Downhole Tool Having Cone Supported Inserts with Serial Wide Teeth

This application claims priority to and the benefit of U.S. Patent Application No. 63/658,737, filed on Jun. 11, 2024, U.S. Patent Application No. 63/708,340, filed on Oct. 17, 2024, and U.S. Patent Application No. 63/763,031, filed on Feb. 25, 2025. All of these prior applications are herein incorporated by reference in their entirety.

The disclosure generally pertains to downhole tools used in oil and gas industry wells that engage a surrounding casing or tubular. The scope of the disclosure, however, is not limited to such tools, industries, and uses.

Settable downhole tools temporarily or permanently isolate zones in a casing, tubular, or other adjacent surfaces. Settable downhole tools used in oil and gas industry wells include frac plugs, bridge plugs, packers, and other tools that grip surrounding casing, tubular, or other adjacent surfaces. For convenience, settable downhole tools are collectively referred to as “downhole tools,” and surrounding casing, tubular, or other adjacent surfaces are collectively referred to as “casing.” Downhole tools may have a slip assembly comprised of a slip and a cone, both disposed on the downhole tool's mandrel and adjacent to each other. The cone has an incline on its outer face relative to the mandrel and facing toward the slip. The slip has a similar matching incline on its inner face toward the cone. The slip may include a slip body with multiple slip pads and slip buttons or other inserts disposed in the slip pads. An insert comprises an inner element located within the slip body for holding the insert within the slip body and end outer gripping element that protrudes outside the slip body's outer surface. The outer gripping element is configured to engage the inner face of the surrounding casing when setting the downhole tool forces the slip body with its inserts outward against the inner wall of the casing.

In operation, setting the downhole tool compresses the slip and cone along the mandrel toward one another. This forces the slip up the cone's incline, radially outward away from the mandrel and toward the casing. Forcing the slip toward the casing forces the slip's inserts to engage, penetrate, and hold the downhole tool against the casing. This insert/inner wall engagement holds the downhole tool to the casing during downhole operations, which may be temporary or permanent.

United States patent Publication No. 2019/0063178 provides relevant background information, teaches various slip and insert designs and combinations, and is fully incorporated herein by reference as if fully copied herein.

A downhole tool slip assembly having inserts with serial wide axial teeth on a long, wide shelf embedded in a slip pad. The insert's base extends to the cone, is thinner than the teeth and shelf, and has an axial groove to facilitate drilling it out. Inner slip pad fingers sliding within cone grooves and guidance fins adjacent to slip pad connections reliably separate slip pads and deter slip rotation. The insert's teeth are wider than the insert's base, and a tooth shelf embedded in the slip body's outer surface securely holds the insert. The slip body is configured to accept and maintain the slip insert. The tooth shelf embedded in the slip body's outer surface, the extended insert base, and the radial pressure on the insert due to being directly squeezed between the cone and casing combine to securely hold the insert in the slip against being rolled out, twisted out, or sheared during setting of the downhole tool or downhole operations. Slip inner face fingers fit within corresponding cone outer face grooves, and guidance lugs between slip segments deter slip rotation of the slip about the cone, further protecting the insert/cone engagement against disengagement.

In an embodiment, the insert's base extends fully through the slip body, from the insert's teeth to against the cone, so the insert's bottom will slide against the outward-facing inclined face of the expansion cone to expand the slip/insert/teeth toward the inner face of the casing when the tool is being set in the casing. During the setting of the downhole tool, the slip is vertically compressed toward the center of the downhole tool along the cone's outer surface. The bottom of the insert is directly against the cone, so axial movement of the insert along the outward-facing incline face of the cone directly expands the insert's teeth against the inner face of the casing. Because the cone and the insert are incompressible relative to many conventional slips, the direct cone to insert to casing structure creates a dependable direct transfer of force between the cone and the insert's teeth.

For descriptive purposes, “upper,” “upward,” and like terms reference the direction along the downhole tool's mandreltoward top ring. “Lower,” downward,” and the like terms refer to the direction along mandreltoward bottom sub. “Inner” and the like terms refer to the direction toward mandrel. “Outer” and the like terms reference the direction outwardly away from mandrel. The casing surface facing toward downhole toolwithin the casing is conventionally referred to as the casing's “inner” face. These directional terms are for descriptive purposes only and do not limit the scope of the description. For example, the tool could be inverted within a casing and function in accordance with the instant-described principles.

shows a first exemplary downhole tool. Arranged on mandrelare top ring, upper sliphaving upper slip buttons(shown here are:(.-.,.-)), upper cone, sealing element, lower cone, and bottom sub. Also arranged on mandrelinare lower slipand lower slip inserts(shown here:.&,.,.&). Upper slip, buttons, and coneare collectively upper slip assembly. Lower slip, inserts, and lower coneare collectively lower slip assembly. Downhole toolis set at a chosen location within a casing. Setting downhole toolcomprises compressing top ringand bottom subtoward each other along mandrel. This compression moves upper slipdownward upon the inclined slope of upper cone, forcing upper slipand slip buttonsradially outward against the inner face of the casing to penetrate and engage the casing and moves lower slipupward upon the inclined slope of lower cone, forcing lower slipand teethradially outward against the inner face of the casing to penetrate and engage the casing. The engaged upper slip buttonsand lower slip insertspermanently or temporarily hold downhole toolto the casing.

shows a perspective view of an embodiment of insert. Inserthas teeth, serially identified as-. Toothis the back tooth. The slip's teethare on the outer face of tooth shelf. Back toothhas back tooth notch. Insert baseis attached to and extends below tooth shelftoward mandrel. Insert baseis comprised of base supports-.shows base right channels-between base supports-. In an alternative embodiment, insert baselacks channels or base supports.

shows a different perspective view of insert.show that insert basehas greater radial length or depth toward mandrelat its back end, i.e., the end below back tooth, than at its front end, i.e., the end below tooth. When the inserts are inserted in lower slip, the slope of insert base's lower surfacegenerally matches the inclined outer surface slope of lower cone. The angles of these matching inclined surfaces can be varied in accordance with the needs of the particular downhole tool and downhole task.

shows a side cross-section view of insertand teeth-. Inserthas back tooth face, back shelf, base back face, base bottom face, base bottom incline, base forward face, and base forward shelf. Preferably, base back faceand base forward faceare generally perpendicular to the mandrel's axis. This structure and orientation facilitate efficiency in manufacturing and placing insertswithin tooth pockets. It facilitates the alignment of insertwith the direct radial compression line of force between the interface of insert baseand coneand the interface of teethand the casing. This structure promotes functional efficiency in setting and holding teeth within the slips and holding downhole toolwithin the casing. In an embodiment, either or both base back faceand base forward facemay be acutely or obliquely angled relative to mandrel. In an embodiment, forward facemay be angled toward the upper end of cone, and base back faceangled inversely. In an embodiment in which insertdoes not have a tooth shelf, the insert may be installed within the slip from within the slip.

shows insertviewed from its back face. Back tooth notchis shown at the top and front center of back tooth. Tooth shelfis shown on base support. In an embodiment, the structure between teethon the outside of the insert and the base bottom incline faceon the bottom of the insert does not need to be as shown infor the insert to function beneficially as described. Insert basemay have different configurations, subject to the set downhole tool's inserts being capable of becoming engaged with the casing and directly supported by the insert's base bottom incline faceagainst the cone. As non-limiting examples, insert basemay have sides that slope from an upper end where they support the teeth down to lower base bottom inclined face. The slope may be a smooth slope, accomplished with stairstep reductions in the base's width or the like, limitation being that the teeth are wider than base bottom incline face. Likewise, the functions of base back faceand base front facemay be accomplished with structures that support wider teethwith a narrower base bottom incline facedirectly on the cone.

Likewise, teeth's function of engaging the casing may be accomplished with engaging structures other than the teeth shown in. The casing engaging function may be performed with any structure on the outside of insertcapable of sufficiently engaging the casing to hold the downhole tool against the casing while the downhole tool's function at that casing location is undertaken. The engaging structure may be pointed, ribbed, or other structures of various sizes and shapes, wide wicker-like teeth, or other structures capable of engaging casing and holding the downhole tool to the casing.

shows an embodiment of insertfrom underneath insert. Base bottom faces-of base supports-are shown.shows right base channels-and left base channels-between base supports-. Tooth shelf lower surfaceis shown.shows a view of insert's base right channels-and base left channels-, interfacing with right pocket ridges-and left pocket ridges-. Preferably, ridgesandand channelsandwill tightly interface with each other for each insert. The outer slip body surface to inner slip body surface depth of slip pocketand insert's base length provide a slip body/insertinterface, which is longer than the slip body/insertinterface of many similar conventional slip assembly's slips having slip pockets which do not fully extend through the slip from the slip's outer surface to the cone. Insert base channelsandon the sides of insert basecorrespond with and interlock with ridgesandon the sides of the slip body. Slip pocket's right pocket ridges-correspond with and interlock with insert's right base channels-. Slip pocket's left pocket ridges-correspond with and interlock with insert's left base channels-. The greater surface area between insertand slip bodythan for many similar conventional slip assemblies provides more than the typical conventional slip body/insert surface area for holding an insert within a slip. The more in-depth interlocking geometry of the corresponding slip body ridgesand, and insert 11 channels combine to provide more than typical conventional geometric interlocking resistance for holding an insert within a slip body.

In an embodiment, ridgesandand channelsandare radial relative to mandrel. In alternative embodiments, ridgesandand channelsandmay be angled to best hold the insert against the axial force against the downhole tool for which the slip assembly is holding the downhole tool within the casing. The lateral extent, width, and angles of ridgesandand the depth, width, and angles of channelsandmay be varied. Some shapes, sizes, materials, and geometries will best hold insertin slip bodyagainst axial force on the downhole tool. Exemplary alternative embodiments comprise other insert base/slip pocket reciprocally interfacing shapes, curves, ribs, and holes to help hold the insert within the slip pocket. In embodiments where the slip is molded about the insert base, the insert base may have protrusions, inclusions, holes, and other discontinuities that interface with reciprocal slip surfaces to help hold insertwithin slip body. An alternative insert embodiment is without channels, base supports, or ridges.

shows an axial view of lower slipfrom the lower end of mandrel. Lower sliphas slip segments-and slip waists-. Smaller slip waists-connect larger slip segments-. In operation, setting downhole toolforces lower slipover lower cone, which movement radially expands the slip; the radial expansion breaks lower slip bodyat slip waists-, releasing slip segments-from each other as they further radially expand outward as further setting of the downhole tool further moves the slip up the cone's incline and radially out toward the casing. Lower slip body's inner facing inclineis shown.

shows a side view of lower slip body. Slip segments,, andare shown. Slip waistsandare shown.

shows a cross-sectional view of slip body. Slip waistconnects slip segmentsand. Slip pocketsand, with their outer slip pocketsandand connecting inner slip pocketsand, are shown. Outer slip pocketconnects through inner slip pocketin slip bodyto slip body inner face. Outer slip pocketconnects through inner slip pocketin slip bodyto slip body inner face. Outer slip pockethas an insert slotdefined by shoulderand wall. Outer slip pockethas an insert slotdefined by shoulderand wall. Other slip pockets are similarly shaped, arranged, and numbered. The several outer slip pockets and inserts are located, sized, and shaped to enable outer slip pockets-to closely accept corresponding tooth shelves-of inserts-. Each inner slip pockethas a right pocket ridgeand a left pocket ridge. Inner slip pocketsand, right pocket ridges.and., and left pocket ridges.and.are shown. Slip body inner face, including slip upper inclineand slip lower incline, are shown. When the downhole tool is set, slip body inner faceis compressed against and moves over coneto radially expand lower slipoutward from the cone and toward the casing.

shows section A-A of's slip body. Slip pocket, slip outer pocket, slip waist, slip inner pockets, and slip fingersare shown.

shows section B-B of's slip body. Slip pockets, slip waists, slip shelf, slip waist, slip inner pockets, and slip fingersare shown.

shows an upper perspective view of slip body. Slip pockets, outer slip pockets, inner slip pockets, slip waist, outer slip shelves, slip lower incline, slip waists, and slip fingersare shown. Outer slip pockethas an insert slotdefined by shoulderand wall. Outer slip pockethas an insert slotdefined by shoulderand wall

shows a lower perspective view of slip body. Outer slip pocketsand inner slip pockets, slip waist-are shown.

shows a perspective view of lower cone.shows cone upper base, ring gapsand, cone incline, guidance grooves-, and cone top.

shows a side cutaway view of lower cone. Cone incline, cone upper base, guidance groove, and ring gapsandare shown.

shows a top-down view of lower cone. Cone incline, guidance grooves-, and cone lower faceare shown.

shows a view of cone upper basefrom above lower cone. Ring gaps-with alternating coin base solid sections and gaps are shown.

show another slip assembly embodiment. Element numbers for elements of, which are consistent with the elements of, are maintained in. Element numbers for elements of, which are functionally the same but structurally not identical to the elements of, are maintained onbut with a different identifying subscript. For simplicity, base bottom faceofretains the same number. However, cone grooves-ofhave the same function but are not identical to cone grooves-of. Accordingly,cone grooveshave different subscripts.

shows a perspective view of an insert embodiment, namely insert. Where's elements are identical to those of the elements of,'s elements are numbered consistently with those of. The inserts ofare, however, different.'s straight base front faceis ininstead curved base front face.'s straight base bottom inclined faceis ininstead curved base bottom incline face.'s straight base back faceis ininstead curved base back face.'s insert basehas base channelsand.'s insert basedoes not have base channelsand; instead, insert base sideis flat. The transition between curved base front faceand flat first insert base sidebegins at forward base transition line. The transition between curved base bottom incline faceand flat insert base sidebegins at lower base transition line. The transition between curved base back faceand flat insert base sidebegins at rear transition line. The transition between curved base front shelf forward face, and straight tooth shelf first sideis at forward tooth shelf transition line. The transition between curved back tooth faceand straight tooth shelf first sideis at back tooth shelf transition line. Likewise, in, bottom transition lineillustrates where curved base bottom incline face, having curved downward from first insert base side, reaches its furthest downward extent and begins curving upward toward first insert base side. Transition lines,,,,, andare illustrative explanatory lines in this disclosure's figures. These transition lines are not marked on insertand are not present as physical lines.

Insert's curved and round surfaces better distribute load into and about insertrelative to an insert with corners, which are stress concentrators. In the embodiment of, the round shapes of curved base front shelf forward faceand curved base front facedistribute the downhole tool's downward axial thrust upon insertin lower slipover the insert's upward full radially shaped end, in contrast to an alternative insert with 90° corners. In other embodiments, curves other than a round curve between the insert's first and second sides are practicable. Back tooth faceand back faceare similarly round or curved.

shows a top-down view of insert. Its elements are numbered consistently with.is a view from underneath insert. Its elements are numbered consistently with.is a side view of slip body. It is numbered consistently with, with different element number subscripts where applicable.is an axial view of cone. Its elements are numbered consistently with, with different element number subscripts where applicable.is a cross-sectional view of cone. Its elements are numbered consistently with, with different element number subscripts where applicable.'s slip inner pockets-functionally correspond withelements-.shows a perspective view of lower cone. It is numbered consistently with, with different element number subscripts where applicable.is an axial view of cone.shows a top-down view of lower cone. It is numbered consistently withwith different element number subscripts where applicable.

Slip insertsare inserted in each slip pocket. Tooth shelfis held within outer slip pocketsand helps hold insertwithin slip body. The depth of insert basewithin slip bodyfrom slip body's outer surface to slip pocket's inner surface against coneis relatively longer than the depth of inserts in otherwise similar conventional inserts and slip assemblies for similarly sized downhole tools. The described embodiment's longer pocket/insertinterface depth helps hold insertwithin slip body. During and after setting, the lower surface of insert baseis compressed directly against the hard surface of cone. Compressing incompressible hard insertdirectly against the incompressible hard surface of coneduring and after setting creates a compressive force at the casing/insertinterface and at the insert/coneinterface, which helps hold insertin place within slip bodyand between the casing and cone.

Each of the slipand insert 11 elements individually and collectively helps hold insertwithin slip bodyduring and after setting more securely than many conventional inserts are held within many conventional slips during and after setting.

Slip inserts may be wickers, buttons, or other structures, for which the inner end is capable of being held in the slip and the outer end of which has one or more projections capable of engaging the inner wall of a casing. Inserts may be made from degradable or non-degradable, composite, or non-composite, metallic or non-metallic materials. In an embodiment, insertis made of a hard material, such as ceramic, cast iron, titanium, carbide, a cement or mineral, glass, or other hard metallic or nonmetallic materials. In an embodiment, a usable ceramic is yttria-stabilized zirconia. In an embodiment, the insert's outer gripping members may be formed on the outer end of the insert by kurling, machining end and/or molding the insert substrate. In an embodiment, the insert's gripping elements and base me molded or formed as a single unit. The gripping members may be hardened to improve their engagement with the casing by using a flame sprayed carbide process on them. A ceramic insert may be advantageously more easily manufactured into desired shapes, less expensive, and easier to drill up into small pieces that do not interfere with subsequent downhole operations after the downhole tool is set and its operations completed than an insert that is otherwise similar but made of cast iron, titanium, or carbide. Inserts, particularly wicker-style inserts, may be radiused to match the curvature of the expected casing ID. In an embodiment, inserts shaped as shown inor inserts with other nonuniform geometries are preferably ceramic. Making such inserts from cast iron or other hard metals would be much more expensive. Drilling up such inserts made of cast iron or other hard metals into small pieces that do not interfere with subsequent downhole operations is more difficult than drilling up otherwise similar inserts, but made of ceramic.

Slip bodyis preferably, but not necessarily, made of a different and softer material than insert. Slip bodyis preferably, but not necessarily, comprised of a polymer with glass fibers, molded plastic, laminated composite, etc. Coneis made of a rigid, incompressible material. The material can be either composite or non-composite, and it can be molded or not molded. Insertand coneare essentially incompressible relative to the slip pad. The cone is also significantly thicker and stronger than the slip pad. In an embodiment, insertis positioned entirely through slip bodyand directly against cone. Setting downhole toolwithin the casing forces the bottom of insertdirectly against coneand forces the teeth of insertdirectly against the casing. Compressing incompressible insertbetween incompressible coneand incompressible casing directly transmits the outward setting forces created by the slip moving up the cone to the insert's teeth, into the casing. This structure of these relatively incompressible elements and compression of the relatively incompressible elements against each other efficiently directly transmits the downhole tool's axial slip sliding over cone setting force into a radially outward insert teeth into the casing setting force. It also creates a direct, relatively incompressible geometric and physical cone/insert/casing impediment to unwanted movement of toolwithin the casing during the downhole tool's setting and operation. The setting tool's vertically downward compressive force along the axis of the downhole tool's mandrelis thus efficiently and directly converted into a radially outward force that pushes insertand its teethinto the inner wall of the casing.

Tooth shelfheld within slip outer pocketprovides additional shoulderand wallsurface areas for holding insertto slip body. Further, wallprovides another axial geometric block against tooth shelf, moving axially responsive to the axial force on the set downhole tool against which the slip assembly holds the set downhole tool.

Setting downhole toolwithin the casing forces the slip assemblies out against the casing. Teethare the outermost portion of the slip assembly to engage the casing. Forcing teethinto the casing compresses teethinward toward mandrel. This compresses tooth shelfinward against slip body. Tooth shelfcompressing slip bodycompresses slip body's base material within ridgesandagainst insert baseand against and within channelsand. Thus, setting the downhole tool pushes teethradially inward, pushing tooth shelfradially inward, pushing slip bodyradially inward, which both makes the compressed slip bodymaterial more rigid about insertand compresses slip bodyaxially against insert. Accordingly, tooth shelfmakes the set downhole tool's slip assembly's insertsmore resistant to insertbeing axially forced from the slip assembly.

In an embodiment, the described slip assembly holds the downhole tool to the casing by compressing at least one insert directly between the cone and the casing so the outer end of the insert is directly compressed against and engages the inner face of the casing to hold downhole toolagainst the casing and the inner end of the insert is directly compressed against the outer face of the cone and is slidable up the slope of the outer face of the cone when downhole toolis being set. Because the insert is more incompressible than the slip, this structure more directly translates the vertical setting force of the setting tool into horizontal setting force against the casing than a similar slip assembly in which a similar insert does not fully extend from the teeth outside the slip body to the cone. It is believed this geometry provides some benefit during plug setting and use, direct axial compression of the inserts between the cone and casing as shown, causing the inserts to radially press outward into a better engagement with the casing. Setting toolin the casing with the disclosed slip and insert combination provides greater resistance to unwanted movement of toolwithin the casing than comparable downhole tools with a structure similar to the described tool, except lacking the described slip assembly's slip body's and insert's described structure.

Preferably, slip pocketsand ridgesandare uniformly shaped and configured, and insertsand channelsandare uniformly shaped and configured so that insertscan be randomly inserted into any slip pockets. This facilitates efficiency in manufacturing and assembling the components. Alternatively, some slip pocketsand their ridgesandand some insertsand their channelsandmay be shaped and configured differently, so a first configuration slip pocketand insertfit with each other, and a second configuration slip pocketand insertfit with each other, etc. Slip pocketsand insertsmay have different depths. Slip pocketsand insertslocated toward the upper end of slip bodymay have a shorter depth and length than slip pocketsand inserts located toward the lower end of slip body. Alternatively, a design choice for some slip assemblies may be for some or all slip pocketsnot to open at the slip inner surface facing cone, such shorter slip pocketsholding correspondingly shorter inserts. This may facilitate manufacturing and assembly efficiencies.

The disclosed embodiments teach similar embodiments having more or fewer, longer or shorter, wider, or narrower structures than the described elements. For example, there may be multiple inserts with multiple teeth or buttons of different compositions, sizes, widths, shapes, etc. The insert bases may have many sizes, shapes, angles, and base supports. Base supports, channels, slip pockets, and ridges may vary in number, size, shape, etc. The teachings for a lower slip apply to an upper slip.

In an alternative embodiment, one or more slip pocketshave ridgesand, and one or more insertshave channelsand; the ridges and channels are shaped and configured so a first configuration slip pocketand insertfit with each other, and a second configuration slip pocketand insertfit with each other, etc. Slip pocketsand insertsmay have varied sizes, shapes, and depths. Slip pocketsand insertslocated toward the upper end of slip bodymay have a shorter depth and length than slip pocketsand inserts located toward the lower end of slip body. In an embodiment, at least some of the multiple inserts have a channel located in the insert's base and extending into the insert, and at least some of the slip pocket ridges correspond with at least some of the insert base channels, and at least some inserts with a channel are located in at least some slip pockets with a ridge, and at least some of the inserts' channels closely correspond with the inserts' respective slip pockets' ridge. In an embodiment, the slip assembly is configured so that when the downhole tool is being set within the casing, the inserts with channels that fit within slip pockets having corresponding and matching ridges are more securely held within the slip pockets and are less likely to be forced from their slip pockets when the downhole tool is being set than similar inserts which do not have channels and are not fit within slip pockets having corresponding and matching ridges. In an embodiment, at least some slip pockets have multiple ridges located within the slip pocket, along the slip pocket's longitudinal axis, and extending into the slip pocket; at least some of the multiple inserts have multiple channels located in the insert's base, along the insert's base's longitudinal axis and extending into the insert. At least some of the slip pocket ridges correspond with at least some of the insert base channels, and at least some inserts with channels are in at least some slip pockets with ridges. At least some of the inserts' channels closely correspond with the slip pockets' ridges. In an embodiment, at least some ridges are oriented radially relative to mandrel, and at least some channels are oriented radially relative to mandrel. In an embodiment, at least some slip pockets have multiple ridges on one side of the pocket and multiple ridges on the other side of the pocket. At least some inserts have multiple channels on one side of the insert base and multiple channels on the other side of the insert base, and the slip pocket has multiple ridges, and the insert's multiple channels are located, shaped, and sized. Hence, the ridges and channels correspond, and at least some inserts with multiple channels on one side of the insert base and multiple channels on the other side of the insert base are capable of being closely held within at least some of the pockets with multiple ridges on one side of the pocket and multiple ridges on the other side of the pocket.

In an alternative embodiment, some, or all, slip pocketsdo not open at the slip's inner surface where it faces cone, such shorter slip pocketsholding correspondingly shorter inserts. Insert baseof shorter inserthas a sufficient depth to hold insertwithin the slip during setting and operations. In an alternative embodiment, the slip assembly is arranged so that the bottom of the insert is close to the bottom of the slip base but does not fully reach through the bottom of the slip base. In this embodiment, a thick or thin portion of the slip base, preferably ⅛ inch or within the range of 1/16-¼ inch, is at the bottom of the slip base pocket between the bottom of the insert and the cone. Alternatively, the slip assembly may be arranged so there is a vacant space between the base bottom faceand the bottom of the slip base pocket. One or more of these alternative embodiments may facilitate manufacturing and assembly efficiencies.

Insertmay be press-fitted within slip pocketsor affixed to the slip body, with adhesives or both. Alternatively, slip bodymay be injection molded, compression molded, or pour molded about the several inserts. In addition to manufacturing efficiencies, molding permits different insert baseand slip pocketgeometries. An insertwithin a molded slip bodymay be designed with one or more flanges extending perpendicularly or at an angle from insert base. Such flanges provide more insert base/slip body surface area and a geometric block against insert basebeing pulled out of slip bodyby axial or radial forces on teethduring and after setting downhole tool. In an embodiment, an insert with base channelsandand slip base ridgesandmay have deeper and thinner channels, and longer and thinner ridges permitted by molding may provide more surface area and more geometric blocking of axial force on insert. Thinner channels and ridges permitted by molding enable the inclusion of more channels and ridges than permitted by inserting and gluing insertsinto slip body.

show various insert base enablements with insert base-beneath tooth shelf-.shows cavitiesandwithin insert base. A molded material or glue within cavitiesandwill have more surface area and provide more mechanical and geometric blocking to hold insert basewithin slipthan a similar base but without cavities.shows cavitiesandwithin insert base. A molded material or glue within cavitiesandwill have more surface area and more mechanical and geometric blocking to hold insert baseorwithin slipthan a similar base but without cavities. Insert baseofhas a thinner upper base, a thicker lower base, and a base shelf. A molded material or glue about basewith its thinner upper baseprovides a slip material area between tooth shelfand thicker lower base, and its base shelfhas more surface area and provides more mechanical and geometric blocking to hold insert basewithin slipagainst being pulled out of slipthan a similar baseof, which lacks thinner upper baseand base shelf. Embodiments shown inprovide different surface areas, voids, and geometries for molding or gluing insertwithin slip.

show an alternative embodiment of downhole tool. About mandrelis top ring, upper slip, upper cone, sealing element, lower cone, and bottom sub. Upper sliphas one insert per slip segment, i.e., slip segmenthas insert, upper slip segmenthas one slip segment, etc. Lower sliphas slip segments,, etc., each slip segment having two inserts. In an embodiment, slip segmenthas two slip segments,and. The slip segments are connected to each other about the mandrelvia slip waists, for example, 148a. In this embodiment, the described cone groove/slip finger anti-twist/anti-rotation structure and function, and other embodiments herein are provided by lugheld tightly within and protruding from cone orifice. Guidance lugfits between slip segmentsand. When downhole toolis being set, slip segmentsandmove over cone. Guidance lugseparates slip segmentfrom slip segmentat the immediately adjacent slip waistas lower slipis expanded over cone. Once lower slipis expanded over coneand lugis forced between slip segmentsand, guidance lugobstructs the rotational movement of lower slipabout cone. Because the rotational movement of the slip is a cause of stress on inserts that may cause the inserts to be pulled or rolled out of a slip, guidance lugfunctions to help keep insertsandfrom being forced from lower slip. The functional effect of this structure and arrangement is to cause downhole toolto be held more securely within the casing after downhole toolis set within the casing than similar downhole tools without such guidance lugs. Similar guidance lugs are located within the downhole tool's upper and lower cones to deter rotation of the downhole tool's upper and lower slips and thus more securely hold downhole toolwithin the casing. The guidance lugs are comprised of a hard material selected for its ability to withstand rotational forces while preventing slips from rotating during downhole tool setting or operations.

Button and insert rolling may occur on a tool's X and/or Y axis or both axes during tool setting and use. Downhole tools with the disclosed guidance fins, guidance lugs, and notches will have slips that rotate about the downhole tool less and have inserts and buttons that are twisted out of the slip in the tool's X and/or Y axis or both axes less than similar downhole tools, but without the disclosed guidance fins, guidance lugs, and notches. Inserts in downhole tools have an outer end that extends outside the slip for engaging the casing and have an inner end that directly abuts the cone. Such inserts are less likely to be twisted out of the slip in the tool's X and/or Y axis or both axes than similar inserts in similar downhole tools, but which similar inserts do not directly abut the cone. Downhole tools with the disclosed guidance fins, guidance lugs, and notches and with inserts, buttons, or other projections that are axially longer than circumferentially wide will have slips that rotate about the downhole tool less and have inserts and buttons that are twisted out of the slip in the tool's X and/or Y axis or both axes less than similar downhole tools, but without the disclosed guidance fins, guidance lugs, and notches.

The several differences between the described embodiment and many conventional slip assemblies advantageously combine to better keep slip's insertsfrom sliding, flipping out, or damaging the casing while setting the downhole tool, more directly transmitting the setting tool's downward vertical force into outward a radial force of the insert teeth against the casing and better hold the tool to the casing than similar conventional slip assemblies that do not use the described slip assembly structures. In an embodiment, the inserts do not extend fully through the slip body, and the insert body is perpendicular to the angle of the cone's sloped outer surface. Conventional downhole tool structures may be substituted for some but not others of these described structures. In an embodiment, the insert may extend fully through the slip to the cone but not have teeth wider than the insert or vice versa.

show an insert embodiment, namely insert.shows first grooveon first base sideof base. Base bottom incline facehas outer edge bevel. First grooveopens to back base faceand does not open to front base face.

shows first grooveon first base faceand second grooveon second base face.is a side view of insertshowing first grooveon first base face. The apparent discontinuity between first groove's back endand back base faceinis perceptual only due to the curvature of back faceshown in.

In an embodiment, during the manufacture of a slip assembly, a slip is molded about insert, injection or compression molded. Insertis a hard material, in an embodiment, ceramic or iron. The slip comprises a weaker and more compressible material, in an embodiment, thermoplastic or other flowable material useful for being molded into a slip about insert. The slip material flows into groovesand, or about the described first and second protrusions, during the molding process. Molding slip material about insertand into groovesandmay more reliably completely fill groovesandor about the described first and second protrusions with slip mold material than a similar process with similar slip mold material would fill insert base hole cavities that extend completely through the insert base as shown inor other cavities that extend completely through the insert base. In another embodiment, the insert has at least a first protrusion on an axial side of the insert base which first protrusion is at least 0.002 inches high and extends at least 40% of the axial length of the base; and a second similar protrusion on the other axial side of the insert base; the slip body is molded about the insert; and the insert is at least partially held within the slip body by slip body material molded about the first protrusion and second protrusion. In an embodiment, the molding process uses a three-piece mold, a first mold on top of the insert, a second mold beneath the insert on the smaller base end, and a third mold on the wide end of the base. This arrangement permits the first mold to be removed, and the third mold removed, which then allows the molded insert to be removed from the second mold. Thereafter, the slip or slip pads may be over molded upon the insert. An insert with radial grooves, such as shown in, may be similarly molded, using a bottom mold and a top mold, and then similarly over molded.