Non-Metallic Mandrel and Element System

Abstract

A non-metallic element system is provided as part of a downhole tool that can effectively seal or pack-off an annulus under elevated temperatures. The element system can also resist high differential pressures without sacrificing performance or suffering mechanical degradation, and is considerably faster to drill-up than a conventional element system. In one aspect, the composite material comprises an epoxy blend reinforced with glass fibers stacked layer upon layer at about 30 to about 70 degrees. In another aspect, a mandrel is formed of a non-metallic polymeric composite material. A downhole tool, such as a bridge plug, frac-plug, or packer, is also provided. The tool comprises a support ring having one or more wedges, an expansion ring, and a sealing member positioned with the expansion ring.

1 . An element system, comprising:
 a non-metallic support ring, comprising:
 an annular section; and 
 a plurality of wedges, detachably connected to the annular section, detachable from the annular section under axial pressure on the support ring; 
   a non-metallic expansion ring, deformable to fill gaps formed between the plurality of wedges; and   a sealing member positioned with the expansion ring.   
     
     
         2 . The element system of  claim 1 , wherein the support ring is formed of a polymeric composite reinforced by fibers stacked in layers angled at about 30 to about 70 degrees relative to an axis of the support ring. 
     
     
         3 . The element system of  claim 2 , wherein the fibers are in layers angled at about 40 to about 70 degrees relative to an axis of the support ring. 
     
     
         4 . The element system of  claim 2 , wherein the polymeric composite comprises an epoxy. 
     
     
         5 . The element system of  claim 4 , wherein the epoxy is a blend of at least two epoxy resins. 
     
     
         6 . The element system of  claim 2 , wherein the fibers are continuous fibers. 
     
     
         7 . The element system of  claim 1 , wherein the plurality of wedges expand radially upon exertion of a predetermined force on the support ring. 
     
     
         8 . The element system of  claim 1 , wherein the expansion ring is formed of a flexible plastic, elastomeric, or resin material that flows at a predetermined temperature. 
     
     
         9 . The element system of  claim 1 , wherein the plurality of wedges are manufactured to angle outwardly from a center axis at about 10 degrees to about 30 degrees. 
     
     
         10 . The element system of  claim 9 , wherein the expansion ring comprises:
 a first section, tapered to a complementary angle of the plurality of wedges.   
     
     
         11 . The element system of  claim 1 , further comprising:
 a cone disposed between the sealing member and the expansion ring.   
     
     
         12 . The element system of  claim 11 , wherein the cone comprises:
 a tapered first section.   
     
     
         13 . The element system of  claim 12 , wherein the expansion ring comprises:
 a second section, disposed about and tapered to complement the tapered first section of the cone.   
     
     
         14 . The element system of  claim 11 , wherein the cone is formed of a polymeric composite reinforced by fibers in layers angled at about 30 to about 70 degrees relative to an axis of the support ring. 
     
     
         15 . The element system of  claim 14 , wherein the fibers are in layers angled at about 40 to about 70 degrees relative to an axis of the support ring. 
     
     
         16 . The element system of  claim 14 , wherein the polymeric composite comprises an epoxy. 
     
     
         17 . The element system of  claim 16 , wherein the epoxy comprises a blend of at least two epoxy resins. 
     
     
         18 . The element system of  claim 1 , further comprising:
 a mandrel, formed of a polymeric composite reinforced by fibers in layers angled at about 30 to about 70 degrees relative to an axis of the mandrel,   wherein the support ring, the expansion ring, and the sealing member are disposed about the mandrel.   
     
     
         19 . The element system of  claim 18 , wherein the fibers are in layers angled at about 30 to about 55 degrees relative to the axis of the mandrel. 
     
     
         20 . The element system of  claim 18 , wherein the polymeric composite comprises an epoxy.