Hybrid expansion cone

Abstract

An expansion cone comprising a cone body having a first expansion surface with a diameter that increases from a leading edge to a first expansion diameter. A resilient sleeve disposed on an actuation mandrel that is coupled to the cone body. Movement of the actuation mandrel relative to the cone body moves an outer surface of the resilient sleeve to a second expansion diameter that is greater than the first expansion diameter.

What is claimed is: 
     
         1 . An expansion cone comprising:
 a cone body having a first expansion surface with a diameter that increases from a leading edge to a first expansion diameter;   an actuation mandrel coupled to the cone body; and   a resilient sleeve disposed on the actuation mandrel, wherein movement of the actuation mandrel relative to the cone body moves an outer surface of the resilient sleeve to a second expansion diameter that is greater than the first expansion diameter.   
     
     
         2 . The expansion cone of  claim 1 , wherein the actuation mandrel further comprises:
 a main body having a first end that is slidably engaged with the cone body; and   an annular flange that projects radially outward from a second end of the main body, wherein the resilient sleeve is disposed about the main body between the annular flange and the cone body.   
     
     
         3 . The expansion cone of  claim 1 , wherein the actuation mandrel further comprises a main body having a cylindrical portion and an expansion portion, wherein the expansion portion of the main body is disposed under the resilient sleeve when the outer surface of the resilient sleeve is moved to the second expansion diameter. 
     
     
         4 . The expansion cone of  claim 1 , wherein the diameter of the first expansion surface increases in a non-linear manner. 
     
     
         5 . The expansion cone of  claim 1 , wherein the diameter of the first expansion surface increases in a linear manner. 
     
     
         6 . The expansion cone of  claim 1 , wherein the actuation mandrel is moved by hydraulic force. 
     
     
         7 . The expansion cone of  claim 1 , wherein the actuation mandrel is moved by applying tension to the actuation mandrel. 
     
     
         8 . An expansion cone comprising:
 a first expansion surface formed by a solid cone body, wherein the first expansion surface has as diameter that increases from a leading edge to a first expansion diameter; and   a second expansion surface formed by a resilient sleeve that is selectively moveable between a first position where the resilient sleeve has an outer diameter that is not greater than the first expansion diameter and a second position where the resilient sleeve has an outer diameter that is greater than the first expansion diameter.   
     
     
         9 . The expansion cone of  claim 8 , further comprising
 an actuation mandrel having a main body with a first end that is slidably engaged with the solid cone body; and   an annular flange that projects radially outward from a second end of the main body, wherein the resilient sleeve is disposed about the main body between the annular flange and the solid cone body.   
     
     
         10 . The expansion cone of  claim 8 , further comprising:
 an actuation mandrel disposed as least partially within the solid cone body, the actuation mandrel having a main body with a cylindrical portion and an expansion portion, wherein in the second position, the expansion portion of the main body is disposed under the resilient sleeve.   
     
     
         11 . The expansion cone of  claim 8 , wherein the diameter of the first expansion surface increases in a non-linear manner. 
     
     
         12 . The expansion cone of  claim 8 , wherein the diameter of the first expansion surface increases in a linear manner. 
     
     
         13 . The expansion cone of  claim 8 , wherein the resilient sleeve is moved from the first position to the second position by hydraulic force. 
     
     
         14 . The expansion cone of  claim 8 , wherein the resilient sleeve is moved from the first position to the second position by applying tension to the expansion cone. 
     
     
         15 . A method of expanding a tubular member comprising:
 expanding the tubular member to a first expanded inner diameter by axially translating a solid cone body having a first expansion surface through the tubular member, wherein the first expansion surface has as diameter that increases from a leading edge to a first expansion diameter that is equal to the first expanded inner diameter; and   expanding the tubular member to a second expanded inner diameter by translating a resilient sleeve having a second expansion surface through the tubular member, wherein the second expansion surface is selectively moveable between a first position where the second expansion surface is not greater than the first expansion diameter and a second position where the second expansion surface is greater than the first expansion diameter.   
     
     
         16 . The method of  claim 15 , wherein the second expansion surface is moved to the second position by translating an actuation mandrel relative to the resilient sleeve. 
     
     
         17 . The method of  claim 16 , wherein the actuation mandrel has a main body with a first end that is slidably engaged with the solid cone body; and
 an annular flange that projects radially outward from a second end of the main body, wherein the resilient sleeve is disposed about the main body between the annular flange and the solid cone body and is moved to the second position by moving the annular flange closer to the solid cone body.   
     
     
         18 . The method of  claim 16 , wherein the actuation mandrel is disposed as least partially within the solid cone body and has a main body with a cylindrical portion and an expansion portion, wherein the resilient sleeve is moved to the second position by disposing the expansion portion of the main body is disposed under the resilient sleeve. 
     
     
         19 . The method of  claim 15 , wherein the resilient sleeve is moved from the first position to the second position by hydraulic force. 
     
     
         20 . The method of  claim 15 , wherein the resilient sleeve is moved from the first position to the second position by applying tension to the expansion cone.