Single use setting tool for actuating a tool in a wellbore

1. A single use setting tool for actuating a tool in a wellbore, the single use setting tool comprising:

an inner piston having a piston proximal end, a piston distal end opposite the piston proximal end, and a piston annular wall, wherein the piston annular wall defines a piston cavity;

an initiator holder, wherein at least a portion of the initiator holder is positioned within the piston cavity and the initiator holder is configured for receiving and retaining an initiator within the piston proximal end;

a gas-generating power charge positioned within the piston cavity, the power charge extending along a longitudinal axis from a proximal end of the power charge to a distal end of the power charge, the power charge having a first width at a first axial position and having a second width at a second axial position,

wherein the first width is different than the second width, and the piston cavity is dimensioned complementarily to the power charge, for receiving the power charge including the first width and the second width within the piston cavity.

2. The single use setting tool of claim 1 , wherein the power charge includes a tapered portion.

3. The single use setting tool of claim 2 , wherein the tapered portion tapers towards the distal end of the power charge.

4. The single use setting tool of claim 1 , wherein the power charge contacts the piston annular wall at circumferentially spaced positions along an external surface of the power charge.

5. The single use setting tool of claim 1 , wherein the power charge has a hexagonal cross-section transverse to the longitudinal axis.

6. The single use setting tool of claim 1 , further comprising

an outer sleeve having a sleeve proximal end, a sleeve distal end, and a sleeve central bore extending from the sleeve proximal end to the sleeve distal end, wherein a portion of the inner piston including the piston cavity is positioned within the sleeve central bore and the inner piston and the outer sleeve are configured for axially sliding relative to one another, wherein

the outer sleeve includes a shear element aperture extending from the outer surface of the outer sleeve to the sleeve central bore, the inner piston includes a shear element groove formed in and extending circumferentially on an outer surface of the inner piston, and the shear element aperture is configured to align with the shear element groove, and

the shear element aperture and the shear element groove are together configured for receiving a shear element extending between and positioned within each of the shear element aperture and the shear element groove.

7. The single use setting tool of claim 6 , further comprising a piston extension connected to the piston distal end, wherein at least a portion of the piston extension is dimensioned to extend within the sleeve central bore when the inner piston slides relative to the outer sleeve at least a certain distance.

8. The single use setting tool of claim 7 , further comprising a shock absorbing wedge positioned on the piston extension, wherein the sleeve distal end includes a cutout dimensioned for receiving a portion of the shock absorbing wedge.

9. The single use setting tool of claim 8 , wherein the shock absorbing wedge has a tapered profile and the cutout in the sleeve distal end is frustoconically shaped.

10. The single use setting tool of claim 1 , wherein the power charge is contained within a power charge container.

11. The single use setting tool of claim 1 , further comprising a booster, wherein the power charge defines an indentation for retaining the booster at the proximal end of the power charge, adjacent to the initiator holder.

12. The single use setting tool of claim 11 , wherein the initiator holder is configured for positioning the initiator such that an ignition material of the initiator is spaced from the booster by an air gap.

13. A single use setting tool for actuating a tool in a wellbore, the single use setting tool comprising:

an inner piston having a piston proximal end, a piston distal end opposite the piston proximal end, and a piston inner wall, wherein the piston proximal end includes a seal adapter portion and the piston inner wall defines a piston cavity;

an outer sleeve having a sleeve proximal end, a sleeve distal end, and a sleeve central bore extending from the sleeve proximal end to the sleeve distal end, wherein a portion of the inner piston including the piston cavity is positioned within the sleeve central bore, a portion of the inner piston extends beyond the sleeve distal end, and the inner piston and the outer sleeve are configured for axially sliding relative to one another,

wherein the outer sleeve includes a shear element aperture extending from an outer surface of the outer sleeve to the sleeve central bore and the inner piston includes a shear element groove circumferentially extending in an outer surface of the inner piston, wherein the shear element aperture and the shear element groove are together configured for receiving a shear element extending between and positioned within each of the shear element aperture and the shear element groove, when the inner piston is at a first position relative to the outer sleeve.

14. The single use setting tool of claim 13 , wherein the shear element aperture is configured to align with the shear element groove at any relative rotational position between the inner piston and the outer sleeve, when the inner piston is at the first position.

15. The single uses setting tool of claim 14 , wherein the inner piston is configured for axially sliding from the first position to a second position relative to the outer sleeve, and the shear element is configured to shear in response to the inner piston axially sliding from the first position to the second position.

16. A single use setting tool for actuating a tool in a wellbore, the single use setting tool comprising:

an inner piston having a piston proximal end, a piston distal end opposite the piston proximal end, and a piston inner wall, wherein the piston proximal end includes a seal adapter portion and the piston inner wall defines a piston cavity;

an outer sleeve having a sleeve proximal end, a sleeve distal end, and a sleeve central bore extending from the sleeve proximal end to the sleeve distal end, wherein a portion of the inner piston including the piston cavity is positioned within the sleeve central bore, a portion of the inner piston extends beyond the sleeve distal end, and the inner piston and the outer sleeve are configured for axially sliding relative to one another; and

a piston extension connected to the piston distal end, wherein at least a portion of the piston extension is dimensioned to extend within the sleeve central bore when the inner piston slides relative to the outer sleeve at least a certain distance.

17. The single use setting tool of claim 16 , wherein the piston extension has a proximal end having external threads and the piston distal end includes internal threads configured for coupling to the external threads of the piston extension.

18. The single use setting tool of claim 16 , further comprising a shock absorbing wedge positioned on the piston extension, wherein the sleeve distal end includes a cutout dimensioned for receiving a portion of the shock absorbing wedge.

19. The single use setting tool of claim 18 , wherein the wedge has a tapered profile and the cutout in the sleeve distal end is frustoconically shaped.

20. The single use setting tool of claim 16 , further comprising a gas-generating power charge positioned within the piston cavity, wherein the power charge extends along a longitudinal axis from a proximal end to a distal end, wherein the power charge has a tapered portion having an outer surface that tapers along the longitudinal axis.