Downhole tool having cone supported inserts with serial wide teeth

Abstract

A downhole tool slip assembly having slip pad inserts with serial wide axial teeth on a long, wide shelf. The insert's base extends to the cone and is narrower than the teeth and shelf. An axial groove facilitates drilling out the insert. Inner slip pad fingers within cone grooves control slip pad separation and rotation.

1 . A settleable downhole tool for use within a casing, comprising:
 a mandrel and a cone mounted about the mandrel, the cone having an outer surface which has an incline relative to the mandrel;   a slip assembly mounted about the mandrel and adjacent to the cone, the slip assembly comprising a slip body and at least one insert in the slip body;   the slip body has a slip body outer surface for facing toward the casing when the downhole tool is within the casing and a slip body inner surface, at least a portion of the slip body inner surface facing toward the cone;   the cone's inclined outer surface and the slip body's inner surface are located and configured so setting the downhole tool will move the slip body over the cone and outward toward the casing;   at least one slip pocket located in the slip body, the slip pocket comprising;
 a cavity which extends through the slip body from an outer slip pocket which opens in the slip body's outer surface to an inner slip pocket which opens in the slip body's inner surface; 
 the slip pocket is sized and shaped to accept an insert which is capable of extending from the slip body's inner surface to the slip body's outer surface; and 
 at least a portion of the outer slip pocket is wider than a portion of the inner slip pocket that opens in the slip body inner surface; 
   the insert is in the slip pocket, the insert being sized and shaped to fit in the slip pocket and extending from at least the slip body's inner surface, through the slip body and at least to the slip body's outer surface, the insert comprising:
 an insert outer end located in the outer slip pocket and extending at least to the slip body's outer surface; 
 a set of at least three outward-facing teeth located at the insert outer end, the at least three outward-facing teeth being serially axially located with respect to each other and configured to engage the casing when the downhole tool is set within the casing; 
 a tooth shelf located in the outer slip pocket and beneath and connected to the teeth; 
 an insert base located in the inner slip pocket and beneath and connected to the tooth shelf; 
 an insert inner end at the inner end of the base, and at or outside of the slip body's inner surface, and at least 25% of the axial length of the insert inner end is located and configured to be parallel to and directly abutting the inclined outer surface of the cone when the downhole tool is set within the casing; 
 at least some of the teeth are at least 5% wider than some portions of the insert inner end are wide, and 
 the tooth shelf is at least twice as long as the insert inner end is wide, and at least some portions of the tooth shelf are at least 5% wider than a portion of the insert inner end is wide; 
 insert base is at least twice as long as the insert inner end is wide; and 
   the slip assembly is configured so when the downhole tool is set in the casing, at least 25% of the insert inner end will directly abut the cone, and setting the downhole tool will force at least some of the teeth outward to engage the casing.   
     
     
         2 . The downhole tool of  claim 1 , further comprising:
 the insert outer end is comprised of a set of at least four outward-facing teeth serially axially located with respect to each other;   the insert inner end is at least twice as long as the insert inner end is wide;   at least 30% of the axial length of the insert inner end is located and configured to directly abut the cone when the downhole tool is set within the casing;   the set of serial teeth on the insert is at least twice as long as the insert inner end is wide, at least 5% axially longer than the insert inner end is long and at least some of the serial teeth are at least 10% wider than some radially directly beneath portions of the insert inner end are wide; and   the tooth shelf is at least twice as long as the insert inner end is wide, at least 5% axially longer than the insert inner end is long, and at least some portions of the tooth shelf are at least 10% wider than some radially directly beneath portions of the insert inner end are wide.   
     
     
         3 . The downhole tool of  claim 2 , further comprising:
 the insert outer end is comprised of a set of at least five teeth serially axially located with respect to each other;   at least 45% of the axial length of the insert inner end is located and configured to directly abut the cone when the downhole tool is set within the casing;   at least some of the serial teeth are at least 20% wider than some radially directly beneath portions of the insert inner end are wide; and   at least some portions of the tooth shelf are at least 20% wider than some radially directly beneath portions of the insert inner end are wide.   
     
     
         4 . The downhole tool of  claim 3 , further comprising:
 the slip body is comprised of at least three slip pads, each of the at least three pads having a slip pocket and an insert within the slip pocket;   the longitudinal end of the tooth shelf facing toward the wider end of the cone is curved in the axial direction of the wider end of the cone and the longitudinal end of the insert inner end facing toward the wider end of the cone is curved in the axial direction of the wider end of the cone;   the insert base has a front face on the longitudinal end of the insert base toward the wider end of the cone and the insert inner end has a bottom face toward the cone's incline, and the junction between the insert base front face and the insert bottom face is a beveled or sloped junction and not a 90° angle junction.   
     
     
         5 . A settleable downhole tool for use within a casing, comprising:
 a mandrel and a cone mounted about the mandrel, the cone having an outer surface which has an incline relative to the mandrel;   a slip assembly mounted about the mandrel and adjacent to the cone, the slip assembly comprising a slip body and at least one insert in the slip body;   the slip body has a slip body outer surface for facing toward the casing when the downhole tool is within the casing and a slip body inner surface, at least a portion of the slip body inner surface facing toward the cone;   the cone's inclined outer surface and the slip body's inner surface are located and configured so setting the downhole tool will move the slip body over the cone and outward toward the casing;   at least one slip pocket in the slip body, the slip pocket comprised of an outer slip pocket that opens to the slip body's outer surface and an inner slip pocket that opens to the slip body's inner surface, and at least some portions of the outer slip pocket are wider than at least some portions of the inner slip pocket are wide, the slip pocket being sized and shaped to accept an object extending from the slip body's outer surface, through the outer slip pocket and through the inner slip pocket to the slip body's inner surface;   an insert located in the slip pocket, the insert being sized and shaped to fit in the slip pocket and extending to at least the slip body's inner surface, through the slip body, and extending at least to the slip body's outer surface, the insert comprising:
 an insert outer end located in the outer slip pocket and extending at least to the slip body's outer surface; 
 a set of at least three outward-facing teeth located on the insert outer end, the at least three outward-facing teeth being serially axially located with respect to each other and configured to engage the casing when the downhole tool is set within the casing; 
 a tooth shelf located in the outer slip pocket, and beneath and connected to the teeth; 
 an insert base located in the inner slip pocket, and beneath and connected to the tooth shelf; 
 an insert inner end being at the inner end of the base, and at or outside of the slip body's inner surface, and at least 25% of the axial length of the insert inner end is located and configured to be parallel to the inclined outer surface of the cone and to directly abut the inclined outer surface of the cone when the downhole tool is set within the casing; 
 the set of serial teeth on the insert is at least twice as long as the insert inner end is wide and at least a portion of the serial teeth is at least 5% wider than at least a directly beneath portion of the insert inner end is wide; 
 the tooth shelf is at least twice as long as the insert inner end is wide and at least some portions of the tooth shelf are at least 5% wider than at least a directly beneath portion of the insert inner end is wide; and 
   the slip assembly is configured so when the downhole tool is set in the casing, at least a portion of the insert inner end will directly abut the cone, and at least some of the teeth will be forced outward to engage the casing.   
     
     
         6 . The downhole tool of  claim 5 , further comprising:
 at least a portion of the tooth shelf is at least 10% wider than radially directly beneath portions of the insert inner end adjacent the slip body's inner surface are wide; and   at least a portion of the outer slip pocket adjacent the slip body's outer surface is at least 10% wider than radially directly beneath portions of the inner slip body pocket opening adjacent the cone are wide.   
     
     
         7 . The downhole tool of  claim 5 , further comprising:
 at least a portion of the tooth shelf is at least 20% wider than radially directly beneath portions of the insert inner end are wide; and   at least a portion of the outer slip pocket adjacent the slip body's outer surface is at least 20% wider than radially directly beneath portions of the inner slip body pocket adjacent the cone are wide.   
     
     
         8 . The downhole tool of  claim 5 , further comprising;
 the tooth shelf is at least 5% axially longer than the insert inner end is long; and   the outer slip pocket adjacent the slip body's outer surface is at least 5% axially longer than the inner slip body pocket opening adjacent the cone is long.   
     
     
         9 . The downhole tool of  claim 5  further comprising:
 the tooth shelf is at least 10% axially longer than the insert inner end is long; and 
 the outer slip pocket adjacent the slip body's outer surface is at least 10% longer than the inner slip body pocket adjacent the cone is long. 
 
     
     
         10 . The downhole tool of  claim 5 , further comprising:
 the teeth and tooth shelf together have a depth of at least 0.1 inches;   at least some portions of the outer slip pocket adjacent the slip body's outer surface are at least 25% wider than at least some portions of the inner slip pocket are wide;   the outer slip pocket transitions to the inner slip pocket at a shoulder located between the wider outer slip pocket and the narrower inner slip pocket;   the tooth shelf fits within the outer slip pocket and abuts the upper side of the shoulder;   the outer surface of the tooth shelf is at the outer surface of the slip body, and at least some teeth located on the outer surface of the tooth shelf extend outside of the slip body's outer surface; and   at least some of the teeth are 25% wider than radially directly beneath portions of the insert inner end adjacent the slip body's inner surface and   at least some portions of the tooth shelf are at least 25% wider than at least some radially directly beneath portions of the insert inner end adjacent the slip body's inner surface.   
     
     
         11 . The downhole tool of  claim 5 , further comprising:
 at least four serially axially located teeth are on each of a multiplicity of the inserts,   
     
     
         12 . The downhole tool of  claim 5 , further comprising:
 at least five serially axially located teeth are on each of a multiplicity of the inserts.   
     
     
         13 . The downhole tool of  claim 5 , further comprising;
 the insert inner end is sized and configured so at least 60% of the axial length of the insert inner end will directly abut the cone when the downhole tool is set within the casing.   
     
     
         14 . The downhole tool of  claim 5 , further comprising:
 the insert inner end is sized and configured so at least 60% of the axial length of the insert inner end will directly abut the cone when the downhole tool is set within the casing; and   a portion of the insert inner end is parallel to the mandrel, and the parallel portion of the insert inner end has an axial length of at least 20% of the insert inner end's total axial length.   
     
     
         15 . The downhole tool of  claim 5 , further comprising:
 the insert has at least a first cavity on an axial side of the insert inner end which first cavity is at least 0.002 inches deep and extends at least 40% of the axial length of the inner end;   the slip body is molded about the insert; and   the insert is at least partially held within the slip body by slip body material molded within the first cavity.   
     
     
         16 . The downhole tool of  claim 15 , further comprising:
 the first cavity is a first groove on an axial side of the insert base which first groove is at least 0.002 inches deep and extends at least 60% of the axial length of the base.   
     
     
         17 . The downhole tool of  claim 16 , further comprising:
 the insert has a second groove on a second axial side of the insert base which second groove is at least 0.002 inches deep and extends at least 60% of the axial length of the base.   
     
     
         18 . The downhole tool of  claim 5 , further comprising:
 the insert has at least a first protrusion on a first axial side of the insert base which first protrusion extends at least 0.002 inches away from the first axial side of the insert base and extends at least 40% of the axial length of the inner base and has at least a second protrusion on a second axial side of the insert base which second protrusion extends at least 0.002 inches away from the second axial side of the insert base and extends at least 40% of the axial length of the inner end;   slip body material is molded about the insert; and   the insert is at least partially held within the slip body against being pulled from the insert body by the slip body material molded about the first protrusion and second protrusion.   
     
     
         19 . The downhole tool of  claim 5 , further comprising:
 the longitudinal end of the tooth shelf is curved toward the wider end of the cone;   the longitudinal end of the insert base toward the wider end of the cone is curved toward the wider end of the cone; and   the insert base has a front face on the longitudinal end of the insert base toward the wider end of the cone and the insert inner end has a bottom face toward the cone's incline, and the junction between the insert base front face and the insert bottom face is a beveled or sloped junction and not a 90° angle junction.   
     
     
         20 . The downhole tool of  claim 5 , further comprising;
 a back tooth, the back tooth being the tooth on the insert furthest from the widest portion of cone, the back tooth has a notch centered on the back tooth face directed away from the widest portion of the cone, the back tooth notch face having at least a 10° angle from the perpendicular to the mandrel and the notch being at least 25% the width of the back tooth's outer edge.   
     
     
         21 . The downhole tool of  claim 20 , further comprising:
 the back tooth notch is angled and sized so the back tooth is less likely to be forced from its slip pocket when the downhole tool is being set in the casing than a similar insert, but which similar insert's back tooth does not have a back tooth notch; and   the back tooth notch is angled and sized, so the back tooth is less likely to damage the casing when the downhole tool is being run downhole through the casing than a similar insert, but which similar insert's back tooth does not have a back tooth notch.   
     
     
         22 . The downhole tool of  claim 5 , further comprising:
 the slip body has multiple slip fingers disposed on the slip body's inner surface, a finger comprising an axial raised portion of the slip body's inner inclined surface, the fingers comprising at least a first finger on a first slip pad and a second finger on a second slip pad;   the cone has multiple cone grooves located on the cone's outer inclined surface, a groove comprising an axial lowered portion of the cone's outer surface, the grooves comprising at least a first groove and a second groove;   the first finger and the first groove are located and configured so when the downhole tool is being set, the first finger will fit within the first groove and the first finger will slide axially through the first groove;   the second finger and the second groove are located and configured so when the downhole tool is being set, the second finger will fit within the second groove and the second finger will slide axially through the second groove; and   the downhole tool is configured so when the downhole tool is being set, the first and second fingers are within the first and second grooves respectively and the first and second fingers in the first and second grooves respectively deter rotation of the slip body about the cone.   
     
     
         23 . The downhole tool of  claim 22 , further comprising:
 the first and second grooves each extend at least one half the length of the cone, and each first and second groove has a portion which has a depth of at least 1/16 of an inch, and   the first and second fingers each has an axial length at least 25% as long as the axial length of each finger's slip and each first and second finger bas a finger portion which extends radially outside the inner surface of its slip pad toward the cone at least 1/16 of an inch.   
     
     
         24 . The downhole tool of  claim 23 , further comprising:
 each first and second groove has a groove portion which has a depth of at least ⅛ of an inch, and   each first and second finger has a finger portion which extends radially outside the inner surface of its slip pad toward the cone at least ⅛ of an inch,   
     
     
         25 . The downhole tool of  claim 5 , further comprising:
 the slip body is comprised of at least a first slip pad having a first slip pocket and a second slip pad having a second slip pocket;   a first insert in the first slip pocket and a second insert in the second slip pocket;   the first insert has a first insert inner end and the second insert has a second insert inner end:   The first insert inner end extends outside of the first slip pad's inner surface toward the cone, comprising an axial raised portion on the first slip pad's inner side, the raised portion being a first insert finger;   the second insert inner end extends outside of the second slip pad's inner surface toward the cone, and comprises an axial raised portion on the first slip pad's inner side, the raised portion being a second insert finger;   the cone has multiple cone grooves located on the cone's outer inclined surface, a groove comprising an axial lowered portion of the cone's outer surface, the grooves comprising at least a first groove and a second groove;   the first insert finger and the first groove are located and configured so when the downhole tool is being set, the first insert finger will fit within the first groove and will slide axially through the first groove;   the second insert finger and the second groove are located and configured so when the downhole tool is being set, the second insert finger will fit within the second groove and will slide axially through the second groove; and   the downhole tool is configured so, when the downhole tool is being set, the first and second insert fingers are within the first and second grooves respectively and the first and second insert fingers within the first and second grooves respectively deter rotation of the slip body about the cone,   
     
     
         26 . The downhole tool of  claim 25 , further comprising:
 the first and second grooves each extend at least one half the length of the cone, and each first and second groove has a portion which has a depth of at least 1/16 of an inch, and   the first insert finger extends at least 1/16 of an inch radially outside the inner surface of the first pad toward the cone and the second insert finger extends at least 1/16 of an inch radially outside the inner surface of the second pad toward the cone.   
     
     
         27 . The downhole tool of  claim 26 , further comprising:
 each first and second groove has a portion which has a depth of at least ⅛ of an inch and each groove comprises an extended curved furrow in the cone;   the first inner finger edge facing the cone is curved with a curvature equivalent to the first groove's curvature and the second inner finger's edge facing the cone is curved with a curvature equivalent to the second groove's curvature; and   the first insert finger extends at least ⅛ of an inch radially outside the inner surface of the first pad toward the cone and the second insert finger extends at least ⅛ of an inch radially outside the inner surface of the second pad toward the cone.   
     
     
         28 . The downhole tool of  claim 5 , further comprising:
 the insert, slip pocket and slip body are sized and configured so:
 before setting of the downhole tool begins, the insert does not extend outside the slip body's outer surface; and 
 when the downhole tool is being set, movement of the insert inner end directly on the cone's inclined outer surface toward the wider end of the cone pushes the insert outwards from the slip body, and the insert's outward movement from the slip body moves the insert teeth to at least 0.05 inches outside the slip body's outer surface, 
   
     
     
         29 . A settleable downhole tool for use within a casing, comprising:
 a mandrel and a cone mounted about the mandrel, the cone having an outer surface inclined relative to the mandrel;   a slip assembly mounted about the mandrel and adjacent to the cone, the slip assembly comprising a slip body;   the slip body has a slip body inner surface facing the cone and a slip body outer surface for facing the casing, at least a portion of the slip body inner surface has an incline relative to the mandrel;   the slip body has multiple slip fingers disposed on the slip body's inner surface, a finger comprising an axial raised portion of the slip body's inner inclined surface, the fingers comprising at least a first finger and a second finger;   the cone has multiple cone grooves located on the cone's outer inclined surface, a groove comprising an axial lowered portion of the cone's outer surface, the grooves comprising at least a first groove and a second groove;   the first finger and the first groove are located and configured so when the downhole tool is being set, the first finger will fit within the first groove and the first finger will slide axially through the first groove;   the second finger and the second groove are located and configured so when the downhole tool is being set, the second finger will fit within the second groove and the second finger will slide axially through the second groove; and   when the downhole tool is being set, the first finger will be within the first groove and the second finger within the second groove and the first finger in the first groove and the second finger in the second groove deter rotation of the slip body about the cone.   
     
     
         30 . The downhole tool of  claim 29 , further comprising:
 the first finger is on a first slip pad and the second finger is on a second slip pad;   the first and second grooves each extend at least one half the length of the cone, and each first and second groove has a portion which has a depth of at least 1/16 of an inch, and   the first and second fingers each has an axial length at least 25% as long as the axial length of each finger's slip pad and each first and second finger has a finger portion which extends radially outside the inner surface of its slip pad toward the cone at least 1/16 of an inch.   
     
     
         31 . An insert for use in a settleable downhole tool for use within a casing, the downhole tool comprising a mandrel and a cone mounted about the mandrel, the cone having an incline relative to the mandrel, a slip assembly mounted about the mandrel and adjacent to the cone, the slip assembly comprised of a slip body, the slip body has a slip body outer surface for facing toward the casing when the downhole tool is within the casing and a slip body inner surface for facing the cone, the insert comprising:
 a set of outward-facing teeth located on an outer end of the insert, the set of outward facing teeth comprising at least three teeth serially axially located with respect to each other, and configured to engage the casing when the downhole tool is set within the casing;   a tooth shelf located beneath and connected to the teeth;   an insert base located beneath and connected to the tooth shelf,   an insert inner end at the inner end of the insert base, at least 40% of the axial length of the insert inner end is located and configured for facing the cone and being parallel to the cone's inclined outer surface so the cone-facing portion will directly abut the cone when the downhole tool is set within the casing;   the insert inner end is at least three times as axially longer than the insert inner end is radially wide;   the set of axially located teeth is at least twice as long as the insert inner end is wide and at least some of portions of the teeth are at least 5% wider than at least some portions of the insert inner end are wide; and   The tooth shelf is at least twice as long as the insert inner end is wide and at least some portions of the tooth shelf are at least 5% wider than at least some portions of the insert inner end are wide; and   the insert is sized and configured so when the insert is within the slip body and the downhole tool is being set within the casing, the insert inner end will be forced along the inclined outer surface of the cone toward the wider inclined outer surface of the cone and out toward the casing, outward movement of the insert inner end will force the insert base outward, outward movement of the base will force the tooth shelf outward and outward movement of the tooth shelf will force the teeth outward and into engagement with the casing; and   the insert is sized and configured so when the downhole tool is set within the casing, the insert inner end will directly abut the cone and the insert's teeth will directly engage the casing.   
     
     
         32 . The insert of  claim 30 , further comprising:
 the teeth and a tooth shelf together have a depth of at least 0.2 inches;   at least some portions of the tooth shelf are at least 10% wider than at least some portions of the insert inner end are wide; and   the tooth shelf is at least 10% axially longer than the insert inner end is long.   
     
     
         33 . The insert of  claim 30 , further comprising:
 some portions of the tooth shelf are at least 20% wider than some portions of the insert inner end are wide; and   at least 40% of the axial length of the insert inner end is located and configured to have a cone facing portion which will directly abut the cone when the downhole tool is set within the casing.   
     
     
         34 . A settleable downhole tool for use within a casing, comprising:
 a mandrel and a cone mounted about the mandrel, the cone having an outer surface which has an incline relative to the mandrel;   a slip assembly mounted about the mandrel and adjacent to the cone, the slip assembly comprising a slip body and at least one insert in the slip body;   the slip body has a slip body outer surface for facing toward the casing when the downhole tool is within the casing and a slip body inner surface, at least a portion of the slip body inner surface facing toward the cone;   the cone's inclined outer surface and the slip body's inner surface are located and configured so setting the downhole tool will expand the slip body over the cone and outward toward the casing;   the slip body is comprised of multiple slip pads separated by axial channels and of filaments;   the multiple slip pads being at least a first slip pad and a second slip pad, the first and second slip pads separated by a first slip pad channel and connected by a first web and a second web; the first and second webs connecting the first and second pads across the first channel;   the first web has multiple first web holes, the first web holes being sized, configured, and located relative to the other first web holes so collectively, the first web holes negate the prospective circumferential path of the slip body's filaments from the first slip pad through the first web to the second slip pad;   the second web has multiple second web holes, the second web holes being sized, configured, and located relative to the other second web holes so that collectively, the second web holes negate the prospective circumferential path of the slip body's filaments from the first slip pad through the first web to the second slip pad;   The first web, the second web, the first web holes and second web holes are comprised, configured and sized so when the downhole tool is being run into a well to its setting location in the well, the first web and the second web will retain their structural integrity and hold the first slip pad and the second slip pad together on the downhole tool, and so when the downhole tool reaches its setting location in the well and is set in the well, setting the downhole tool will break second web and the second web, releasing the first slip pad and the second slip pad from each other and toward the casing.   
     
     
         35 . The downhole tool of  claim 33 , further comprising:
 at least some of the first web holes and some of the second web holes are between 0.03 to 0.08 in width.   
     
     
         36 . A method for making a slip body with slip pads for a settleable downhole tool, comprising:
 winding filaments about a circular slip body cage;   molding slip body material about the slip body cage and the wound filaments to create a molded slip body, the wound filaments having a circumferential path through the circular slip body;   mechanically removing axial channels from the molded slip body to create at least three slip pads but for leaving slip body webs between adjacent slip pads, each slip pad separated from adjacent slip pads by the axial channels, which channels negate the circumferential path of the slip body's wound filaments, but for the slip body webs within each channel, each web connecting adjacent slip pads and containing wound filaments;   creating multiple web holes in at least one web in each channel;   a first web has multiple first web holes, each of the first web holes being sized, configured, and located relative to the other first web holes so, the first web holes collectively negate the circumferential path of the slip body's wound filaments through the web and the remaining web portion continues to connect adjacent slip pads;   a second web has multiple second web holes, each of the second web holes being sized, configured, and located relative to the other second web holes so, the second web holes collectively negate the circumferential path of the slip body's wound filaments through the web and the remaining web portion continues to connect adjacent slip pads; and   the first web, the second web, the first web holes and second web holes are comprised, configured and sized so when the downhole tool is being run into a well to its setting location in the well, the first web and the second web will retain their structural integrity and hold the first slip pad and the second slip pad together on the downhole tool, and so when the downhole tool reaches its setting location in the well and is set in the well, setting the downhole tool will break second web and the second web, releasing the first slip pad and the second slip pad from each other and toward the casing.