Ceramic insert into a composite slip segment

Abstract

In composite slips and downhole tools using composite slips, there are provided one or more slip segments. The slip segments comprise a body and one or more inserts. The body is a composite material having an outer surface. The inserts each have an upper surface and each of the inserts is mechanically affixed into the body such that the upper surface of each of the inserts extends at least partially out from the outer surface. In some embodiments, the inserts are oval or stadium shaped and have a shoulder that locks the insert from moving by interaction with a shoulder in a cavity wall of the body.

What is claimed is: 
     
         1 . A composite slip comprising:
 one or more slip segments comprised of:
 a body of composite material having an outer surface; and 
 one or more inserts with each insert having an upper surface, wherein each of the inserts are mechanically affixed into the body such the upper surface of each of the inserts extends at least partially out from the outer surface. 
   
     
     
         2 . The composite slip of  claim 1 , wherein each of the inserts further comprises a lower surface and a sidewall, wherein the sidewall has a perimeter and is shaped such that a cross-section taken perpendicular to the sidewall has an oval shape. 
     
     
         3 . The composite slip of  claim 2 , wherein the oval shape is a stadium shape. 
     
     
         4 . The composite slip of  claim 3 , wherein the sidewall has a base portion, a top portion and an angular portion, the base portion having a larger perimeter than the top portion and the angular portion connecting the bottom and top portions so as to form a shoulder around the perimeter of sidewall. 
     
     
         5 . The composite slip of  claim 4 , wherein the insert is mechanically affixed within the body so as to form a cavity wall defining a cavity in the body, wherein the cavity contains at least part of the insert and the cavity wall has an opposing shoulder to the shoulder around the perimeter of the sidewall to thus lock the insert into position within the body. 
     
     
         6 . The composite slip of  claim 5 , wherein the angular portion is at an angle from about 0 degrees to about 75 degrees from the base portion. 
     
     
         7 . The composite slip of  claim 6 , where the upper surface of each of the inserts extends from a first edge adjacent to the outer surface to the body to a second edge that is outward from the outer surface such that the upper surface extends out from the outer surface at an angle from about 5 degrees to about 45 degrees to the outer surface. 
     
     
         8 . The composite slip of  claim 7 , wherein the body has a plurality of the inserts mechanically affixed into the body. 
     
     
         9 . The composite slip of  claim 7 , wherein the body has only two inserts mechanically affixed into the body. 
     
     
         10 . The composite slip of  claim 7 , further comprising a plurality of the slip segments, wherein each slip segment has a first side and a second side opposing the first side with the first side of one slip segment contacted with the second side of another of the slip segments in a frangible connection so as to form a slip ring, which will separate upon application of a predetermined radial force. 
     
     
         11 . A downhole tool comprising:
 a mandrel; and   a slip assembly positioned on the mandrel, the slip assembly having at least one outwardly expandable slip ring and at least one slip wedge, wherein the slip wedge and slip ring are movable relative to one another when force is applied to the slip assembly, and the slip ring will expand radially outward in response to such movement, and wherein the slip ring comprises a plurality of slip segments having:   a body of composite material having an outer surface; and   one or more inserts with each insert having an upper surface, wherein each of the inserts are mechanically affixed into the body such that the upper surface of each of the inserts extends at least partially out from the outer surface.   
     
     
         12 . The downhole tool of  claim 11 , wherein each slip segment has a first side and a second side opposing the first side with the first side of one slip segment contacted with the second side of another of the slip segments in a frangible connection so as to form the slip ring, which will separate upon movement of the slip wedge relative to the slip ring. 
     
     
         13 . The downhole tool of  claim 12 , wherein each of the inserts further comprises a lower surface and a sidewall, wherein the sidewall has a perimeter and is shaped such that a cross-section taken perpendicular to the sidewall has an oval shape. 
     
     
         14 . The downhole tool of  claim 13 , wherein the oval shape is a stadium shape. 
     
     
         15 . The downhole tool of  claim 14 , wherein the sidewall has a base portion, a top portion and an angular portion, the base portion having a larger perimeter than the top portion and the angular portion connecting the bottom and top portions so as to form a shoulder around the perimeter of the sidewall. 
     
     
         16 . The downhole tool of  claim 15 , wherein the insert is mechanically affixed within the body so as to form a cavity wall defining a cavity in the body, wherein the cavity contains at least part of the insert and the cavity wall has an opposing shoulder to the shoulder around the perimeter of the sidewall to thus lock the insert into position within the body. 
     
     
         17 . The downhole tool of  claim 16 , wherein the angular portion is at an angle from about 0 degrees to about 75 degrees from the base portion. 
     
     
         18 . The downhole tool of  claim 17 , where the upper surface of each of the inserts extends from a first edge adjacent to the outer surface to the body to a second edge that is outward from the outer surface such that the upper surface extends out from the outer surface at an angle from about 5 degrees to about 45 degrees to the outer surface. 
     
     
         19 . The downhole tool of  claim 18 , wherein the body has a plurality of the inserts mechanically affixed into the body. 
     
     
         20 . The downhole tool of  claim 19 , wherein the body has only two inserts mechanically affixed into the body.