     
         20 . The apparatus of  claim 18 , wherein the component of the downhole apparatus comprises a mandrel of the downhole apparatus about which the segments are disposed, the portion of each of the segments bonded by bonding material to the mandrel, the segments separating from one another and separating at the bonded portions when expanded outward from the mandrel. 
     
     
         21 . The apparatus of  claim 18 , wherein the component of the downhole apparatus comprises a setting shoulder of the downhole apparatus adjacent which the segments are disposed, the portion of each of the segments bonded by bonding material to the setting shoulder, the segments separating from one another and separating at the bonded portions when expanded outward from the downole apparatus. 
     
     
         22 . The apparatus of  claim 18 , wherein sides of the segments are bonded by bonding material to the sides of adjacent ones of the segments. 
     
     
         23 . A method of forming a slip assembly on a downhole tool, the method comprising:
 forming a plurality of independent segments;   positioning the segments side-by-side about the downhole tool; and   bonding at least a portion of each of the segments to a component of the downhole tool with bonding material.   
     
     
         24 . The method of  claim 23 , wherein the bonding material is selected from the group consisting of a thermoplastic resin, a thermoset resin, an elastomer, an epoxy adhesive, a bonding agent manufactured using ceramic agent, a bonding agent manufactured using a metallic agent, and a bonding agent manufactured using a combination of ceramic and metallic agents. 
     
     
         25 . The method of  claim 23 , wherein bonding the portion of each of the segments to the component of the downhole tool with bonding material comprises applying bonding material before or after positioning the segments side-by-side about the downhole tool. 
     
     
         26 . The method of  claim 23 , wherein the component of the downhole apparatus comprises a cone disposed on the downhole apparatus, and wherein bonding the portion of each of the segments comprises bonding the portion of each of the segments to the cone of the downhole tool with bonding material. 
     
     
         27 . The method of  claim 23 , wherein the component of the downhole apparatus comprises a mandrel of the downhole apparatus about which the segments are disposed, and wherein bonding the portion of each of the segments comprises bonding the portion of each of the segments to the mandrel of the downhole tool with bonding material. 
     
     
         28 . The method of  claim 23 , wherein the component of the downhole apparatus comprises a setting shoulder of the downhole apparatus adjacent which the segments are disposed, and wherein bonding the portion of each of the segments comprises bonding the portion of each of the segments to the setting shoulder of the downhole tool with bonding material.