Complex components for molded composite frac plugs
A downhole isolation tool for sealing a casing in a well, the downhole isolation including plural parts made of a composite material, each part having a preset functionality with regard to sealing the casing; and a sealing element configured to seal the casing. At least two parts of the plural parts have a single, combined body.
1. A downhole isolation plug for sealing a casing in a well, the downhole isolation plug comprising:
plural parts made of a composite material, each part having a preset functionality with regard to sealing the casing; and
a sealing element configured to seal the casing,
wherein at least two parts of the plural parts have a single, combined body,
wherein the body includes at least one layer of fibers, and the layer extends from an upstream end of the body to a downstream end of the body, and
wherein the body has a same thickness at a region where the at least two parts are combined.
2. The plug of claim 1 , wherein the two parts correspond to a slip ring and a mule shoe.
3. The plug of claim 2 , wherein the part that corresponds to the slip ring has plural buttons for engaging the casing.
4. The plug of claim 3 , wherein the part that corresponds to the mule shoe has an oblique face relative to a longitudinal axis of the plug.
5. The plug of claim 3 , wherein the part that corresponds to the mule shoe part has threads inside of a bore for being attached to a mandrel.
6. The plug of claim 1 , wherein one part of the plural parts is a mandrel and the other plural parts are located on the mandrel.
7. The plug of claim 1 , wherein there is no mandrel.
8. The plug of claim 1 , wherein the at least two parts correspond to a slip ring and a push ring.
9. The plug of claim 1 , wherein the at least two parts correspond to a mule shoe, a slip ring and a wedge.
10. The plug of claim 1 , wherein the at least two parts include all the plural parts.
11. The plug of claim 1 , wherein the sealing element is plastically deformable.
12. A method of manufacturing a downhole isolation plug for sealing a casing in a well, the method comprising:
manufacturing at least two parts of plural parts during a single step by using a composite material, each part having a preset functionality with regard to sealing the casing; and
adding a sealing element to the plural parts, wherein the sealing element is configured to seal the casing,
wherein the at least two parts of the plural parts have a single, combined body,
wherein the body includes at least one layer of fibers, and the layer extends from an upstream end of the body to a downstream end of the body, and
wherein the body has a same thickness at a region where the at least two parts are combined.
13. The method of claim 12 , wherein the fibers of the layer are added at the same time across the entire body.
14. The method of claim 12 , wherein the two parts correspond to a slip ring and a mule shoe.
15. The method of claim 12 , wherein the at least two parts correspond to a slip ring and a push ring.
16. The method of claim 12 , wherein the at least two parts correspond to a mule shoe, a slip ring and a wedge.
17. The method of claim 12 , wherein the at least two parts include all the plural parts.
18. A downhole isolation plug for sealing a casing in a well, the downhole isolation plug comprising:
a slip ring disposed on a mandrel;
a mule shoe also disposed on the mandrel;
a sealing element configured to seal the casing; and
a wedge that is partially placed under the mule shoe and is configured to press the mule shoe away from the mandrel,
wherein the mule shoe is attached to the mandrel with a locking mechanism located at an interface between the mandrel and the mule shoe,
wherein the slip ring and the mule shoe are made unitary, as a single element, from a composite material, and
wherein the single element includes at least one layer of fibers, and the layer extends from a downstream end to an upstream end of the single element.
19. The plug of claim 18 , wherein the locking element includes ceramic buttons, formed on the mandrel, which are configured to engage with J slots formed in the mule shoe.
20. The plug of claim 18 , wherein the locking element includes dowel pins configured to extend from an interior bore of the mandrel into the mule shoe.
21. The plug of claim 18 , wherein the locking element includes multi-lead threads or interrupted threads.