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.

We claim: 
     
         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.