Frac plug apparatus, setting tool, and method

Abstract

An improved frac plug apparatus and method for setting a plug in a downhole. In an embodiment, the apparatus comprises an inner cone shaped member having a first end and second end, the inner cone shaped member having a generally increasing outer diameter from the first end, and an expandable outer sleeve having a first end and a second end, the first end of the expandable outer sleeve adapted to receive the first end of the inner cone shaped member and the second end of the expandable outer sleeve having a plurality of fingers joined at their tips at predetermined break points. In use, upon receiving the first end of the inner cone shaped member further into the expandable outer sleeve, the fingers of the expandable outer sleeve are adapted to break at their tips at their predetermined break points and expand outwardly to engage a surface of the downhole.

1 - 21 . (canceled) 
     
     
         22 . A downhole apparatus for use in a well, the apparatus comprising:
 an inner cone shaped member having a first end and a second end, the inner cone shaped member having, at least in some part, an increasing outer diameter from the first end to the second end, wherein a beveled seat is defined on the second end of the inner cone shaped member;   an expandable outer sleeve having a first end and a second end, the first end of the expandable outer sleeve configured to receive the first end of the inner cone shaped member and the second end of the expandable outer sleeve having a plurality of fingers, wherein upon receiving the first end of the inner cone shaped member further into the expandable outer sleeve, the plurality of fingers of the expandable outer sleeve are configured to expand radially to engage with a wall of the downhole; and   a sealing ball having a diameter suitable, for being received in the beveled seat at the second end of the inner cone shaped member, as a means to restrict longitudinal flow passage through the downhole apparatus.   
     
     
         23 . The downhole apparatus of  claim 22 , wherein the end of the plurality of fingers are joined at the second end of the expandable outer sleeve and are configured to break at their tips at their predetermined break points by the pressure applied upon receiving the first end of the inner cone shaped member further into the expandable outer sleeve. 
     
     
         24 . The downhole apparatus of  claim 22 , wherein the outer surface of the plurality of fingers is provided with means for enhancing engagement and gripping of the wall of the downhole. 
     
     
         25 . The downhole apparatus of  claim 22 , wherein the plurality of fingers expand radially without breaking. 
     
     
         26 . The downhole apparatus of  claim 22 , wherein at least one of the inner cone shaped member, the expandable outer sleeve, or the sealing ball is made of a dissolvable material, which disintegrates after a period of use. 
     
     
         27 . The downhole apparatus of  claim 26 , wherein the dissolvable material disintegrates when exposed to a chemical solution. 
     
     
         28 . The downhole apparatus of  claim 26 , wherein the dissolvable material is customizable to achieve a desired dissolution rate. 
     
     
         29 . The downhole apparatus of  claim 26 , wherein the dissolvable material dissolves in the presence of moisture or water, at a temperature in the range of 100° F. to 400° F. and at a pressure in the range of 1 ksi to 20 ksi. 
     
     
         30 . The downhole apparatus of  claim 26 , wherein the dissolvable material is comprised of resin, fiber, or both. 
     
     
         31 . The downhole apparatus of  claim 26 , wherein the dissolvable material dissolves in saline, wherein the dissolution rate depends on the salinity. 
     
     
         32 . The downhole apparatus of  claim 22 , wherein the expandable outer sleeve is comprised of a plurality of outer seal seated in a groove formed in an outer wall near the first end of the expandable outer sleeve configured to hydraulically seal the downhole. 
     
     
         33 . The downhole apparatus of  claim 22 , wherein the expandable outer sleeve is constructed of a sufficiently ductile material such that the plurality of fingers can expand radially to the expanded second radial position without breaking or fracturing. 
     
     
         34 . A method of re-stimulating a wellbore using a flow diversion tool, the method comprising:
 loading a frac plug apparatus onto a setting tool, the frac plug apparatus comprising:
 an inner cone shaped member having a first end and a second end, the inner cone shaped member having, at least in some part, an increasing outer diameter from the first end to the second end, wherein a beveled seat is defined on the second end of the inner cone shaped member; 
 an expandable outer sleeve having a first end and a second end, the first end of the expandable outer sleeve configured to receive the first end of the inner cone shaped member and the second end of the expandable outer sleeve having a plurality of fingers, wherein upon receiving the first end of the inner cone shaped member further into the expandable outer sleeve, the plurality of fingers of the expandable outer sleeve are configured to expand radially to engage with a wall of the downhole; and 
 a sealing ball having a diameter suitable, for being received in the beveled seat at the second end of the inner cone shaped member, as a means to restrict longitudinal flow passage through the downhole apparatus; 
   running the setting tool loaded with the frac plug apparatus into the downhole;   at a desired location, pushing the inner cone shaped member into the expandable outer sleeve until the plurality of fingers of the expandable outer sleeve expand radially to engage with a wall of the downhole; and   withdrawing the setting tool through the set frac plug.   
     
     
         35 . The method of  claim 34 , wherein the end of the plurality of fingers are joined at the second end of the expandable outer sleeve and are configured to break at their tips at their predetermined break points by the pressure applied upon receiving the first end of the inner cone shaped member further into the expandable outer sleeve. 
     
     
         36 . The method of  claim 34 , wherein the outer surface of the plurality of fingers is provided with means for enhancing engagement and gripping of the wall of the downhole. 
     
     
         37 . The method of  claim 34 , wherein the plurality of fingers expand radially without breaking. 
     
     
         38 . The method of  claim 34 , wherein at least one of the inner cone shaped member, the expandable outer sleeve, or the sealing ball is made of a dissolvable material, which disintegrates after a period of use. 
     
     
         39 . The method of  claim 38 , wherein the dissolvable material disintegrates when exposed to a chemical solution. 
     
     
         40 . The method of  claim 34 , wherein the dissolvable material dissolves in saline, wherein the dissolution rate depends on the salinity. 
     
     
         41 . The method of  claim 34 , wherein the expandable outer sleeve is constructed of a sufficiently ductile material such that the plurality of fingers can expand radially to the expanded second radial position without breaking or fracturing.