Anti-extrusion slip assemblies for a downhole sealing device

1. A downhole plug for plugging a tubular member, the downhole plug comprising:

a packer configured to plug the tubular member in response to the plug being actuated from a first configuration to a second configuration; and

a slip assembly having a central axis and configured to couple to the tubular member in response to the plug being actuated from the first configuration to the second configuration, the slip assembly comprising:

a plurality of slip segments circumferentially spaced around the central axis, each slip segment comprising a body where each body comprises:

a first end;

a second end longitudinally opposite the first end;

an outward face with at least one engagement member for coupling to the tubular member; and

sides each facing an adjacent slip segment of the plurality of slip segments;

wherein the plurality of slip segments comprises a first set of slip segments and a second set of slip segments wherein each of the first set of slip segments is positioned directly between a pair of the second set of slip segments;

wherein a maximum longitudinal length of the body of each of the first set of slip segments is less than a maximum longitudinal length of the body of each of the second set of slip segments;

wherein each of the second set of slip segments include a pair of arcuately extending anti-extrusion members monolithically formed with the bodies of the second set of slip segments;

wherein the slip assembly has a radially inner configuration, and a radially outer configuration in which two anti-extrusion members arcuately overly each of the first set of slip segments.

2. The downhole plug of claim 1 , further comprising a mandrel configured to couple to a setting tool for actuating the plug from the first configuration to the second configuration, wherein the packer and the slip assembly are each positioned about the mandrel.

3. The downhole plug of claim 1 , wherein the anti-extrusion members of each of the first set of slip segments extend laterally from the first end of the body of the slip segment.

4. The downhole plug of claim 1 , wherein:

the body of each of the first set of slip segments has a first width extending between the pair of lateral of sides of the body; and

wherein a second width extending between a terminal end of a first anti-extrusion member of the pair of anti-extrusion members and a terminal end of a second anti-extrusion member of the pair of anti-extrusion members of each of the second set of slip segments is greater than the first width.

5. The downhole plug of claim 1 , wherein a terminal end of one of the anti-extrusion members of the second set of slip segments contacts a terminal end of another of the anti-extrusion members of the second set of slip segments when the plug is in the first configuration.

6. The downhole plug of claim 1 , wherein one of the pair of the anti-extrusion member of one of the second set of slip segments extends entirely across an arcuate gap formed between the one of the second set of segments and one of the first set of slip segments when the plug is in the second configuration.

7. The downhole plug of claim 1 , wherein one of the anti-extrusion members of each of the second set of slip segments arcuately overlaps one of the first set of slip segments when the slip assembly is in the radially inner configuration.

8. The downhole plug of claim 1 , wherein one of the anti-extrusion members of one of the second set of slip segments extends entirely across a gap formed between the one of the second set of slip segments and one of the first set of slip segments when the plug is in the second configuration.

9. The downhole plug of claim 1 , wherein the first ends of each of both the first slip segments and the second slip segments are axially aligned with one another at a first axial position, the second ends of the second slip segments are axially aligned with one another at a second axial position, and the second ends of the first slip segments are axially aligned with one another at a third axial position located axially between the first axial position and the second axial position.

10. The downhole plug of claim 1 , wherein the anti-extrusion members have a width oriented with the central axis of the slip assembly that is equal to an axial distance extending between the second axial position and the third axial position where an engagement surface is arranged to circumferentially extend from the second end of the second slip segment and a support surface is opposite the engagement surface across the width of the anti-extrusion member and contact and overlie the second end of the first slip segment.

11. The downhole plug of claim 1 , wherein the pair of anti-extrusion members comprise a pair of arms positioned at the first end of the body and extending arcuately in opposing directions.

12. The downhole plug of claim 11 , wherein each of the pair of arms of each second slip segment comprises a shoulder which slidingly engages the first end of the body of one of the first set of slip segments.

13. A downhole plug for plugging a tubular member, comprising:

a packer configured to plug the tubular member in response to the plug being actuated from a first configuration to a second configuration; and

a slip assembly having a central axis and configured to couple to the tubular member in response to the plug being actuated from the first configuration to the second configuration, the slip assembly comprising:

a plurality of slip segments circumferentially spaced around the central axis, each slip segment comprising a body where each body comprises:

a first end;

a second end longitudinally opposite the first end:

an outward face with at least one engagement member for coupling to the tubular member; and

sides each facing an adjacent slip segment of the plurality of slip segments;

wherein the plurality of slip segments comprises a first set of slip segments and a second set of slip segments wherein each of the first set of slip segments is positioned directly between a pair of the second set of slip segments;

wherein a maximum longitudinal length of the body of each of the first set of slip segments is less than a maximum longitudinal length of the body of each of the second set of slip segments, and wherein the first ends of each of both the first slip segments and the second slip segments are axially aligned with one another at a first axial position the second ends of the second slip segments are axially aligned with one another at a second axial position, and the second ends of the first slip segments are axially aligned with one another at a third axial position located axially between the first axial position and the second axial position;

wherein each of the second set of slip segments includes a pair of arcuately extending anti-extrusion members monolithically formed with the bodies of the second set of slip segments, and wherein the anti-extrusion members have a width oriented with the central axis of the slip assembly that is equal to an axial distance extending between the second axial position and the third axial position where an engagement surface is arranged to circumferentially extend from the second end of the second slip segment and a support surface is opposite the engagement surface across the width of the anti-extrusion member and contact and overlie the second end of the first slip segment;

wherein the slip assembly has a radially inner configuration, and a radially outer configuration in which two anti-extrusion members arcuately overlay each of the first set of slip segments.

14. The downhole plug of claim 13 , further comprising a mandrel configured to couple to a setting tool for actuating the plug from the first configuration to the second configuration, wherein the packer and the slip assembly are each positioned about the mandrel.

15. The downhole plug of claim 13 , wherein the pair of anti-extrusion members comprise a pair of arms positioned at the first end of the body and extending arcuately in opposing directions.

16. The downhole plug of claim 15 , wherein each of the pair of arms of each second slip segment comprises a shoulder which slidingly engages the first end of the body of one of the first set of slip segments.