Expandable frac plug

Inventors: Adam J. Milne (Carrollton, TX); Daniel Keith Moeller (Carrollton, TX); Donald Ray Smith (Duncan, OK)

Assignee: Halliburton Energy Services, Inc.

E21B33/128 E21B33/12 E21B43/26

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Quick Facts

Patent No.: US 12680415
App. No.: 18/443,440
Granted: Jul 14, 2026
Kind: B2

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Abstract

An apparatus comprising a frac plug to be positioned inside casing of a wellbore formed in a subsurface formation. The frac plug is configured to expand to contact an inner wall of the casing and maintain, via one or more components coupled with the frac plug, a position while the frac plug is expanded.

Claims (31)

1 . An apparatus comprising:

a frac plug to be positioned inside casing of a wellbore formed in a subsurface formation, wherein the frac plug is configured to expand to contact an inner wall of the casing and maintain, via one or more components coupled with the frac plug, a position while the frac plug is expanded, and wherein a first distal end of the frac plug is configured with one or more relief channels to allow a corresponding section of the first distal end of the frac plug to expand.

2 . The apparatus of claim 1 further comprising:

an isolating component positioned in an inner bore of the frac plug to provide differential pressure integrity in the wellbore.

3 . The apparatus of claim 2 , wherein the isolating component includes a sealing device, wherein the sealing device includes a dart or a ball.

4 . The apparatus of claim 1 , wherein the one or more components are positioned on an outer face of the frac plug to engage with the inner wall of the casing while the frac plug is expanded.

5 . The apparatus of claim 1 , wherein the frac plug is a single structure comprising material configured to expand the frac plug to form to the inner wall of the casing.

6 . The apparatus of claim 1 , wherein one or more swedges are traversed through an inner bore of the frac plug to expand the frac plug to contact the inner wall of the casing.

7 . The apparatus of claim 1 further comprising:

one or more elements positioned on an outer face of the frac plug that contacts the inner wall of the casing while the frac plug is expanded, wherein the one or more elements provide a hydraulic seal between the outer face of the frac plug and the inner wall of the casing.

8 . The apparatus of claim 7 , wherein the one or more elements includes a polymer or an elastomer.

9 . A system comprising:

a frac plug, wherein the frac plug is positioned inside casing of a wellbore formed in a subsurface formation configured to expand into an inner wall of the casing, and wherein a first distal end of the frac plug is configured with one or more relief channels to allow a corresponding section of the first distal end of the frac plug to expand; and

one or more components coupled with the frac plug and configured to hold the frac plug in a position while the frac plug is expanded.

10 . The system of claim 9 further comprising:

an isolating component positioned in an inner bore of the frac plug to provide differential pressure integrity in the wellbore.

11 . The system of claim 10 , wherein the isolating component includes a sealing device.

12 . The system of claim 9 , wherein the one or more components includes buttons, wedges, heavy grit, or any combination thereof.

13 . The system of claim 12 , wherein the one or more components are positioned on an outer face of the frac plug to engage with the inner wall of the casing while the frac plug is expanded.

14 . The system of claim 9 , wherein the frac plug is a single structure comprising material configured to expand the frac plug to form to the inner wall of the casing.

15 . The system of claim 9 wherein one or more swedges are traversed through an inner bore of the frac plug to expand the frac plug to contact the inner wall of the casing.

16 . The system of claim 9 further comprising:

17 . The system of claim 16 , wherein the one or more elements includes a polymer or an elastomer.

18 . A method comprising:

positioning a frac plug at a depth inside a casing of a wellbore formed in a subsurface formation, wherein one or more components are coupled with the frac plug;

expanding, via a setting tool, the frac plug to contact an inner wall of the casing, wherein the depth of the frac plug is maintained via the one or more components, and wherein a first distal end of the frac plug is configured with one or more relief channels to allow a corresponding section of the first distal end of the frac plug to expand;

removing the setting tool from singular tubular structure; and

positioning an isolating component in the singular tubular structure to provide differential pressure integrity in the wellbore.

19 . The method of claim 18 , wherein the one or more components are configured to engage with the casing while the frac plug is expanded.

20 . The method of claim 18 , wherein the setting tool is configured with one or more swedges, and wherein the one or more swedges are traversed through an inner bore of the frac plug to expand the frac plug to contact the inner wall of the casing.