U.S. patent application number 11/494045 was filed with the patent office on 2007-02-22 for method and apparatus for coupling expandable tubular members.
This patent application is currently assigned to Enventure Global Technology, LLC. Invention is credited to Scott Costa.
Application Number | 20070039742 11/494045 |
Document ID | / |
Family ID | 37684000 |
Filed Date | 2007-02-22 |
United States Patent
Application |
20070039742 |
Kind Code |
A1 |
Costa; Scott |
February 22, 2007 |
Method and apparatus for coupling expandable tubular members
Abstract
An expandable tubular coupling apparatus includes a first
expandable tubular member, a second expandable tubular member, and
means for coupling the first expandable tubular member to the
second expandable tubular member.
Inventors: |
Costa; Scott; (Katy,
TX) |
Correspondence
Address: |
HAYNES AND BOONE, LLP
901 MAIN STREET, SUITE 3100
DALLAS
TX
75202
US
|
Assignee: |
Enventure Global Technology,
LLC
Houston
TX
|
Family ID: |
37684000 |
Appl. No.: |
11/494045 |
Filed: |
July 27, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10546084 |
Aug 17, 2005 |
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11494045 |
Jul 27, 2006 |
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PCT/US04/04740 |
Feb 17, 2004 |
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10546084 |
Aug 17, 2005 |
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60702935 |
Jul 27, 2005 |
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Current U.S.
Class: |
166/380 ;
166/207 |
Current CPC
Class: |
E21B 43/106 20130101;
E21B 43/103 20130101 |
Class at
Publication: |
166/380 ;
166/207 |
International
Class: |
E21B 43/10 20060101
E21B043/10; E21B 23/02 20060101 E21B023/02 |
Claims
1. An expandable tubular member, comprising: a first tubular member
comprising a first tubular member diameter which decreases from a
first outside diameter along the length of the first tubular member
to a second outside diameter adjacent a first tubular member
connection end on the first tubular member; a second tubular member
comprising a second tubular member diameter which decreases from a
third outside diameter along the length of the second tubular
member to a fourth outside diameter adjacent a second tubular
member connection end on the second tubular member, whereby the
second tubular member connection end is positioned adjacent the
first tubular member connection end; and a connection member
coupled to the second outside diameter and the fourth outside
diameter, whereby the connection member comprises a connection
member diameter which is not substantially greater than the first
outside diameter and the third outside diameter.
2. An expandable tubular member, comprising: a first tubular member
comprising an inner surface and an outer surface; a thread member
extending from the inner surface; an expansion channel defined by
the first tubular member and located on the outer surface and
adjacent the thread member; a tubular connection sleeve positioned
on the first tubular member; an expansion slot defined by the
tubular connection sleeve in a substantially axial orientation with
respect to the tubular connection sleeve and located adjacent the
expansion channel; and a second tubular member coupled the first
tubular member and engaging the thread member, whereby upon radial
expansion and plastic deformation of the first tubular member and
the second tubular member, the first tubular member and the second
tubular member can withstand a pressure of up to approximately 4000
pounds per square inch.
3. An expandable tubular member, comprising: a first tubular member
comprising a flange member extending from a surface on the first
tubular member, the flange member comprising a resilient beam
extending from a distal end of the flange member for forming a seal
between the first tubular member and a second tubular member.
4. An expandable tubular member, comprising: a first tubular member
defining a flange channel on a surface of the first tubular member;
a second tubular member comprising a flange member extending from a
surface on the second tubular member, the second tubular member
coupled to the first tubular member with the flange member
positioned in the flange channel, whereby a sealing passageway is
defined between the flange member and the flange channel; and a
resilient element for forming a seal between the first tubular
member and the second tubular member positioned in the sealing
passageway.
5. An expandable tubular member, comprising: a first tubular member
comprising a first connection end; a second tubular member
comprising a second connection end; and a connection member
coupling together the first tubular member and the second tubular
member, the connection member comprising: a tubular connection
member comprising an inner surface and an outer surface, the inner
surface engaging the first tubular member and the second tubular
member; a primary sealing member having a substantially diamond
shaped cross section, extending from a substantially central
location on the inner surface, and positioned between the first
connection end and the second connection end; a reinforced section
located on the outer surface and adjacent the primary sealing
member; and a plurality of secondary sealing surfaces located on
opposite distal ends of the tubular connection member and on
opposite sides of the primary sealing member, the secondary sealing
surfaces coupled to the first connection end and the second
connection end.
6. An expandable tubular member, comprising: a first tubular member
comprising a first connection end; a second tubular member
comprising a second connection end; a connection member coupled to
the first connection end and the second connection end; and means
for providing a primary and secondary metal to metal seal between
the connection member and the first tubular member and the second
tubular member.
7. An expandable tubular member, comprising: a first tubular
member; a second tubular member coupled to the first tubular
member; and means for effecting a gas and fluid tight seal between
the first tubular member and the second tubular member before,
during, and after radial expansion and plastic deformation of the
first tubular member and the second tubular member, the means
providing a seal which can withstand a pressure of up to 4000
pounds per square inch.
8. An expandable tubular member, comprising: a first tubular member
comprising a first tubular member diameter which decreases from a
first outside diameter along the length of the first tubular member
to a second outside diameter adjacent a first tubular member
connection end on the first tubular member; a second tubular member
comprising a second tubular member diameter which decreases from
first outside diameter along the length of the second tubular
member to the second outside diameter adjacent a second tubular
member connection end on the second tubular member, whereby the
second tubular member connection end is coupled to the first
tubular member connection end; and a connection member coupled to
the second outside diameter, whereby the connection member
comprises a connection member diameter which is less than or equal
to the first outside diameter.
9. An expandable tubular member, comprising: a first tubular member
comprising a first connection end; a second tubular member
comprising a second connection end; and a connection member
coupling together the first tubular member and the second tubular
member, the connection member comprising: a tubular connection
member comprising an inner surface and an outer surface, the inner
surface engaging the first tubular member and the second tubular
member; a primary sealing member having a substantially diamond
shaped cross section, extending from a substantially central
location on the inner surface, positioned between the first
connection end and the second connection end, and deformable to
provide a metal to metal seal between the connection member and the
first tubular member and the second tubular member; a reinforced
section located on the outer surface and adjacent the primary
sealing member; and a plurality of secondary sealing surfaces
located on opposite distal ends of the tubular connection member
and on opposite sides of the primary sealing member, the secondary
sealing surfaces coupled to the first connection end and the second
connection end and deformable to provide a metal to metal seal
between the connection member and the first tubular member and the
second tubular member.
10. A connection member for coupling expandable tubular members,
comprising: a tubular connection member comprising an inner surface
and an outer surface; a primary sealing member having a
substantially diamond shaped cross section and extending from a
substantially central location on the inner surface; a reinforced
section located on the outer surface and adjacent the primary
sealing member; and a plurality of secondary sealing surfaces
located on opposite distal ends of the tubular connection member
and on opposite sides of the primary sealing member.
11. A connection member for coupling expandable tubular members,
comprising: a tubular connection member comprising an inner surface
and an outer surface; a primary sealing member having a
substantially diamond shaped cross section, extending from a
substantially central location on the inner surface, and deformable
to provide a metal to metal seal between the tubular connection
member and an expandable tubular member; a reinforced section
located on the outer surface and adjacent the primary sealing
member; and a plurality of secondary sealing surfaces located on
opposite distal ends of the tubular connection member on opposite
sides of the primary sealing member, and deformable to provide a
metal to metal seal between the tubular connection member and an
expandable tubular member.
12. A method for coupling expandable tubular members, comprising:
providing a first tubular member comprising a maximum first tubular
member diameter; providing a second tubular comprising a maximum
second tubular member diameter; and coupling the first tubular
member to the second tubular member with a connection member
comprising a maximum connection member diameter which is not
substantially greater than the maximum first tubular member
diameter and the maximum second tubular member diameter.
13. A method for coupling expandable tubular members, comprising:
providing a first tubular member comprising a flange member
extending from an inner surface; providing a second tubular member
defining a flange channel on an outer surface; positioning a
resilient member in the flange channel; and coupling the first
tubular member to the second tubular member by positioning the
flange member in the flange channel and adjacent the resilient
member.
14. A method for coupling expandable tubular members, comprising:
providing a first tubular member comprising a first connection end;
providing a second tubular member comprising a second connection
end; positioning a connection member adjacent the first connection
end and the second connection end such that a primary sealing
member on the connection member is positioned between the first
connection end and the second connection end, and a plurality of
secondary sealing surfaces are positioned adjacent the first
tubular member and the second tubular member; and coupling the
first tubular member to the second tubular member using the
connection member.
15. A method for coupling expandable tubular members, comprising:
providing a first tubular member comprising a maximum first tubular
member diameter; providing a second tubular comprising a maximum
second tubular member diameter; coupling the first tubular member
to the second tubular member with a connection member comprising a
maximum connection member diameter which is not substantially
greater than the maximum first tubular member diameter and the
maximum second tubular member diameter; positioning the first
tubular member, the second tubular member, and the connection
member in a wellbore; and radially expanding and plastically
deforming the first tubular member and the second tubular member,
wherein the radially expanding and plastically deforming comprises
one of either radially expanding and plastically deforming a first
reduced diameter section on the first tubular member to
substantially the maximum first tubular member diameter and
radially expanding and plastically deforming a second reduced
diameter section on the second tubular member to substantially the
maximum second tubular member diameter or radially expanding and
plastically deforming the first tubular member and the second
tubular member into engagement with the wellbore.
16. A method for coupling expandable tubular members, comprising:
providing a first tubular member comprising a flange member
extending from an inner surface; providing a second tubular member
defining a flange channel on an outer surface; positioning a
resilient member in the flange channel; coupling the first tubular
member to the second tubular member by positioning the flange
member in the flange channel and adjacent the resilient member;
positioning the first tubular member and the second tubular member
in a wellbore; and radially expanding and plastically deforming the
first tubular member and the second tubular member, whereby the
radially expanding and plastically deforming compresses the
resilient member and provides a seal between the flange member and
the flange channel; whereby the radially expanding and plastically
deforming provides a metal to metal seal between the flange member
and the flange channel.
17. A method for coupling expandable tubular members, comprising:
providing a first tubular member comprising a first connection end;
providing a second tubular member comprising a second connection
end; positioning a connection member adjacent the first connection
end and the second connection end such that a primary sealing
member on the connection member is positioned between the first
connection end and the second connection end, and a plurality of
secondary sealing surfaces are positioned adjacent the first
tubular member and the second tubular member; coupling the first
tubular member to the second tubular member using the connection
member, whereby the coupling includes providing a metal sealing
member between the first tubular member, the second tubular member,
and the secondary sealing surfaces; positioning the first tubular
member, the second tubular member, and the connection member in a
wellbore; and radially expanding and plastically deforming the
first tubular member and the second tubular member, whereby the
radially expanding and plastically deforming provides a primary
seal between the primary sealing member and the first tubular
member and the second tubular member, and the radially expanding
and plastically deforming provides a secondary seal between the
secondary sealing surfaces and the first tubular member and the
second tubular member.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of
U.S. provisional patent application Ser. No. 60/702,935, attorney
docket number 25791.133, filed on Jul. 27, 2005, the disclosure of
which is incorporated herein by reference.
[0002] The present application is a continuation in part of U.S.
utility patent application Ser. No. 10/546,084, attorney docket no.
25791.185.05, filed on Aug. 17, 2005, which was the National Stage
patent application for PCT patent application serial no.
PCT/US04/04740, filed on Feb. 17, 2004, attorney docket no.
25791.185.02, which was a continuation in part of U.S. utility
patent application Ser. No. 10/528,222, attorney docket no.
25791.129.03, filed on Mar. 20, 2005, which was the National Stage
patent application for PCT patent application serial no.
PCT/US03/25716, filed on Aug. 18, 2003, attorney docket no.
25791.129.02, which was a continuation in part of U.S. utility
patent application Ser. No. 10/528,223, attorney docket no.
25791.127.03, filed on Mar. 18, 2005, which was the National Stage
patent application for PCT patent application serial no.
PCT/US03/25707, filed on Aug. 18, 2003, attorney docket number
25791.127.02, which was a continuation in part of U.S. utility
patent application Ser. No. 10/525,402, attorney docket no.
25791.120.05, filed on Feb. 23, 2005, which was the National Stage
patent application for PCT patent application serial no.
PCT/US03/25676, filed on Aug. 18, 2003, attorney docket number
25791.120.02, which was a continuation in part of U.S. utility
patent application Ser. No. 10/525,332, attorney docket no.
25791.119.03, filed on Feb. 23, 2005, which was the National Stage
patent application for PCT patent application serial no.
PCT/US03/25677, filed on Aug. 18, 2003, attorney docket number
25791.119.02, which was a continuation in part of U.S. utility
patent application Ser. No. 10/522,039, attorney docket no.
25791.106.05, filed on Jan. 19, 2005, which was the National Stage
patent application for PCT patent application serial no.
PCT/US03/19993, filed on Jun. 24, 2003, attorney docket number
25791.106.02, which was a continuation in part of U.S. utility
patent application Ser. No. 10/511,410, attorney docket no.
25791.101.05, filed on Oct. 14, 2004, which was the National Stage
patent application for PCT patent application serial no.
PCT/US03/10144, filed on Mar. 31, 2003, attorney docket number
25791.101.02, which was a continuation in part of U.S. utility
patent application Ser. No. 10/510,966, attorney docket no.
25791.93.05, filed on Oct. 12, 2004, which was the National Stage
patent application for PCT patent application serial no.
PCT/US03/06544, filed on Mar. 4, 2003, attorney docket number
25791.93.02, which was a continuation in part of U.S. utility
patent application Ser. No. 10/500,745, attorney docket no.
25791.92.05, filed on Jul. 6, 2004, which was the National Stage
patent application for PCT patent application PCT/US02/39418, filed
on Dec. 10, 2002, attorney docket number 25791.92.02, the
disclosures of which are incorporated herein by reference.
This application is related to the following co-pending
applications: (1) U.S. Pat. No. 6,497,289, which was filed as U.S.
patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, which claims priority from
provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S.
patent application Ser. No. 09/510,913, attorney docket no.
25791.7.02, filed on Feb. 23, 2000, which claims priority from
provisional application 60/121,702, filed on Feb. 25, 1999, (3)
U.S. patent application Ser. No. 09/502,350, attorney docket no.
25791.8.02, filed on Feb. 10, 2000, which claims priority from
provisional application 60/119,611, filed on Feb. 11, 1999, (4)
U.S. Pat. No. 6,328,113, which was filed as U.S. patent application
Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on
Nov. 15, 1999, which claims priority from provisional application
60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application
Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul.
1, 2002, which claims priority from provisional application
60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application
Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar.
10, 2000, which claims priority from provisional application
60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471,
which was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent
application Ser. No. 09/511,941, attorney docket no. 25791.16.02,
filed on Feb. 24, 2000, which claims priority from provisional
application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No.
6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (10) U.S. patent application Ser. No.
09/981,916, attorney docket no. 25791.18, filed on Oct. 18, 2001 as
a continuation-in-part application of U.S. Pat. No. 6,328,113,
which was filed as U.S. patent application Ser. No. 09/440,338,
attorney docket number 25791.9.02, filed on Nov. 15, 1999, which
claims priority from provisional application 60/108,558, filed on
Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as
application Ser. No. 09/559,122, attorney docket no. 25791.23.02,
filed on Apr. 26, 2000, which claims priority from provisional
application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent
application Ser. No. 10/030,593, attorney docket no. 25791.25.08,
filed on Jan. 8, 2002, which claims priority from provisional
application 60/146,203, filed on Jul. 29, 1999, (13) U.S.
provisional patent application Ser. No. 60/143,039, attorney docket
no. 25791.26, filed on Jul. 9, 1999, (14) U.S. patent application
Ser. No. 10/111,982, attorney docket no. 25791.27.08, filed on Apr.
30, 2002, which claims priority from provisional patent application
Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1,
1999, (15) U.S. provisional patent application Ser. No. 60/154,047,
attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S.
provisional patent application Ser. No. 60/438,828, attorney docket
no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875,
which was filed as application Ser. No. 09/679,907, attorney docket
no. 25791.34.02, on Oct. 5, 2000, which claims priority from
provisional patent application Ser. No. 60/159,082, attorney docket
no. 25791.34, filed on Oct. 12, 1999, (18) U.S. patent application
Ser. No. 10/089,419, filed on Mar. 27, 2002, attorney docket no.
25791.36.03, which claims priority from provisional patent
application Ser. No. 60/159,039, attorney docket no. 25791.36,
filed on Oct. 12, 1999, (19) U.S. patent application Ser. No.
09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02,
which claims priority from provisional patent application Ser. No.
60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999,
(20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22,
2002, attorney docket no. 25791.38.07, which claims priority from
provisional patent application Ser. No. 60/212,359, attorney docket
no. 25791.38, filed on Jun. 19, 2000, (21) U.S. provisional patent
application Ser. No. 60/165,228, attorney docket no. 25791.39,
filed on Nov. 12, 1999, (22) U.S. provisional patent application
Ser. No. 60/455,051, attorney docket no. 25791.40, filed on Mar.
14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002,
attorney docket no. 25791.44.02, which claims priority from U.S.
provisional patent application Ser. No. 60/303,711, attorney docket
no. 25791.44, filed on Jul. 6, 2001, (24) U.S. patent application
Ser. No. 10/311,412, filed on Dec. 12, 2002, attorney docket no.
25791.45.07, which claims priority from provisional patent
application Ser. No. 60/221,443, attorney docket no. 25791.45,
filed on Jul. 28, 2000, (25) U.S. patent application serial no.
10/______, filed on Dec. 18, 2002, attorney docket no. 25791.46.07,
which claims priority from provisional patent application Ser. No.
60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000,
(26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22,
2003, attorney docket no. 25791.47.03, which claims priority from
provisional patent application Ser. No. 60/233,638, attorney docket
no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patent application
Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docket no.
25791.48.06, which claims priority from provisional patent
application Ser. No. 60/237,334, attorney docket no. 25791.48,
filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on
Feb. 14, 2002, attorney docket no. 25791.50.02, which claims
priority from U.S. provisional patent application Ser. No.
60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001,
(29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13,
2003, attorney docket no. 25791.51.06, which claims priority from
provisional patent application Ser. No. 60/262,434, attorney docket
no. 25791.51, filed on Jan. 17, 2001, (30) U.S. patent application
Ser. No. 10/465,831, filed on Jun. 13, 2003, attorney docket no.
25791.52.06, which claims priority from U.S. provisional patent
application Ser. No. 60/259,486, attorney docket no. 25791.52,
filed on Jan. 3, 2001, (31) U.S. provisional patent application
Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docket no.
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application Ser. No. 09/850,093, filed on May 7, 2001, attorney
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6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (33) U.S. Pat. No. 6,561,227, which was
filed as patent application Ser. No. 09/852,026, filed on May 9,
2001, attorney docket no. 25791.56, as a divisional application of
U.S. Pat. No. 6,497,289, which was filed as U.S. patent application
Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec.
3, 1999, which claims priority from provisional application
60/111,293, filed on Dec. 7, 1998, (34) U.S. patent application
Ser. No. 09/852,027, filed on May 9, 2001, attorney docket no.
25791.57, as a divisional application of U.S. Pat. No. 6,497,289,
which was filed as U.S. patent application Ser. No. 09/454,139,
attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which
claims priority from provisional application 60/111,293, filed on
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provisional application 60/318,021, filed on Sep. 7, 2001, attorney
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priority from U.S. provisional patent application Ser. No.
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(37) PCT Application US02/29856, attorney docket no. 25791.60.02,
filed on Sep. 19, 2002, which claims priority from U.S. provisional
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attorney docket no. 25791.61.02, filed on Jun. 26, 2002, which
claims priority from U.S. provisional patent application Ser. No.
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(39) U.S. patent application Ser. No. 09/962,469, filed on Sep. 25,
2001, attorney docket no. 25791.62, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (40)
U.S. patent application Ser. No. 09/962,470, filed on Sep. 25,
2001, attorney docket no. 25791.63, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (41)
U.S. patent application Ser. No. 09/962,471, filed on Sep. 25,
2001, attorney docket no. 25791.64, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (42)
U.S. patent application Ser. No. 09/962,467, filed on Sep. 25,
2001, attorney docket no. 25791.65, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (43)
U.S. patent application Ser. No. 09/962,468, filed on Sep. 25,
2001, attorney docket no. 25791.66, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (44)
PCT application US 02/25727, filed on Aug. 14, 2002, attorney
docket no. 25791.67.03, which claims priority from U.S. provisional
patent application Ser. No. 60/317,985, attorney docket no.
25791.67, filed on Sep. 6, 2001, and U.S. provisional patent
application Ser. No. 60/318,386, attorney docket no. 25791.67.02,
filed on Sep. 10, 2001, (45) PCT application US 02/39425, filed on
Dec. 10, 2002, attorney docket no. 25791.68.02, which claims
priority from U.S. provisional patent application Ser. No.
60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001,
(46) U.S. utility patent application Ser. No. 09/969,922, attorney
docket no. 25791.69, filed on Oct. 3, 2001, which is a
continuation-in-part application of U.S. Pat. No. 6,328,113, which
was filed as U.S. patent application Ser. No. 09/440,338, attorney
docket number 25791.9.02, filed on Nov. 15, 1999, which claims
priority from provisional application 60/108,558, filed on Nov. 16,
1998, (47) U.S. utility patent application Ser. No. 10/516,467,
attorney docket no. 25791.70, filed on Dec. 10, 2001, which is a
continuation application of U.S. utility patent application Ser.
No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3,
2001, which is a continuation-in-part application of U.S. Pat. No.
6,328,113, which was filed as U.S. patent application Ser. No.
09/440,338, attorney docket number 25791.9.02, filed on Nov. 15,
1999, which claims priority from provisional application
60/108,558, filed on Nov. 16, 1998, (48) PCT application US
03/00609, filed on Jan. 9, 2003, attorney docket no. 25791.71.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/357,372, attorney docket no. 25791.71, filed on Feb. 15,
2002, (49) U.S. patent application Ser. No. 10/074,703, attorney
docket no. 25791.74, filed on Feb. 12, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (50) U.S. patent application
Ser. No. 10/074,244, attorney docket no. 25791.75, filed on Feb.
12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (51) U.S. patent application Ser. No. 10/076,660, attorney
docket no. 25791.76, filed on Feb. 15, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (52) U.S. patent application
Ser. No. 10/076,661, attorney docket no. 25791.77, filed on Feb.
15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (53) U.S. patent application Ser. No. 10/076,659, attorney
docket no. 25791.78, filed on Feb. 15, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (54) U.S. patent application
Ser. No. 10/078,928, attorney docket no. 25791.79, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (55) U.S. patent application Ser. No. 10/078,922, attorney
docket no. 25791.80, filed on Feb. 20, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (56) U.S. patent application
Ser. No. 10/078,921, attorney docket no. 25791.81, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (57) U.S. patent application Ser. No. 10/261,928, attorney
docket no. 25791.82, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999, (58) U.S. patent application
Ser. No. 10/079,276, attorney docket no. 25791.83, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (59) U.S. patent application Ser. No. 10/262,009, attorney
docket no. 25791.84, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999, (60) U.S. patent application
Ser. No. 10/092,481, attorney docket no. 25791.85, filed on Mar. 7,
2002, which is a divisional of U.S. Pat. No. 6,568,471, which was
filed as patent application Ser. No. 09/512,895, attorney docket
no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from
provisional application 60/121,841, filed on Feb. 26, 1999, (61)
U.S. patent application Ser. No. 10/261,926, attorney docket no.
25791.86, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.
No. 6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (62) PCT application US 02/36157, filed on
Nov. 12, 2002, attorney docket no. 25791.87.02, which claims
priority from U.S. provisional patent application Ser. No.
60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001,
(63) PCT application US 02/36267, filed on Nov. 12, 2002, attorney
docket no. 25791.88.02, which claims priority from U.S. provisional
patent application Ser. No. 60/339,013, attorney docket no.
25791.88, filed on Nov. 12, 2001, (64) PCT application US 03/11765,
filed on Apr. 16, 2003, attorney docket no. 25791.89.02, which
claims priority from U.S. provisional patent application Ser. No.
60/383,917, attorney docket no. 25791.89, filed on May 29, 2002,
(65) PCT application US 03/15020, filed on May 12, 2003, attorney
docket no. 25791.90.02, which claims priority from U.S. provisional
patent application Ser. No. 60/391,703, attorney docket no.
25791.90, filed on Jun. 26, 2002, (66) PCT application US 02/39418,
filed on Dec. 10, 2002, attorney docket no. 25791.92.02, which
claims priority from U.S. provisional patent
application Ser. No. 60/346,309, attorney docket no. 25791.92,
filed on Jan. 7, 2002, (67) PCT application US 03/06544, filed on
Mar. 4, 2003, attorney docket no. 25791.93.02, which claims
priority from U.S. provisional patent application Ser. No.
60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002,
(68) U.S. patent application Ser. No. 10/331,718, attorney docket
no. 25791.94, filed on Dec. 30, 2002, which is a divisional U.S.
patent application Ser. No. 09/679,906, filed on Oct. 5, 2000,
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provisional patent application Ser. No. 60/159,033, attorney docket
no. 25791.37, filed on Oct. 12, 1999, (69) PCT application US
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which claims priority from U.S. provisional patent application Ser.
No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13,
2002, (70) U.S. patent application Ser. No. 10/261,927, attorney
docket no. 25791.97, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999, (71) U.S. patent application
Ser. No. 10/262,008, attorney docket no. 25791.98, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (72)
U.S. patent application Ser. No. 10/261,925, attorney docket no.
25791.99, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.
No. 6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (73) U.S. patent application Ser. No.
10/199,524, attorney docket no. 25791.100, filed on Jul. 19, 2002,
which is a continuation of U.S. Pat. No. 6,497,289, which was filed
as U.S. Patent Application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, which claims priority from
provisional application 60/111,293, filed on Dec. 7, 1998, (74) PCT
application US 03/10144, filed on Mar. 28, 2003, attorney docket
no. 25791.101.02, which claims priority from U.S. provisional
patent application Ser. No. 60/372,632, attorney docket no.
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application Ser. No. 60/412,542, attorney docket no. 25791.102,
filed on Sep. 20, 2002, (76) PCT application US 03/14153, filed on
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priority from U.S. provisional patent application Ser. No.
60/380,147, attorney docket no. 25791.104, filed on May 6, 2002,
(77) PCT application US 03/19993, filed on Jun. 24, 2003, attorney
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provisional patent application Ser. No. 60/397,284, attorney docket
no. 25791.106, filed on Jul. 19, 2002, (78) PCT application US
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which claims priority from U.S. provisional patent application Ser.
No. 60/387,486, attorney docket no. 25791.107, filed on Jun. 10,
2002, (79) PCT application US 03/18530, filed on Jun. 11, 2003,
attorney docket no. 25791.108.02, which claims priority from U.S.
provisional patent application Ser. No. 60/387,961, attorney docket
no. 25791.108, filed on Jun. 12, 2002, (80) PCT application US
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which claims priority from U.S. provisional patent application Ser.
No. 60/398,061, attorney docket no. 25791.110, filed on Jul. 24,
2002, (81) PCT application US 03/20870, filed on Jul. 2, 2003,
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provisional patent application Ser. No. 60/399,240, attorney docket
no. 25791.111, filed on Jul. 29, 2002, (82) U.S. provisional patent
application Ser. No. 60/412,487, attorney docket no. 25791.112,
filed on Sep. 20, 2002, (83) U.S. provisional patent application
Ser. No. 60/412,488, attorney docket no. 25791.114, filed on Sep.
20, 2002, (84) U.S. patent application Ser. No. 10/280,356,
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continuation of U.S. Pat. No. 6,470,966, which was filed as patent
application Ser. No. 09/850,093, filed on May 7, 2001, attorney
docket no. 25791.55, as a divisional application of U.S. Pat. No.
6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (85) U.S. provisional patent application
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20, 2002, (86) U.S. provisional patent application Ser. No.
60/412,653, attorney docket no. 25791.118, filed on Sep. 20, 2002,
(87) U.S. provisional patent application Ser. No. 60/405,610,
attorney docket no. 25791.119, filed on Aug. 23, 2002, (88) U.S.
provisional patent application Ser. No. 60/405,394, attorney docket
no. 25791.120, filed on Aug. 23, 2002, (89) U.S. provisional patent
application Ser. No. 60/412,544, attorney docket no. 25791.121,
filed on Sep. 20, 2002, (90) PCT application US 03/24779, filed on
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priority from U.S. provisional patent application Ser. No.
60/407,442, attorney docket no. 25791.125, filed on Aug. 30, 2002,
(91) U.S. provisional patent application Ser. No. 60/423,363,
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provisional patent application Ser. No. 60/412,196, attorney docket
no. 25791.127, filed on Sep. 20, 2002, (93) U.S. provisional patent
application Ser. No. 60/412,187, attorney docket no. 25791.128,
filed on Sep. 20, 2002, (94) U.S. provisional patent application
Ser. No. 60/412,371, attorney docket no. 25791.129, filed on Sep.
20, 2002, (95) U.S. patent application Ser. No. 10/382,325,
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continuation of U.S. Pat. No. 6,557,640, which was filed as patent
application Ser. No. 09/588,946, attorney docket no. 25791.17.02,
filed on Jun. 7, 2000, which claims priority from provisional
application 60/137,998, filed on Jun. 7, 1999, (96) U.S. patent
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filed on Jul. 22, 2003, which is a divisional of U.S. patent
application Ser. No. 09/502,350, attorney docket no. 25791.8.02,
filed on Feb. 10, 2000, which claims priority from provisional
application 60/119,611, filed on Feb. 11, 1999, (97) U.S.
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filed on Feb. 18, 2003, (99) U.S. provisional patent application
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60/462,750, attorney docket no. 25791.193, filed on Apr. 14, 2003,
(101) U.S. provisional patent application Ser. No. 60/436,106,
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provisional patent application Ser. No. 60/442,942, attorney docket
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patent application Ser. No. 60/442,938, attorney docket no.
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application Ser. No. 60/418,687, attorney docket no. 25791.228,
filed on Apr. 18, 2003, (105) U.S. provisional patent application
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60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003,
(107) U.S. provisional patent application Ser. No. 60/451,152,
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patent application Ser. No. 60/453,678, attorney docket no.
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60/124,042, filed on Mar. 11, 1999, (111) U.S. provisional patent
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filed on Mar. 27, 2003, (112) U.S. provisional patent application
Ser. No. 60/455,718, attorney docket no. 25791.262, filed on Mar.
18, 2003, (113) U.S. Pat. No. 6,550,821, which was filed as patent
application Ser. No. 09/811,734, filed on Mar. 19, 2001, (114) U.S.
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09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26,
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60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patent
application Ser. No. 60/459,776, attorney docket no. 25791.270,
filed on Apr. 2, 2003, (116) U.S. provisional patent application
Ser. No. 60/461,094, attorney docket no. 25791.272, filed on Apr.
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60/461,038, attorney docket no. 25791.273, filed on Apr. 7, 2003,
(118) U.S. provisional patent application Ser. No. 60/463,586,
attorney docket no. 25791.277, filed on Apr. 17, 2003, (119) U.S.
provisional patent application Ser. No. 60/472,240, attorney docket
no. 25791.286, filed on May 20, 2003, (120) U.S. patent application
Ser. No. 10/619,285, attorney docket no. 25791.292, filed on Jul.
14, 2003, which is a continuation-in-part of U.S. utility patent
application Ser. No. 09/969,922, attorney docket no. 25791.69,
filed on Oct. 3, 2001, which is a continuation-in-part application
of U.S. Pat. No. 6,328,113, which was filed as U.S. patent
application Ser. No. 09/440,338, attorney docket number 25791.9.02,
filed on Nov. 15, 1999, which claims priority from provisional
application 60/108,558, filed on Nov. 16, 1998, (121) U.S. utility
patent application Ser. No. 10/418,688, attorney docket no.
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utility patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (122)
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no. 25791.238.02, filed on Feb. 26, 2004, (123) PCT patent
application serial number PCT/US04/08170, attorney docket number
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serial number PCT/US04/08171, attorney docket number 25791.236.02,
filed on Mar. 15, 2004, (125) PCT patent application serial number
PCT/US04/08073, attorney docket number 25791.262.02, filed on Mar.
18, 2004, (126) PCT patent application serial number
PCT/US04/07711, attorney docket number 25791.253.02, filed on Mar.
11, 2004, (127) PCT patent application serial number
PCT/US2004/009434, attorney docket number 25791.260.02, filed on
Mar. 26, 2004, (128) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on
Apr. 2, 2004, (129) PCT patent application serial number
PCT/US2004/010712, attorney docket number 25791.272.02, filed on
Apr. 6, 2004, (130) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on
Apr. 6, 2004, (131) PCT patent application serial number
PCT/2004/011973, attorney docket number 25791.277.02, filed on Apr.
15, 2004, (132) U.S. provisional patent application Ser. No.
60/495,056, attorney docket number 25791.301, filed on Aug. 14,
2003, (133) U.S. provisional patent application Ser. No.
60/600,679, attorney docket number 25791.194, filed on Aug. 11,
2004; (134) PCT patent application serial number PCT/US2005/027318,
attorney docket number 25791.329.02, filed on Jul. 29, 2005; (135)
PCT patent application serial number PCT/US2005/028936, attorney
docket number 25791.338.02, filed on Aug. 12, 2005; (136) PCT
patent application serial number PCT/US2005/028669, attorney docket
number 25791.194.02, filed on Aug. 11, 2005; (137) PCT patent
application serial number PCT/US2005/028453, attorney docket number
25791.371, filed on Aug. 11, 2005; (138) PCT patent application
serial number PCT/US2005/028641, attorney docket number 25791.372,
filed on Aug. 11, 2005; (139) PCT patent application serial number
PCT/US2005/028819, attorney docket number 25791.373, filed on Aug.
11, 2005; (140) PCT patent application serial number
PCT/US2005/028446, attorney docket number 25791.374, filed on Aug.
11, 2005; (141) PCT patent application serial number
PCT/US2005/028642, attorney docket number 25791.375, filed on Aug.
11, 2005; (142) PCT patent application serial number
PCT/US2005/028451, attorney docket number 25791.376, filed on Aug.
11, 2005, and (143). PCT patent application serial number
PCT/US2005/028473, attorney docket number 25791.377, filed on Aug.
11, 2005, (144) U.S. utility patent application Ser. No.
10/546,082, attorney docket number 25791.378, filed on Aug. 16,
2005, (145) U.S. utility patent application Ser. No. 10/546,076,
attorney docket number 25791.379, filed on Aug. 16, 2005, (146)
U.S. utility patent application Ser. No. 10/545,936, attorney
docket number 25791.380, filed on Aug. 16, 2005, (147) U.S. utility
patent application Ser. No. 10/546,079, attorney docket number
25791.381, filed on Aug. 16, 2005 (148) U.S. utility patent
application Ser. No. 10/545,941, attorney docket number 25791.382,
filed on Aug. 16, 2005, (149) U.S. utility patent application
serial number 546078, attorney docket number 25791.383, filed on
Aug. 16, 2005, filed on Aug. 11, 2005., (150) U.S. utility patent
application Ser. No. 10/545,941, attorney docket number
25791.185.05, filed on Aug. 16, 2005, (151) U.S. utility patent
application Ser. No. 11/249,967, attorney docket number 25791.384,
filed on Oct. 13, 2005, (152) U.S. provisional patent application
Ser. No. 60/734,302, attorney docket number 25791.24, filed on Nov.
7, 2005, (153) U.S. provisional patent application Ser. No.
60/725,181, attorney docket number 25791.184, filed on Oct. 11,
2005, (154) PCT patent application serial number PCT/US2005/023391,
attorney docket number 25791.299.02 filed Jun. 29, 2005 which
claims priority from U.S. provisional patent application Ser. No.
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2005, (156) U.S. provisional patent application Ser. No.
60/717,391, attorney docket number 25791.214, filed on Sep. 15,
2005, (157) U.S. provisional patent application Ser. No.
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60/663,913, attorney docket number 25791.32, filed on Mar. 21,
2005, (159) U.S. provisional patent application Ser. No.
60/652,564, attorney docket number 25791.348, filed on Feb. 14,
2005, (160) U.S. provisional patent application Ser. No.
60/645,840, attorney docket number 25791.324, filed on Jan. 21,
2005, (161) PCT patent application serial number PCT/US2005/043122,
attorney docket number 25791.326.02, filed on Nov. 29, 2005 which
claims priority from U.S. provisional patent application Ser. No.
60/631,703, attorney docket number 25791.326, filed on Nov. 30,
2004, (162) U.S. provisional patent application Ser. No.
60/752,787, attorney docket number 25791.339, filed on Dec. 22,
2005, (163) U.S. National Stage application Ser. No. 10/548,934,
attorney docket no. 25791.253.05, filed on Sep. 12, 2005; (164)
U.S. National Stage application Ser. No. 10/549,410, attorney
docket no. 25791.262.05, filed on Sep. 13, 2005; (165) U.S.
Provisional Patent Application No. 60/717,391, attorney docket no.
25791.214 filed on Sep. 15, 2005; (166) U.S. National Stage
application Ser. No. 10/550,906, attorney docket no. 25791.260.06,
filed on Sep. 27, 2005; (167) U.S. National Stage application Ser.
No. 10/551,880, attorney docket no. 25791.270.06, filed on Sep. 30,
2005; (168) U.S. National Stage application Ser. No. 10/552,253,
attorney docket no. 25791.273.06, filed on Oct. 4, 2005; (169) U.S.
National Stage application Ser. No. 10/552,790, attorney docket no.
25791.272.06, filed on Oct. 11, 2005; (170) U.S. Provisional Patent
Application No. 60/725,181, attorney docket no. 25791.184 filed on
Oct. 11, 2005; (171) U.S. National Stage application Ser. No.
10/553,094, attorney docket no. 25791.193.03, filed on Oct. 13,
2005; (172) U.S. National Stage application Ser. No. 10/553,566,
attorney docket no. 25791.277.06, filed on Oct. 17, 2005; (173) PCT
Patent Application No. PCT/US2006/002449, attorney docket no.
25791.324.02 filed on Jan. 20, 2006, and (174) PCT Patent
Application No. PCT/US2006/004809, attorney docket no. 25791.348.02
filed on Feb. 9, 2006; (175) U.S. Utility patent application Ser.
No. 11/356,899, attorney docket no. 25791.386, filed on Feb. 17,
2006, (176) U.S. National Stage application Ser. No. 10/568,200,
attorney docket no. 25791.301.06, filed on Feb. 13, 2006, (177)
U.S. National Stage application Ser. No.
10/568,719, attorney docket no. 25791.137.04, filed on Feb. 16,
2006, filed on Feb. 16, 2006, (178) U.S. National Stage application
Ser. No. 10/569,323, attorney docket no. 25791.215.06, filed on
Feb. 17, 2006, (179) U.S. National State patent application Ser.
No. 10/571,041, attorney docket no. 25791.305.05, filed on Mar. 3,
2006; (180) U.S. National State patent application Ser. No.
10/571,017, attorney docket no. 25791.306.04, filed on Mar. 3,
2006; (181) U.S. National State patent application Ser. No.
10/571,086, attorney docket no. 25791.307.04, filed on Mar. 6,
2006; and (182) U.S. National State patent application Ser. No.
10/571,085, attorney docket no. 25791.308.07, filed on Mar. 6,
2006, (183) U.S. utility patent application Ser. No. 10/938,788,
attorney docket number 25791.330, filed on Sep. 10, 2004, (184)
U.S. utility patent application Ser. No. 10/938,225, attorney
docket number 25791.331, filed on Sep. 10, 2004, (185) U.S. utility
patent application Ser. No. 10/952,288, attorney docket number
25791.332, filed on Sep. 28, 2004, (186) U.S. utility patent
application Ser. No. 10/952,416, attorney docket number 25791.333,
filed on Sep. 28, 2004, (187) U.S. utility patent application Ser.
No. 10/950,749, attorney docket number 25791.334, filed on Sep. 27,
2004, (188) U.S. utility patent application Ser. No. 10/950,869,
attorney docket number 25791.335, filed on Sep. 27, 2004; (189)
U.S. provisional patent application Ser. No. 60/761,324, attorney
docket number 25791.340, filed on Jan. 23, 2006, (190) U.S.
provisional patent application Ser. No. 60/754,556, attorney docket
number 25791.342, filed on Dec. 28, 2005, (191) U.S. utility patent
application Ser. No. 11/380,051, attorney docket number 25791.388,
filed on Apr. 25, 2006, and (192) U.S. utility patent application
Ser. No. 11/380,055, attorney docket number 25791.389 the
disclosures of which are incorporated herein by reference.
[0003] BACKGROUND
[0004] This invention relates generally to oil and gas exploration,
and in particular to the expandable tubular members used to
facilitate oil and gas exploration.
[0005] Conventionally, when a wellbore is created, a number of
expandable tubular members are installed in the borehole to prevent
collapse of the borehole wall and to prevent undesired outflow of
drilling fluid into the formation or inflow of fluid from the
formation into the borehole. Typically, the expandable tubular
members are coupled together and may be radially expanded and
plastically deformed against the borehole wall. The coupling
together of the expandable tubular members and the radially
expanding and plastically deforming of the coupled together
expandable tubular members can raise a number of issues relating to
the seal between adjacent tubular members needed to prevent
undesired outflow from or inflow to the wellbore.
[0006] The present disclosure is directed to overcoming one or more
of the limitations of the existing procedures for coupling
expandable tubular members together during oil and gas
exploration.
SUMMARY
[0007] According to one aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member comprising a first tubular member diameter which decreases
from a first outside diameter along the length of the first tubular
member to a second outside diameter adjacent a first tubular member
connection end on the first tubular member, a second tubular member
comprising a second tubular member diameter which decreases from a
third outside diameter along the length of the second tubular
member to a fourth outside diameter adjacent a second tubular
member connection end on the second tubular member, whereby the
second tubular member connection end is positioned adjacent the
first tubular member connection end, and a connection member
coupled to the second outside diameter and the fourth outside
diameter, whereby the connection member comprises a connection
member diameter which is not substantially greater than the first
outside diameter and the third outside diameter.
[0008] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member comprising a maximum first tubular member diameter, a second
tubular member comprising a maximum second tubular member diameter,
whereby the second tubular member is positioned adjacent the first
tubular member, and means for allowing a connection member to be
coupled to the first tubular member and the second tubular without
a maximum connection member diameter being substantially greater
than the maximum first tubular member diameter and the maximum
second tubular member diameter.
[0009] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a tubular
member comprising an inner surface and an outer surface, a thread
member extending from the inner surface, and an expansion channel
defined by the tubular member and located on the outer surface and
adjacent the thread member.
[0010] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a tubular
member comprising an inner surface and an outer surface, a thread
member extending from the inner surface, and means for providing a
stress concentration in the thread member during radial expansion
and plastic deformation of the tubular member.
[0011] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member comprising an inner surface and an outer surface, a thread
member extending from the inner surface, an expansion channel
defined by the first tubular member and located on the outer
surface and adjacent the thread member, and a second tubular member
coupled the first tubular member and engaging the thread
member.
[0012] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member comprising an inner surface and an outer surface, a thread
member extending from the inner surface, an expansion channel
defined by the first tubular member and located on the outer
surface and adjacent the thread member, a tubular connection sleeve
positioned on the first tubular member, an expansion slot defined
by the tubular connection sleeve in a substantially axial
orientation with respect to the tubular connection sleeve and
located adjacent the expansion channel, a second tubular member
coupled the first tubular member and engaging the thread member,
whereby upon radial expansion and plastic deformation of the first
tubular member and the second tubular member, the first tubular
member and the second tubular member can withstand a pressure of up
to approximately 4000 pounds per square inch.
[0013] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member defining a flange channel on a first surface of the first
tubular member, and resilient means positioned in the flange
channel for forming a seal between the first tubular member and a
second tubular member.
[0014] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member comprising a flange member extending from a surface on the
first tubular member, the flange member comprising a resilient beam
extending from a distal end of the flange member for forming a seal
between the first tubular member and a second tubular member.
[0015] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member defining a flange channel on a surface of the first tubular
member, a second tubular member comprising a flange member
extending from a surface on the second tubular member, the second
tubular member coupled to the first tubular member with the flange
member positioned in the flange channel, whereby a sealing
passageway is defined between the flange member and the flange
channel, and resilient means for forming a seal between the first
tubular member and the second tubular member positioned in the
sealing passageway.
[0016] According to another aspect of the present disclosure, a
connection member for coupling expandable tubular members is
provided that includes a tubular connection member comprising an
inner surface and an outer surface, a primary sealing member having
a substantially diamond shaped cross section and extending from a
substantially central location on the inner surface, a reinforced
section located on the outer surface and adjacent the primary
sealing member, and a plurality of secondary sealing surfaces
located on opposite distal ends of the tubular connection member
and on opposite sides of the primary sealing member.
[0017] According to another aspect of the present disclosure, a
connection member for coupling expandable tubular members is
provided that includes a tubular connection member, and means for
providing a primary and secondary metal to metal seal between the
tubular connection member and an expandable tubular member.
[0018] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member comprising a first connection end, a second tubular member
comprising a second connection end, and a connection member
coupling together the first tubular member and the second tubular
member, the connection member including a tubular connection member
comprising an inner surface and an outer surface, the inner surface
engaging the first tubular member and the second tubular member, a
primary sealing member having a substantially diamond shaped cross
section, extending from a substantially central location on the
inner surface, and positioned between the first connection end and
the second connection end, a reinforced section located on the
outer surface and adjacent the primary sealing member, and a
plurality of secondary sealing surfaces located on opposite distal
ends of the tubular connection member and on opposite sides of the
primary sealing member, the secondary sealing surfaces coupled to
the first connection end and the second connection end.
[0019] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member comprising a first connection end, a second tubular member
comprising a second connection end, a connection member coupled to
the first connection end and the second connection end; and means
for providing a primary and secondary metal to metal seal between
the connection member and the first tubular member and the second
tubular member.
[0020] According to another aspect of the present disclosure, a
method for coupling expandable tubular members is provided that
includes providing a first tubular member comprising a maximum
first tubular member diameter, providing a second tubular
comprising a maximum second tubular member diameter, and coupling
the first tubular member to the second tubular member with a
connection member comprising a maximum connection member diameter
which is not substantially greater than the maximum first tubular
member diameter and the maximum second tubular member diameter.
[0021] According to another aspect of the present disclosure, a
method for coupling expandable tubular members is provided that
includes providing a first tubular member comprising a thread
member extending from an inner surface and defining a expansion
channel on the outer surface which is located adjacent the thread
member, and coupling a second tubular member to the first tubular
member by engaging the thread member with a thread channel in the
second tubular member.
[0022] According to another aspect of the present disclosure, a
method for coupling expandable tubular members is provided that
includes providing a first tubular member comprising a flange
member extending from an inner surface, providing a second tubular
member defining a flange channel on an outer surface, positioning a
resilient member in the flange channel, and coupling the first
tubular member to the second tubular member by positioning the
flange member in the flange channel and adjacent the resilient
member.
[0023] According to another aspect of the present disclosure, a
method for coupling expandable tubular members is provided that
includes providing a first tubular member comprising a first
connection end, providing a second tubular member comprising a
second connection end, positioning a connection member adjacent the
first connection end and the second connection end such that a
primary sealing member on the connection member is positioned
between the first connection end and the second connection end, and
a plurality of secondary sealing surfaces are positioned adjacent
the first tubular member and the second tubular member, and
coupling the first tubular member to the second tubular member
using the connection member.
[0024] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member, a second tubular member coupled to the first tubular
member, and means for effecting a gas and fluid tight seal between
the first tubular member and the second tubular member before,
during, and after radial expansion and plastic deformation of the
first tubular member and the second tubular member, the means
providing a seal which can withstand a pressure of up to 4000
pounds per square inch.
[0025] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member comprising a first tubular member diameter which decreases
from a first outside diameter along the length of the first tubular
member to a second outside diameter adjacent a first tubular member
connection end on the first tubular member, a second tubular member
comprising a second tubular member diameter which decreases from
first outside diameter along the length of the second tubular
member to the second outside diameter adjacent a second tubular
member connection end on the second tubular member, whereby the
second tubular member connection end is coupled to the first
tubular member connection end, and a connection member coupled to
the second outside diameter, whereby the connection member
comprises a connection member diameter which is less than or equal
to the first outside diameter.
[0026] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a tubular
member comprising an inner surface and an outer surface, a
plurality of thread members extending from the inner surface, and a
helical expansion channel defined by the tubular member and located
on the outer surface and radially adjacent each of the plurality of
thread members, whereby the expansion channel provides a stress
concentration in the thread member during radial expansion and
plastic deformation of the tubular member.
[0027] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member comprising an inner surface and an outer surface, a
plurality of thread member extending from the inner surface, a
helical expansion channel defined by the first tubular member and
located on the outer surface and radially adjacent each of the
plurality of thread members, a second tubular member coupled the
first tubular member and engaging the plurality of thread members,
whereby the expansion channel provides a stress concentration in
the thread member during radial expansion and plastic deformation
of the first tubular member and the second tubular member, a
tubular connection sleeve positioned on the first tubular member,
and a plurality of spaced apart expansion slots defined by the
tubular connection sleeve in a substantially axial orientation with
respect to the tubular connection sleeve and oriented substantially
perpendicularly adjacent to and with respect to the expansion
channel; whereby the plurality of expansion slots on the tubular
connection sleeve provides a plurality of discrete point stress
concentrations on the thread member during radial expansion and
plastic deformation of the first tubular member, the second tubular
member, and the connection sleeve.
[0028] According to another aspect of the present disclosure, a
connection member for coupling expandable tubular members is
provided that includes a tubular connection member comprising an
inner surface and an outer surface, a primary sealing member having
a substantially diamond shaped cross section, extending from a
substantially central location on the inner surface, and deformable
to provide a metal to metal seal between the tubular connection
member and an expandable tubular member, a reinforced section
located on the outer surface and adjacent the primary sealing
member, and a plurality of secondary sealing surfaces located on
opposite distal ends of the tubular connection member on opposite
sides of the primary sealing member, and deformable to provide a
metal to metal seal between the tubular connection member and an
expandable tubular member.
[0029] According to another aspect of the present disclosure, an
expandable tubular member is provided that includes a first tubular
member comprising a first connection end, a second tubular member
comprising a second connection end, and a connection member
coupling together the first tubular member and the second tubular
member, the connection member including a tubular connection member
comprising an inner surface and an outer surface, the inner surface
engaging the first tubular member and the second tubular member, a
primary sealing member having a substantially diamond shaped cross
section, extending from a substantially central location on the
inner surface, positioned between the first connection end and the
second connection end, and deformable to provide a metal to metal
seal between the connection member and the first tubular member and
the second tubular member, a reinforced section located on the
outer surface and adjacent the primary sealing member, and a
plurality of secondary sealing surfaces located on opposite distal
ends of the tubular connection member and on opposite sides of the
primary sealing member, the secondary sealing surfaces coupled to
the first connection end and the second connection end and
deformable to provide a metal to metal seal between the connection
member and the first tubular member and the second tubular
member.
[0030] According to another aspect of the present disclosure, a
method for coupling expandable tubular members is provided that
includes providing a first tubular member comprising a maximum
first tubular member diameter, providing a second tubular
comprising a maximum second tubular member diameter, coupling the
first tubular member to the second tubular member with a connection
member comprising a maximum connection member diameter which is not
substantially greater than the maximum first tubular member
diameter and the maximum second tubular member diameter,
positioning the first tubular member, the second tubular member,
and the connection member in a wellbore, and radially expanding and
plastically deforming the first tubular member and the second
tubular member, wherein the radially expanding and plastically
deforming comprises one of either radially expanding and
plastically deforming a first reduced diameter section on the first
tubular member to substantially the maximum first tubular member
diameter and radially expanding and plastically deforming a second
reduced diameter section on the second tubular member to
substantially the maximum second tubular member diameter or
radially expanding and plastically deforming the first tubular
member and the second tubular member into engagement with the
wellbore.
[0031] According to another aspect of the present disclosure, a
method for coupling expandable tubular members is provided that
includes providing a first tubular member comprising a thread
member extending from an inner surface and defining a expansion
channel on the outer surface which is located adjacent the thread
member, coupling a connection sleeve to the outer surface of the of
the first tubular member, the connection sleeve defining an
expansion slot oriented axially with respect the connection sleeve
and which is positioned substantially perpendicularly to the
expansion channel, coupling a second tubular member to the first
tubular member by engaging the thread member with a thread channel
in the second tubular member, positioning the first tubular member,
the second tubular member, and the connection sleeve in a wellbore,
and radially expanding and plastically deforming the first tubular
member, the second tubular member, and the connection sleeve,
whereby the expansion slot and the expansion channel provide a
stress concentration which increases the deformation of the thread
member in the thread channel during the radially expanding and
plastically deforming and provides a metal to metal seal between
the thread member and the thread channel.
[0032] According to another aspect of the present disclosure, a
method for coupling expandable tubular members is provided that
includes providing a first tubular member comprising a flange
member extending from an inner surface, providing a second tubular
member defining a flange channel on an outer surface, positioning a
resilient member in the flange channel, coupling the first tubular
member to the second tubular member by positioning the flange
member in the flange channel and adjacent the resilient member,
positioning the first tubular member and the second tubular member
in a wellbore, and radially expanding and plastically deforming the
first tubular member and the second tubular member, whereby the
radially expanding and plastically deforming compresses the
resilient member and provides a seal between the flange member and
the flange channel; whereby the radially expanding and plastically
deforming provides a metal to metal seal between the flange member
and the flange channel.
[0033] According to another aspect of the present disclosure, a
method for coupling expandable tubular members is provided that
includes providing a first tubular member comprising a first
connection end, providing a second tubular member comprising a
second connection end, positioning a connection member adjacent the
first connection end and the second connection end such that a
primary sealing member on the connection member is positioned
between the first connection end and the second connection end, and
a plurality of secondary sealing surfaces are positioned adjacent
the first tubular member and the second tubular member, coupling
the first tubular member to the second tubular member using the
connection member, whereby the coupling includes providing a metal
sealing member between the first tubular member, the second tubular
member, and the secondary sealing surfaces, positioning the first
tubular member, the second tubular member, and the connection
member in a wellbore, and radially expanding and plastically
deforming the first tubular member and the second tubular member,
whereby the radially expanding and plastically deforming provides a
primary seal between the primary sealing member and the first
tubular member and the second tubular member, and the radially
expanding and plastically deforming provides a secondary seal
between the secondary sealing surfaces and the first tubular member
and the second tubular member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a cross sectional view illustrating an exemplary
embodiment of a wellbore.
[0035] FIG. 2 is a cross sectional view illustrating an exemplary
embodiment of an expandable tubular member.
[0036] FIG. 3 is a cross sectional view illustrating an exemplary
embodiment of an expandable tubular member used with the expandable
tubular member of FIG. 2.
[0037] FIG. 4 is a cross sectional view illustrating an exemplary
embodiment of a connection member used with the expandable tubular
members of FIG. 2 and FIG. 3.
[0038] FIG. 5a is a flow chart illustrating an exemplary embodiment
of a method for coupling expandable tubular members.
[0039] FIG. 5b is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 2 and FIG. 3
coupled together by the connection member of FIG. 4.
[0040] FIG. 5c is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 2 and FIG. 3
coupled together by the connection member of FIG. 4 and including a
protective sleeve coupled to the connection member.
[0041] FIG. 5d is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members and the connection
member of FIG. 5b positioned in the wellbore of FIG. 1.
[0042] FIG. 5e is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members and the connection
member positioned in the wellbore of FIG. 5d and being radially
expanded and plastically deformed.
[0043] FIG. 5f is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members and the connection
member positioned in the wellbore of FIG. 5d and radially expanded
and plastically deformed.
[0044] FIG. 5g is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members and the connection
member positioned in the wellbore of FIG. 5f and being radially
expanded and plastically deformed.
[0045] FIG. 6a is a side view illustrating an exemplary embodiment
of an expandable tubular member.
[0046] FIG. 6b is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular member of FIG. 6a.
[0047] FIG. 7 is a cross sectional view illustrating an exemplary
embodiment of an expandable tubular member used with the expandable
tubular member of FIG. 6b.
[0048] FIG. 8a is a flow chart illustrating an exemplary embodiment
of a method for coupling expandable tubular members.
[0049] FIG. 8b is a side view illustrating an exemplary embodiment
of the expandable tubular members of FIG. 6b and FIG. 7 coupled
together.
[0050] FIG. 8c is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 6b and FIG. 7
coupled together.
[0051] FIG. 8d is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 8c positioned
in the wellbore of FIG. 1.
[0052] FIG. 8e is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members positioned in the
wellbore of FIG. 8d and being radially expanded and plastically
deformed.
[0053] FIG. 8f is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members positioned in the
wellbore of FIG. 5d and radially expanded and plastically
deformed.
[0054] FIG. 8g is a schematic view illustrating an exemplary
embodiment of the stress concentrations on the expandable tubular
members of FIG. 8e.
[0055] FIG. 9a is a side view illustrating an exemplary embodiment
of a connection sleeve.
[0056] FIG. 9b is a cross sectional view illustrating an exemplary
embodiment of the connection sleeve of FIG. 9a.
[0057] FIG. 10a is a flow chart illustrating an exemplary
embodiment of a method for coupling expandable tubular members.
[0058] FIG. 10b is a side view illustrating an exemplary embodiment
of the expandable tubular members of FIG. 6a and FIG. 7 coupled
together and with the connection sleeve of FIG. 9a coupled to the
expandable tubular member of FIG. 6a.
[0059] FIG. 10c is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 6b and FIG. 7
coupled together and with the connection sleeve of FIG. 9a coupled
to the expandable tubular member of FIG. 6b.
[0060] FIG. 10d is a side view illustrating an exemplary embodiment
of the expandable tubular members and the connection sleeve of FIG.
10c positioned in the wellbore of FIG. 1.
[0061] FIG. 10e is a fragmentary cross sectional view illustrating
an exemplary embodiment of the expandable tubular members and the
connection sleeve positioned in the wellbore of FIG. 10d and being
radially expanded and plastically deformed.
[0062] FIG. 10f is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members and the connection
sleeve positioned in the wellbore of FIG. 10d and radially expanded
and plastically deformed.
[0063] FIG. 10g is a schematic view illustrating an exemplary
embodiment of the stress concentrations on the expandable tubular
members of FIG. 10e.
[0064] FIG. 10h is a graph of the results of an experimental
embodiment of the method illustrated in FIGS. 10a, 10b, 10c, 10d,
10e and 10f.
[0065] FIG. 11 is a cross sectional view illustrating an exemplary
embodiment of an expandable tubular member.
[0066] FIG. 12 is a cross sectional view illustrating an exemplary
embodiment of an expandable tubular member used with the expandable
tubular member of FIG. 11.
[0067] FIG. 13a is a flow chart illustrating an exemplary
embodiment of a method for coupling expandable tubular members.
[0068] FIG. 13b is a side cross sectional view illustrating an
exemplary embodiment of the expandable tubular members of FIG. 11
and FIG. 12 coupled together with a resilient member positioned
between them.
[0069] FIG. 13c is a top cross sectional view illustrating an
exemplary embodiment of the expandable tubular members of FIG. 11
and FIG. 12 coupled together with a resilient member positioned
between them.
[0070] FIG. 13d is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 13b positioned
in the wellbore of FIG. 1 and being radially expanded and
plastically deformed.
[0071] FIG. 13e is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 13c positioned
in the wellbore of FIG. 1 and radially expanded and plastically
deformed.
[0072] FIG. 14a is a flow chart illustrating an exemplary
embodiment of a method for coupling expandable tubular members.
[0073] FIG. 14b is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 11 and FIG. 12
coupled together with a resilient member positioned between
them.
[0074] FIG. 14c is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 11 and FIG. 12
coupled together with a resilient member positioned between
them.
[0075] FIG. 14d is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 14b positioned
in the wellbore of FIG. 1 and being radially expanded and
plastically deformed.
[0076] FIG. 14e is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 14c positioned
in the wellbore of FIG. 1 and radially expanded and plastically
deformed.
[0077] FIG. 15a is a flow chart illustrating an exemplary
embodiment of a method for coupling expandable tubular members.
[0078] FIG. 15b is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 11 and FIG. 12
coupled together with a resilient member positioned between
them.
[0079] FIG. 15c is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 11 and FIG. 12
coupled together with a resilient member positioned between
them.
[0080] FIG. 15d is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 15b positioned
in the wellbore of FIG. 1 and being radially expanded and
plastically deformed.
[0081] FIG. 15e is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 15c positioned
in the wellbore of FIG. 1 and radially expanded and plastically
deformed.
[0082] FIG. 16 is a cross sectional view illustrating an exemplary
embodiment of an expandable tubular member.
[0083] FIG. 17a is a flow chart illustrating an exemplary
embodiment of a method for coupling expandable tubular members.
[0084] FIG. 17b is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 12 and FIG. 16
coupled together.
[0085] FIG. 17c is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 12 and FIG. 16
coupled together.
[0086] FIG. 17d is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 17b positioned
in the wellbore of FIG. 1 and being radially expanded and
plastically deformed.
[0087] FIG. 17e is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 17c positioned
in the wellbore of FIG. 1 and radially expanded and plastically
deformed.
[0088] FIG. 18 is a cross sectional view illustrating an exemplary
embodiment of an expandable tubular member.
[0089] FIG. 19 is a cross sectional view illustrating an exemplary
embodiment of an expandable tubular member used with the expandable
tubular member of FIG. 18.
[0090] FIG. 20 is a cross sectional view illustrating an exemplary
embodiment of a connection member used with the expandable tubular
members of FIG. 18 and FIG. 19.
[0091] FIG. 21a is a flow chart illustrating an exemplary
embodiment of a method for coupling expandable tubular members.
[0092] FIG. 21b is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 18 and FIG. 19
coupled together with the connection member of FIG. 20.
[0093] FIG. 21c is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 18 and FIG. 19
coupled together with the connection member of FIG. 20.
[0094] FIG. 21d is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 21b positioned
in the wellbore of FIG. 1 and being radially expanded and
plastically deformed.
[0095] FIG. 21e is a cross sectional view illustrating an exemplary
embodiment of the expandable tubular members of FIG. 21c positioned
in the wellbore of FIG. 1 and radially expanded and plastically
deformed.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0096] Referring now to FIG. 1, a wellbore 100 is illustrated.
Wellbore 100 includes a volume of earth 102 which defines a
passageway 104 extending through the earth 102. The passageway 104
includes passageway surface 104a which defines an outer edge of the
passageway 104. In an exemplary embodiment, the wellbore 100 is
formed using conventional drilling methods known in the art. In an
exemplary embodiment, the wellbore 100 may be a cased hole.
[0097] Referring now to FIG. 2, an expandable tubular member 200 is
illustrated. The expandable tubular member 200 includes a base 202
having an outer surface 202a, an inner surface 202b located
opposite the outer surface 202a, and defining a passageway 202c
extending along the length of the base 202. Expandable tubular
member 200 includes a connection end 204 located on a distal end of
the base 202. Expandable tubular member 200 has an outside diameter
which decreases from a maximum outside diameter 206 along a length
of the base 202 to an outside diameter 208 located adjacent the
connection end 204. In an embodiment, the expandable tubular member
200 decreases in diameter over a length 210 of the base 202. In an
exemplary embodiment, the expandable tubular member 200 is
fabricated from a metal material.
[0098] Referring now to FIG. 3, an expandable tubular member 300 is
illustrated. The expandable tubular member 300 includes a base 302
having an outer surface 302a, an inner surface 302b located
opposite the outer surface 302a, and defining a passageway 302c
extending along the length of the base 302. Expandable tubular
member 300 includes a connection end 304 located on a distal end of
the base 302. Expandable tubular member 300 has an outside diameter
which decreases from a maximum outside diameter 306 along a length
of the base 302 to an outside diameter 308 located adjacent the
connection end 304. In an embodiment, the expandable tubular member
300 decreases in diameter over a length 310 of the base 302. In an
exemplary embodiment, the expandable tubular member 300 is
fabricated from a metal material.
[0099] Referring now to FIG. 4, a connection member 400 is
illustrated. Connection member 400 includes a tubular base 402
having an outer surface 402a and an inner surface 402b located
opposite the outer surface 402a. A pair of opposing distal ends
404a and 404b are included on opposite sides of the tubular base
402. A passageway 406 is defined by the tubular base 402 and
located along the length of the tubular base 402 between distal
ends 404a and 404b. The tubular base 402 has a connection member
diameter 408 along the length of the tubular base 402. In an
exemplary embodiment, the connection member 400 may be a variety of
conventional connection members known in the art for coupling
expandable tubular members. In an exemplary embodiment, the
connection member 400 is fabricated from a metal material.
[0100] Referring now to FIGS. 2, 3, 4, 5a, 5b, and 5c, a method 500
for coupling expandable tubular members is illustrated. The method
500 begins at step 502 where the expandable tubular member 200 and
the expandable tubular member 300 are provided. The expandable
tubular member 200 is positioned adjacent the expandable tubular
member 300 such that the connection end 204 on expandable tubular
member 200 is adjacent the connection end 304 on expandable tubular
member 300.
[0101] The method 500 then proceeds to step 504 where the
expandable tubular members 200 and 300 are coupled together with
the connection member 400. The connection member 400 is engaged
with the expandable tubular member 200 such that the inner surface
402b of the connection member 400 engages the outer surface 202a of
the expandable tubular member 200 adjacent the connection end 204.
The connection member 400 is then engaged with the expandable
tubular member 300 such that the inner surface 402b of the
connection member 400 engages the outer surface 302a of the
expandable tubular member 300 adjacent the connection end 304. With
the connection member 400 engaging the expandable tubular members
200 and 300, the connection ends 204 and 304 or expandable tubular
members 200 and 300, respectively, are positioned in the passageway
406 on connection member 400 and engage each other, as illustrated
in FIG. 5b. In an exemplary embodiment, the expandable tubular
members 200 and 300 are coupled together by the engagement of the
connection ends 204 and 304, respectively, such as, for example,
using a convention threaded connection, and/or the engagement of
the connection member 400 with the expandable tubular members 200
and 300 using convention methods known in the art. In an exemplary
embodiment, the engagement of the expandable tubular members 200
and 300 and the connection member 400 provides a gas and liquid
tight seal between the expandable tubular members 200 and 300 and
the connection member 400. In an exemplary embodiment, the
engagement of the expandable tubular members 200 and 300 and the
connection member 400 provides a metal to metal seal between the
expandable tubular members 200 and 300 and the connection member
400.
[0102] With the connection member 400 engaging the expandable
tubular members 200 and 300, an expandable tubular member 502a is
provided in which the connection member diameter 408 is not
substantially greater than the maximum outside diameter 206 on the
expandable tubular member 200 or the maximum outside diameter 306
on the expandable tubular member 300. Thus, an expandable tubular
member 502a is provided which has a maximum diameter that is the
maximum diameter of the expandable tubular members 200 or 300 which
are coupled together to form the expandable tubular member 502a,
rather than the diameter of the connection member 400 which couples
together the expandable tubular members 200 and 300. In an
exemplary embodiment, an outer protective sleeve 502b may be
coupled to the outer surface 402a of the connection member 400 and
an inner protective sleeve 502c may be coupled to the inner
surfaces 202b and 302b of the expandable tubular members 200 and
300, respectively, adjacent the connection ends 204 and 304,
respectively, as illustrated in FIG. 5c.
[0103] Referring now to FIGS. 1, 5a, 5b, and 5d, the method 500
proceeds to step 506 where the expandable tubular members 200 and
300 are positioned in the wellbore 100. The expandable tubular
member 502a is positioned in the passageway 104 on wellbore 100, as
illustrated in FIG. 5d. The passageway 104 may be dimensioned such
that there is only a small amount of space between the passageway
surface 104a and the outer surfaces 202a, 302a, and 402a of the
expandable tubular member 200, the expandable tubular member 300,
and the connection member 400, respectively. However, relatively
large diameter expandable tubular members 200 and 300 may be used
with the wellbore 100 because the coupling of the expandable
tubular members 200 and 300 with the connection member 400 does not
increase the outside diameter of the expandable tubular member
502a. This allows larger diameter expandable tubular members 200
and 300 to be coupled together and used in the wellbore 100 than is
possible using conventional coupling methods.
[0104] Referring now to FIGS. 1, 5a, 5b, 5e, 5f, and 5g, the method
proceeds to step 508 where the expandable tubular members 200 and
300 are radially expanded and plastically deformed. An expansion
device 508a which is coupled to a drill string 508b is provided
which has larger outside diameter than the inside diameters of the
portions of the expandable tubular members 200 and 300 with outside
diameters 208 and 308, respectively. The expansion device 508a is
positioned in the expandable tubular member 502b and moved in a
direction A, as illustrated in FIG. 5e. Movement of the expansion
device 508a in direction A expands the length 310 of the expandable
tubular member 300 and the portion of the expandable tubular member
300 with outside diameter 308 to a inside diameter equal to the
outside diameter of the expansion device 508a.
[0105] Continued movement of the expansion device 508a in direction
A expands the length 210 of the expandable tubular member 200 and
the portion of the expandable tubular member 200 with outside
diameter 208 to a inside diameter equal to the outside diameter of
the expansion device 508a, as illustrated in FIG. 5f. In an
exemplary embodiment, the expansion device 508a may be a fixed
diameter expansion device, a rotary expansion device, a
hydroforming device, combinations thereof, and/or a variety of
other expansion devices known in the art.
[0106] Thus, the expandable tubular member 502a may be positioned
in a wellbore 100 with tight clearance between the expandable
tubular member 502a and the passageway surface 104a and then
radially expanded and plastically deformed to a monodiameter
tubular member. In an exemplary embodiment, an expansion device
508c which is coupled to a drill string 50 db is provided which has
larger outside diameter than the inside diameters of the portions
of the expandable tubular members 200 and 300 with maximum outside
diameters 206 and 306, respectively. The expansion device 508c is
then moved in a direction B, radially expanding and plastically
deforming the expandable tubular member 502a into engagement with
the passageway surface 104a of wellbore 100, as illustrated in FIG.
5g. In an exemplary embodiment, the expansion device 508c may be a
fixed diameter expansion device, a rotary expansion device, a
hydroforming device, combinations thereof, and/or a variety of
other expansion devices known in the art. Thus, the expandable
tubular member 502a may be positioned in a wellbore 100 with tight
clearance between the expandable tubular member 502a and the
passageway surface 104a and then radially expanded and plastically
deformed into engagement with the passageway surface 104a of the
wellbore 104.
[0107] Referring now to FIGS. 6a and 6b, an expandable tubular
member 600 is illustrated. The expandable tubular member 600
includes a tubular base 602 having an outer surface 602a, and inner
surface 602b located opposite the outer surface 602a, a distal end
602c, and defining a passageway 602d extending along its length of
the tubular base 602 to the distal end 602c. A plurality of thread
members, which may be conventional thread members known in the art,
such as, for example, thread member 604, extend from the inner
surface 602b of the tubular base 602 into the passageway 602d and
are located circumferentially about the inner surface 602b. A
stress concentrator is provided on the expandable tubular member
600 and may include a plurality of expansion channels such as, for
example, expansion channel 606, which are defined by the tubular
base 602 and located helically about the outer surface 602a and
adjacent the plurality of thread members such as, for example, the
thread member 604. In an embodiment, the expandable tubular member
600 is fabricated from a metal material.
[0108] Referring now to FIG. 7, an expandable tubular member 700 is
illustrated. Expandable tubular member 700 includes a tubular base
702 having an outer surface 702a, an inner surface 702b located
opposite the outer surface 702a, a distal end 702c, and defining a
passageway 702d which extends from the distal end 702c and along
the length of the tubular base 702. A plurality of thread channels,
which may be conventional thread channels known in the art, such
as, for example, the thread channel 704, are defined by the tubular
base 702 and located circumferentially about the outer surface
702a. In an embodiment, the expandable tubular member 700 is
fabricated from a metal material.
[0109] Referring now to FIGS. 6a, 6b, 7, 8a, 8b, and 8c, a method
800 for coupling expandable tubular members is illustrated. The
method 800 begins at step 802 where the expandable tubular members
600 and 700, illustrated in FIGS. 6a, 6b, and 7, are provided. The
method 800 then proceeds to step 804 where the expandable tubular
members 600 and 700 are coupled together. The expandable tubular
member 600 is positioned adjacent the expandable tubular member 700
such that the distal end 602c on expandable tubular member 600 is
adjacent the distal end 702c on expandable tubular member 700. The
distal end 702c on expandable tubular member 700 is then positioned
in the passageway 602d on expandable tubular member 600 such that
the plurality of thread members such as, for example, the thread
member 604, engage the plurality of thread channels such as, for
example, the thread channel 704, as illustrated in FIG. 8c,
providing an expandable tubular member 804a.
[0110] Referring now to FIGS. 1, 8a, and 8d, the method 800 then
proceeds to step 806 where the expandable tubular members 600 and
700 are positioned in the wellbore 100. The expandable tubular
member 804a is positioned in the passageway 104 of wellbore 100
such that the outer surfaces 602a and 702a of the expandable
tubular members 600 and 700, respectively, are positioned adjacent
the passageway surface 104a, as illustrated in FIG. 8d.
[0111] Referring now to FIGS. 8a, 8b, 8e, 8f, and 8g, the method
800 proceeds to step 808 where the expandable tubular members 600
and 700 are radially expanded and plastically deformed. An
expansion device 808a which is coupled to a drill string 808b is
provided which has larger outside diameter than the inside
diameters of the expandable tubular members 600 and 700. The
expansion device 808a is positioned in the expandable tubular
member 804a and moved in a direction C, as illustrated in FIG. 8e.
Movement of the expansion device 808a in direction C expands the
expandable tubular members 600 and 700 such that the outer surfaces
602a and 702a, respectively, engage the passageway surface 104a of
the wellbore 100. In an exemplary embodiment, the expansion device
808a may be a fixed diameter expansion device, a rotary expansion
device, a hydroforming device, combinations thereof, and/or a
variety of other expansion devices known in the art. Furthermore,
the expansion of the expandable tubular member 804a between the
distal ends 602c and 702c on expandable tubular members 600 and
700, respectively, results in the deformation of the plurality of
thread members in the plurality of thread channels.
[0112] With the provision of the stress concentrator, shown as the
plurality of expansion channels in this embodiment, the deformation
of the plurality of thread members in the plurality of thread
channels is increased relative to the deformation of a thread
member in a thread channel without the stress concentrator. For
example, during deformation, the expansion channel 606 allows
increased deformation of the thread member 604 in the thread
channel 704 by increasing the stress experienced by the thread
member 604 during radial expansion and plastic deformation of the
expandable tubular members 600 and 700 and increasing the
deformation of the thread member 604, as illustrated in FIG. 8f,
which provides a gas and liquid tight seal between the expandable
tubular members 600 and 700. In an exemplary embodiment, the gas
and liquid tight seal provided between the expandable tubular
members 600 and 700 is a metal to metal seal.
[0113] Thus, a method and apparatus are provided which provide
stress concentrations on the expandable tubular members 600 and 700
in order increase the deformation of thread members in thread
channels such as, for example, the thread member 604 in the thread
channel 704, to provide a seal between the thread member 604 and
the thread channel 704 after the expansion of coupled together
expandable tubular members 600 and 700. In an exemplary embodiment,
the stress concentrator provided on the expandable tubular member
804a is a circumferential and helical stress concentration 810, as
illustrated in FIG. 8g. In an exemplary embodiment, the stress
concentrator may provide a variety of stress concentrations with
different geometries such as, for example, point to point stress
concentrations, discrete stress concentrations, and/or continuous
stress concentrations.
[0114] Referring now to FIGS. 9a and 9b, a connection sleeve 900 is
illustrated. The connection sleeve 900 includes a tubular base 902
having an outer surface 902a, an inner surface 902b located
opposite the outer surface 902a, a distal end 902c, and a
passageway 902d which extends from the distal end 902c and along
the length of the tubular base 902. A stress concentrator is
provided on the connection sleeve 900 and may include a plurality
of expansion slots 904 defined by the tubular base 902, extending
from the outer surface 902a to the inner surface 902b, and located
in a substantially axially orientation with respect to the tubular
base 902 and spaced apart circumferentially about the tubular base
902. In an exemplary embodiment, the connection sleeve 900 is
fabricated from a metal material.
[0115] Referring now to FIGS. 6a, 6b, 7, 9a, 9b, 10a, and 10b, a
method 1000 for coupling expandable tubular members is illustrated.
The method 1000 begins at step 1002 where the expandable tubular
members 600 and 700 and the connection sleeve, illustrated in FIGS.
6a, 6b, 7, 9a and 9b, are provided.
[0116] The method 1000 then proceeds to step 1004 where the
expandable tubular members 600 and 700 are coupled together. The
distal end 602c of expandable tubular member 600 is positioned in
the passageway 902d on the connection sleeve 900 such that the
inner surface 902b of the connection sleeve 900 engages the outer
surface 602a of the expandable tubular member 600. With the
connection sleeve 900 coupled to the expandable tubular member 600,
the expansion slots 904 on connection sleeve 900 are oriented
substantially perpendicularly to the plurality of expansion
channels such as, for example, expansion channel 606 on expandable
tubular member 600. Coupling the connection sleeve 900 to the
expandable tubular member 600 provides a plurality of discrete
point stress concentrators located at the intersection of the
expansion slots 904 and the expansion channels.
[0117] The expandable tubular member 600 and connection sleeve 900
are then positioned adjacent the expandable tubular member 700 such
that the distal ends 602c and 902c on the expandable tubular member
600 and connection sleeve 900, respectively, are adjacent the
distal end 702c on expandable tubular member 700. The distal end
702c on expandable tubular member 700 is then positioned in the
passageway 602d on expandable tubular member 600 such that the
plurality of thread members such as, for example, the thread member
604, engage the plurality of thread channels such as, for example,
the thread channel 704, and are positioned adjacent the expansion
slot 904, as illustrated in FIG. 10c, providing an expandable
tubular member 1004a.
[0118] Referring now to FIGS. 1, 10a, and 10d, the method 1000 then
proceeds to step 1006 where the expandable tubular members 600 and
700 and the connection sleeve 900 are positioned in the wellbore
100. The expandable tubular member 1004a is positioned in the
passageway 104 of wellbore 100 such that the outer surface 902a of
the connection sleeve 900 and the outer surfaces 602a and 702a of
the expandable tubular members 700, respectively, are positioned
adjacent the passageway surface 104a, as illustrated in FIG.
10d.
[0119] Referring now to FIGS. 10a, 10b, 10e, 10f, and 10g, the
method 1000 proceeds to step 1008 where the expandable tubular
members 600 and 700 and the connection sleeve 900 are radially
expanded and plastically deformed. An expansion device 1008a which
is coupled to a drill string 1008b is provided which has larger
outside diameter than the inside diameters of the expandable
tubular members 600 and 700. The expansion device 1008a is
positioned in the expandable tubular member 1004a and moved in a
direction D, as illustrated in FIG. 10e. Movement of the expansion
device 1008a in direction D expands the expandable tubular members
600 and 700 and the connection sleeve 900 such that the outer
surfaces 602a, 702a, and 902a, respectively, engage the passageway
surface 104a of the wellbore 100. In an exemplary embodiment, the
expansion device 808a may be a fixed diameter expansion device, a
rotary expansion device, a hydroforming device, combinations
thereof, and/or a variety of other expansion devices known in the
art. Furthermore, the expansion of the expandable tubular member
1004a between the distal ends 902c and 702c on the connection
sleeve 900 and the expandable tubular member 700, respectively,
results in the deformation of the plurality of thread members in
the plurality of thread channels.
[0120] With the provision of the discrete point stress
concentrators, shown as the intersection of the expansion slots 904
and the expansion channels, the deformation of the plurality of
thread members in the plurality of thread channels is increased
relative to the deformation of a thread member in a thread channel
without the discrete point stress concentrators. For example,
during deformation, the expansion channel 606 and the expansion
slot 904 allow increased deformation of the thread member 604 in
the thread channel 704 by increasing the stress experienced by the
thread member 604 during radial expansion and plastic deformation
of the expandable tubular members 600 and 700 and increasing the
deformation of the thread member 604, as illustrated in FIG. 10f,
which provides a gas and liquid tight seal between the expandable
tubular members 600 and 700. In an exemplary embodiment, the gas
and liquid tight seal provided between the expandable tubular
members 600 and 700 is a metal to metal seal.
[0121] Thus, a method and apparatus are provided which provide
stress concentrations on the expandable tubular member 1004a in
order increase the deformation of thread members in thread channels
such as, for example, the thread member 604 in the thread channel
704, to provide a seal between the thread member 604 and the thread
channel 704 after the expansion of coupled together expandable
tubular members 600 and 700. In an exemplary embodiment, the stress
concentrator may provide stress concentrations on the expandable
tubular member 1004a in discrete point stress concentrations 1010,
illustrated in FIG. 10g. In an exemplary embodiment, the stress
concentrator may provide stress concentrations on the expandable
tubular member 1004a in variety of different manners on the
expandable tubular members such as circumferential stress
concentrations, point to point stress concentrations, discrete
stress concentrations, and/or continuous stress concentrations. In
an exemplary embodiment, the connection sleeve 900 increases the
compression limits of the connection between the expandable tubular
members 600 and 700 between thread member 604 and the thread
channel 704.
[0122] Referring now to FIG. 10h, in an experimental embodiment
EXP.sub.1, an expandable tubular member substantially similar to
the expandable tubular member 1004a, described above with reference
to FIGS. 10b, 10c, 10d, 10e, 10f and 10g, was provided and radially
expanded and plastically deformed in substantially the same manner
as described above. The ends of the expandable tubular members 600
and 700 were capped, and the pressure in the passageways 602a and
702a of expandable tubular members 600 and 700, respectively, was
increased to test the gas and liquid tight seal between the thread
member 604 and the thread channel 704 on the expandable tubular
members 600 and 700, respectively. The pressure was first increased
to a pressure EXP.sub.1A, which was approximately 2000 psig, and
the pressure held constant for a time period. The pressure was then
increased to a pressure EXP.sub.1B, which was approximately 3000
psig, and the pressure held constant for a time period. This was an
unexpected result, as seal failure was expected for this
combination of expandable tubular members 600 and 700 including the
connection sleeve 900 at 3000 psig. The pressure was then increased
to a pressure EXP.sub.1C, which was approximately 4000 psig, above
which the seal failed. Thus, a method and apparatus have been
provided which provides a seal between coupled and radially
expanded and plastically deformed expandable tubular members 600
and 700 and connection sleeve 900 that can withstand increased
pressure without failing relative to conventional coupling
methods.
[0123] Referring now to FIG. 11, an expandable tubular member 1100
is illustrated. The expandable tubular member 1100 includes a
tubular base 1102 having an outer surface 1102a, and inner surface
1102b located opposite the outer surface 1102a, a distal end 1102c,
and defining a passageway 1102d extending along its length of the
tubular base 1102 to the distal end 1102c. A plurality of flange
members 1104 extend from the inner surface 1102b of the tubular
base 1102 and into the passageway 1102d. In an exemplary
embodiment, the expandable tubular member 1100 is fabricated from
metal material.
[0124] Referring now to FIG. 12, an expandable tubular member 1200
is illustrated. The expandable tubular member 1200 includes a
tubular base 1202 having an outer surface 1202a, and inner surface
1202b located opposite the outer surface 1202a, a distal end 1202c,
and defining a passageway 1202d extending along its length of the
tubular base 1202 to the distal end 1202c. A plurality of flange
channels 1204 are defined by the tubular base 1202 and located on
the outer surface 1202a of the tubular base 1202. In an exemplary
embodiment, the expandable tubular member 1200 is fabricated from
metal material.
[0125] Referring now to FIGS. 11, 12, 13a, 13b, and 13c, a method
1300 for coupling expandable tubular members is illustrated. The
method 1300 begins at step 1302 where the expandable tubular
members 1100 and 1200, illustrated in FIGS. 11 and 12, are
provided. The method 1300 then proceeds to step 1304 where the
expandable tubular members 1100 and 1200 are coupled together. A
wave spring resilient member 1304a is positioned in the flange
channels 1204 and about the circumference of the expandable tubular
member 1200. In an exemplary embodiment, the wave spring resilient
member 1304a is fabricated from a metal material.
[0126] The expandable tubular member 1100 is then coupled to the
expandable tubular member 1200 by positioning the flange members
1104 in the flange channels 1204. In an exemplary embodiment, the
flange members 1104 are positioned in the flange channels 1204 by
heating the expandable tubular member 1100, causing the expandable
tubular member 1100 to expand, which increases the diameter of the
passageway 1102d and allows the distal end of expandable tubular
member 1200 to be positioned in the passageway 1102d of the
expandable tubular member 1100. In an exemplary embodiment, the
flange members 1104 are positioned in the flange channels 1204 by
forcing the distal end of expandable tubular member 1200 into the
passageway 1102d of the expandable tubular member 1100, causing the
expandable tubular member 1100 to elastically deform to allow the
distal end of expandable tubular member 1200 to be positioned in
the passageway 1102d of the expandable tubular member 1100. In an
exemplary embodiment, the flange members 1104 are conventional
thread members known in the art and the flange channels 1204 are
conventional thread channels known in the art, and the flange
members 1104 are positioned in the flange channels 1204 by
threading the thread members into the thread channels. In an
exemplary embodiment, the flange members 1104 may be positioned in
the flange channels 1204 using a variety of other conventional
methods known in the art.
[0127] With the expandable tubular member 1200 coupled to the
expandable tubular member 1100, a sealing channel is defined
between the flange member 1104 and the flange channel 1204 and the
wave spring resilient member 1304a is positioned in the sealing
channel, as illustrated in FIGS. 13b and 13c. With the expandable
tubular member 1100 coupled to the expandable tubular member 1200,
an expandable tubular member 1304b is provided.
[0128] Referring now to FIGS. 1, 13a, 13d, and 13e, the method 1300
then proceeds to step 1306 where the expandable tubular members
1100 and 1200 are positioned in the wellbore 100. The expandable
tubular member 1304b is positioned in the passageway 104 of
wellbore 100 such that outer surfaces 1102a and 1202a of the
expandable tubular members 1100 and 1200, respectively, are
positioned adjacent the passageway surface 104a, as illustrated in
FIG. 13d.
[0129] The method 1300 proceeds to step 1308 where the expandable
tubular members 1100 and 1200 are radially expanded and plastically
deformed. An expansion device 1308a which is coupled to a drill
string 1308b is provided which has larger outside diameter than the
inside diameters of the expandable tubular members 1100 and 1200.
The expansion device 1308a is positioned in the expandable tubular
member 1304b and moved in a direction E, as illustrated in FIG.
13d. Movement of the expansion device 1308a in direction E expands
the expandable tubular members 1100 and 1200 such that the outer
surfaces 1102a and 1202a, respectively, engage the passageway
surface 104a of the wellbore 100. In an exemplary embodiment, the
expansion device 1308a may be a fixed diameter expansion device, a
rotary expansion device, a hydroforming device, combinations
thereof, and/or a variety of other expansion devices known in the
art. Furthermore, the expansion of the expandable tubular member
1304b adjacent the flange member 1104 and the flange channel 1204
results in the deformation of the wave spring resilient member
1304a. Deformation of the wave spring resilient member 1304a
provides a gas and liquid tight seal between the expandable tubular
members 1100 and 1200. In an exemplary embodiment, the gas and
liquid tight seal provided between the expandable tubular members
1100 and 1200 is a metal to metal seal. Thus, a method and
apparatus are provided which provide a gas and liquid tight seal
between two expandable tubular members 1100 and 1200 which are
coupled together and radially expanded and plastically
deformed.
[0130] Referring now to FIGS. 11, 12, 14a, 14b, and 14c, a method
1400 for coupling expandable tubular members is illustrated. The
method 1400 begins at step 1402 where the expandable tubular
members 1100 and 1200, illustrated in FIGS. 11 and 12, are
provided. The method 1400 then proceeds to step 1404 where the
expandable tubular members 1100 and 1200 are coupled together. A
wave spring resilient member 1404a is positioned in the flange
channels 1204 and about the circumference of the expandable tubular
member 1200. In an exemplary embodiment, the wave spring resilient
member 1404a is fabricated from a metal material.
[0131] The expandable tubular member 1100 is then coupled to the
expandable tubular member 1200 by positioning the flange members
1204 in the flange channels 1204. In an exemplary embodiment, the
flange members 1104 are positioned in the flange channels 1204 by
heating the expandable tubular member 1100, causing the expandable
tubular member 1100 to expand, which increases the diameter of the
passageway 1202d and allows the distal end of expandable tubular
member 1200 to be positioned in the passageway 1202d of the
expandable tubular member 1100. In an exemplary embodiment, the
flange members 1104 are positioned in the flange channels 1204 by
forcing the distal end of expandable tubular member 1200 into the
passageway 1202d of the expandable tubular member 1100, causing the
expandable tubular member 1100 to elastically deform to allow the
distal end of expandable tubular member 1200 to be positioned in
the passageway 1202d of the expandable tubular member 1100. In an
exemplary embodiment, the flange members 1104 are conventional
thread members known in the art and the flange channels 1204 are
conventional thread channels known in the art, and the flange
members 1104 are positioned in the flange channels 1204 by
threading the thread members into the thread channels. In an
exemplary embodiment, the flange members 1104 may be positioned in
the flange channels 1204 using a variety of other conventional
methods known in the art.
[0132] With the expandable tubular member 1200 coupled to the
expandable tubular member 1100, a sealing channel is defined
between the flange member 1104 and the flange channel 1204 and the
wave spring resilient member 1404a is positioned in the sealing
channel, as illustrated in FIGS. 14b and 14c. With the expandable
tubular member 1100 coupled to the expandable tubular member 1200,
an expandable tubular member 1404b is provided.
[0133] Referring now to FIGS. 1, 14a, 14d, and 14e, the method 1400
then proceeds to step 1406 where the expandable tubular members
1100 and 1200 are positioned in the wellbore 100. The expandable
tubular member 1404b is positioned in the passageway 104 of
wellbore 100 such that outer surfaces 1102a and 1202a of the
expandable tubular members 1100 and 1200, respectively, are
positioned adjacent the passageway surface 104a, as illustrated in
FIG. 14d.
[0134] The method 1400 proceeds to step 1408 where the expandable
tubular members 1100 and 1200 are radially expanded and plastically
deformed. An expansion device 1408a which is coupled to a drill
string 1408b is provided which has larger outside diameter than the
inside diameters of the expandable tubular members 1100 and 1200.
The expansion device 1408a is positioned in the expandable tubular
member 1404b and moved in a direction F, as illustrated in FIG.
14d. Movement of the expansion device 1408a in direction F expands
the expandable tubular members 1100 and 1200 such that the outer
surfaces 1102a and 1202a, respectively, engage the passageway
surface 104a of the wellbore 100. In an exemplary embodiment, the
expansion device 1408a may be a fixed diameter expansion device, a
rotary expansion device, a hydroforming device, combinations
thereof, and/or a variety of other expansion devices known in the
art. Furthermore, the expansion of the expandable tubular member
1404b adjacent the flange member 1104 and the flange channel 1204
results in the deformation of the wave spring resilient member
1404a. Deformation of the wave spring resilient member 1404a
provides a gas and liquid tight seal between the expandable tubular
members 1100 and 1200. In an exemplary embodiment, the gas and
liquid tight seal provided between the expandable tubular members
1100 and 1200 is a metal to metal seal. Thus, a method and
apparatus are provided which provide a gas and liquid tight seal
between two expandable tubular members 1100 and 1200 which are
coupled together and radially expanded and plastically
deformed.
[0135] Referring now to FIGS. 11, 12, 15a, 15b, and 15c, a method
1500 for coupling expandable tubular members is illustrated. The
method 1500 begins at step 1502 where the expandable tubular
members 1100 and 1200, illustrated in FIGS. 11 and 12, are
provided. The method 1500 then proceeds to step 1504 where the
expandable tubular members 1100 and 1200 are coupled together. An
O-ring resilient member 1504a is positioned in the flange channels
1204 and about the circumference of the expandable tubular member
1200. In an exemplary embodiment, the O-ring resilient member 1504a
is fabricated from a metal material.
[0136] The expandable tubular member 1100 is then coupled to the
expandable tubular member 1200 by positioning the flange members
1104 in the flange channels 1204. In an exemplary embodiment, the
flange members 1104 are positioned in the flange channels 1204 by
heating the expandable tubular member 1100, causing the expandable
tubular member 1100 to expand, which increases the diameter of the
passageway 1102d and allows the distal end of expandable tubular
member 1200 to be positioned in the passageway 1102d of the
expandable tubular member 1100. In an exemplary embodiment, the
flange members 1104 are positioned in the flange channels 1204 by
forcing the distal end of expandable tubular member 1200 into the
passageway 1102d of the expandable tubular member 1100, causing the
expandable tubular member 1100 to elastically deform to allow the
distal end of expandable tubular member 1200 to be positioned in
the passageway 1102d of the expandable tubular member 1100. In an
exemplary embodiment, the flange members 1104 are conventional
thread members known in the art and the flange channels 1204 are
conventional thread channels known in the art, and the flange
members 1104 are positioned in the flange channels 1204 by
threading the thread members into the thread channels. In an
exemplary embodiment, the flange members 1104 may be positioned in
the flange channels 1204 using a variety of other conventional
methods known in the art.
[0137] With the expandable tubular member 1200 coupled to the
expandable tubular member 1100, a sealing channel is defined
between the flange member 1104 and the flange channel 1204 and the
O-ring resilient member 1504a is positioned in the sealing channel,
as illustrated in FIGS. 15b and 15c. With the expandable tubular
member 1100 coupled to the expandable tubular member 1200, an
expandable tubular member 1504b is provided.
[0138] Referring now to FIGS. 1, 15a, 15d, and 15e, the method 1500
then proceeds to step 1506 where the expandable tubular members
1100 and 1200 are positioned in the wellbore 100. The expandable
tubular member 1504b is positioned in the passageway 104 of
wellbore 100 such that outer surfaces 1102a and 1202a of the
expandable tubular members 1100 and 1200, respectively, are
positioned adjacent the passageway surface 104a, as illustrated in
FIG. 15d. The method 1500 proceeds to step 1508 where the
expandable tubular members 1100 and 1200 are radially expanded and
plastically deformed. An expansion device 1508a which is coupled to
a drill string 1508b is provided which has larger outside diameter
than the inside diameters of the expandable tubular members 1100
and 1200. The expansion device 1508a is positioned in the
expandable tubular member 1504b and moved in a direction G, as
illustrated in FIG. 15d. Movement of the expansion device 1508a in
direction G expands the expandable tubular members 1100 and 1200
such that the outer surfaces 1102a and 1202a, respectively, engage
the passageway surface 104a of the wellbore 100. In an exemplary
embodiment, the expansion device 1508a may be a fixed diameter
expansion device, a rotary expansion device, a hydroforming device,
combinations thereof, and/or a variety of other expansion devices
known in the art. Furthermore, the expansion of the expandable
tubular member 1504b adjacent the flange member 1104 and the flange
channel 1204 results in the deformation of the O-ring resilient
member 1504a. Deformation of the O-ring resilient member 1504a
provides a gas and liquid tight seal between the expandable tubular
members 1100 and 1200. In an exemplary embodiment, the gas and
liquid tight seal provided between the expandable tubular members
1100 and 1200 is a metal to metal seal. Thus, a method and
apparatus are provided which provide a gas and liquid tight seal
between two expandable tubular members 1100 and 1200 which are
coupled together and radially expanded and plastically
deformed.
[0139] Referring now to FIG. 16, an expandable tubular member 1600
is illustrated. The expandable tubular member 1600 includes a
tubular base 1602 having an outer surface 1602a, and inner surface
1602b located opposite the outer surface 1602a, a distal end 1602c,
and defining a passageway 1602d extending along its length of the
tubular base 1602 to the distal end 1602c. A plurality of flange
members 1604 extend from the inner surface 1602b of the tubular
base 1602 and into the passageway 1602d, each flange member 1604
including a resilient beam 1604a extending from a distal end of the
flange member 1604 at an angle with respect to the flange member
1604 and into the passageway 1602d. In an exemplary embodiment, the
expandable tubular member 1600 is fabricated from a metal
material.
[0140] Referring now to FIGS. 12, 16, 17a, 17b, and 17c, a method
1700 for coupling expandable tubular members is illustrated. The
method 1700 begins at step 1702 where the expandable tubular
members 1200 and 1600, illustrated in FIGS. 12 and 16, are
provided.
[0141] The method 1700 then proceeds to step 1704 where the
expandable tubular members 1200 and 1600 are coupled together. The
expandable tubular member 1600 is coupled to the expandable tubular
member 1200 by positioning the flange members 1604 in the flange
channels 1204. In an exemplary embodiment, the flange members 1604
are positioned in the flange channels 1204 by heating the
expandable tubular member 1100, causing the expandable tubular
member 1100 to expand, which increases the diameter of the
passageway 1602d and allows the distal end of expandable tubular
member 1200 to be positioned in the passageway 1602d of the
expandable tubular member 1600. In an exemplary embodiment, the
flange members 1604 are positioned in the flange channels 1204 by
forcing the distal end of expandable tubular member 1200 into the
passageway 1602d of the expandable tubular member 1600, causing the
expandable tubular member 1600 to elastically deform to allow the
distal end of expandable tubular member 1200 to be positioned in
the passageway 1602d of the expandable tubular member 1100. In an
exemplary embodiment, the flange members 1604 are conventional
thread members known in the art and the flange channels 1204 are
conventional thread channels known in the art, and the flange
members 1604 are positioned in the flange channels 1204 by
threading the thread members into the thread channels. In an
exemplary embodiment, the flange members 1604 may be positioned in
the flange channels 1204 using a variety of other conventional
methods known in the art. With the expandable tubular member 1600
coupled to the expandable tubular member 1200, a sealing channel is
defined between the flange member 1604 and the flange channel 1204
and the resilient beam 1604a is positioned in the sealing channel,
as illustrated in FIGS. 17b and 17c. With the expandable tubular
member 1600 coupled to the expandable tubular member 1200, an
expandable tubular member 1704a is provided.
[0142] Referring now to FIGS. 1, 17a, 17d, and 17e, the method 1700
then proceeds to step 1706 where the expandable tubular members
1200 and 1600 are positioned in the wellbore 100. The expandable
tubular member 1704a is positioned in the passageway 104 of
wellbore 100 such that outer surfaces 1202a and 1602a of the
expandable tubular members 1200 and 1600, respectively, are
positioned adjacent the passageway surface 104a, as illustrated in
FIG. 17d.
[0143] The method 1700 proceeds to step 1708 where the expandable
tubular members 1200 and 1600 are radially expanded and plastically
deformed. An expansion device 1708a which is coupled to a drill
string 1708b is provided which has larger outside diameter than the
inside diameters of the expandable tubular members 1200 and 1600.
The expansion device 1708a is positioned in the expandable tubular
member 1704a and moved in a direction H, as illustrated in FIG.
17d. Movement of the expansion device 1708a in direction H expands
the expandable tubular members 1200 and 1600 such that the outer
surfaces 1202a and 1602a, respectively, engage the passageway
surface 104a of the wellbore 100. In an exemplary embodiment, the
expansion device 1708a may be a fixed diameter expansion device, a
rotary expansion device, a hydroforming device, combinations
thereof, and/or a variety of other expansion devices known in the
art. Furthermore, the expansion of the expandable tubular member
1704a adjacent the flange member 1604 and the flange channel 1204
results in the deformation of the resilient beam 1604a. Deformation
of the resilient beam 1604a provides a gas and liquid tight seal
between the expandable tubular members 1200 and 1600. In an
exemplary embodiment, the gas and liquid tight seal provided
between the expandable tubular members 1200 and 1600 is a metal to
metal seal. Thus, a method and apparatus are provided which provide
a gas and liquid tight seal between two expandable tubular members
1200 and 1600 which are coupled together and radially expanded and
plastically deformed.
[0144] Referring now to FIG. 18, an expandable tubular member 1800
is illustrated. The expandable tubular member 1800 includes a
tubular base 1802 having an outer surface 1802a, and inner surface
1802b located opposite the outer surface 1802a, a distal end 1802c,
and defining a passageway 1802d extending along its length of the
tubular base 1802 to the distal end 1802c. A secondary sealing
surface 1804 is defined by the tubular base 1802 and is located on
the outer surface 1802a and adjacent the distal end 1802c. A
beveled primary sealing surface 1806 is defined by the tubular base
1802 and is located on the inner surface 1802b and adjacent the
distal end 1802c. In an exemplary embodiment, the expandable
tubular member 1800 is fabricated from a metal material.
[0145] Referring now to FIG. 19, an expandable tubular member 1900
is illustrated. The expandable tubular member 1900 includes a
tubular base 1902 having an outer surface 1902a, and inner surface
1902b located opposite the outer surface 1902a, a distal end 1902c,
and defining a passageway 1902d extending along its length of the
tubular base 1902 to the distal end 1902c. A secondary sealing
surface 1904 is defined by the tubular base 1902 and is located on
the outer surface 1902a and adjacent the distal end 1902c. A
beveled primary sealing surface 1906 is defined by the tubular base
1902 and is located on the inner surface 1902b and adjacent the
distal end 1902c. In an exemplary embodiment, the expandable
tubular member 1900 is fabricated from a metal material.
[0146] Referring now to FIG. 20, a connection member 2000 is
illustrated. Connection member 2000 includes a tubular base member
2002 having an outer surface 2002a, and inner surface 2002b located
opposite the outer surface 2002a, a pair of opposing distal ends
2002c and 2002d, and defining a passageway 2002e along the length
of the tubular base member 2002 from distal end 2002c to distal end
2002d. The tubular base member 2002 defines a plurality of
secondary sealing surfaces 2004 on the inner surface 2002b adjacent
the distal ends 2002c and 200d and on the distal ends 2002c and
2002d. A primary sealing member 2006 having a substantially diamond
shaped cross section extends from the inner surface 2002b,
centrally located between the distal ends 2002c and 2002d of the
tubular base member 2002, and into the passageway 2002e. A
reinforcing member 2008 is located on the outer surface 2002a
radially adjacent the primary sealing member 2006 on tubular base
member 2002, and provides a circumferential section of the
connection member 2000 located adjacent the primary sealing member
2006 which is thicker than the rest of the connection member 2000
in order assist in the plastic deformation for the primary sealing
member 2006. In an exemplary embodiment, the connection member 2000
is fabricated from a metal material.
[0147] Referring now to FIGS. 18, 19, 20, 21a, 21 b, and 21c, a
method 2100 for coupling expandable tubular members is illustrated.
The method 2100 begins at step 2102 where the expandable tubular
members 1800 and 1900, illustrated in FIGS. 18 and 19, and the
connection member 2000, illustrated in FIG. 20, are provided. The
method 2100 then proceeds to step 2104 where the expandable tubular
members 1800 and 1900 are coupled together. The connection member
2000 is positioned between the expandable tubular members 1800 and
1900 such that the distal end 2002d on connection member 2000 is
adjacent the distal end 1902c on expandable tubular member 1900 and
the distal end 2002c on connection member 2000 is adjacent the
distal end 1802c on expandable tubular member 1900. The expandable
tubular members 1800 and 1900 are then engaged with the connection
member 2000 such that the beveled primary sealing surfaces 1806 and
1906, respectively, engage the primary sealing member 2006 on
connection member 2000. A coupling member 2104a is them provided
between the secondary sealing surfaces 1804 and 1904 on expandable
tubular members 1800 and 1900, respectively, and the secondary
sealing surfaces 2004 on the connection member 2000, as illustrated
in FIGS. 21b and 21c. In an exemplary embodiment, the coupling
member 2104a may be a variety of coupling members known in the art
such as, for example, a weld.
[0148] Referring now to FIGS. 1, 21a, 21d, and 21e, the method 2100
then proceeds to step 2106 where the expandable tubular members
1800 and 1900 are positioned in the wellbore 100. The expandable
tubular member 2104b is positioned in the passageway 104 of
wellbore 100 such that outer surfaces 1802a and 1902a of the
expandable tubular members 1800 and 1900, respectively, are
positioned adjacent the passageway surface 104a, as illustrated in
FIG. 21d.
[0149] The method 2100 proceeds to step 2108 where the expandable
tubular members 1800 and 1900 are radially expanded and plastically
deformed. An expansion device 2108a which is coupled to a drill
string 2108b is provided which has larger outside diameter than the
inside diameters of the expandable tubular members 1800 and 1900.
The expansion device 2108a is positioned in the expandable tubular
member 2104b and moved in a direction I, as illustrated in FIG.
21d. Movement of the expansion device 2108a in direction I expands
the expandable tubular members 1800 and 1900 such that the outer
surfaces 1802a and 1902a, respectively, engage the passageway
surface 104a of the wellbore 100. In an exemplary embodiment, the
expansion device 2108a may be a fixed diameter expansion device, a
rotary expansion device, a hydroforming device, combinations
thereof, and/or a variety of other expansion devices known in the
art.
[0150] Furthermore, the expansion of the connection member 2000
deforms the coupling member 2104a against the secondary sealing
surfaces 1804, 1904, and 2004, and deforms the primary sealing
member 2006 again the primary sealing surfaces 1806 and 1906, as
illustrated in FIG. 21e, which results in a gas and liquid tight
seal between the expandable tubular members 1800 and 1900 and the
connection member 2000. In an exemplary embodiment, the gas and
liquid tight seal provided between the expandable tubular members
1800 and 1900 and the connection member 2000 is a metal to metal
seal. Thus, a method and apparatus are provided which provide a gas
and liquid tight seal between two expandable tubular members 1800
and 1900 which are coupled together and radially expanded and
plastically deformed.
[0151] An expandable tubular member has been described that
includes a first tubular member comprising a first tubular member
diameter which decreases from a first outside diameter along the
length of the first tubular member to a second outside diameter
adjacent a first tubular member connection end on the first tubular
member, a second tubular member comprising a second tubular member
diameter which decreases from a third outside diameter along the
length of the second tubular member to a fourth outside diameter
adjacent a second tubular member connection end on the second
tubular member, whereby the second tubular member connection end is
positioned adjacent the first tubular member connection end, and a
connection member coupled to the second outside diameter and the
fourth outside diameter, whereby the connection member comprises a
connection member diameter which is not substantially greater than
the first outside diameter and the third outside diameter. In an
exemplary embodiment, the first outside diameter is substantially
equal to the third outside diameter. In an exemplary embodiment,
the second outside diameter is substantially equal to the fourth
outside diameter. In an exemplary embodiment, the connection member
diameter is less than or equal to the first outside diameter and
the third outside diameter. In an exemplary embodiment, the
connection member diameter is less than the first outside diameter
and the third outside diameter. In an exemplary embodiment, the
first tubular member connection end is coupled the second tubular
member connection end. In an exemplary embodiment, a protective
sleeve is coupled to the connection member. In an exemplary
embodiment, the first tubular member, the second tubular member,
and the connection member are positioned in a wellbore.
[0152] An expandable tubular member has been described that
includes a first tubular member comprising a maximum first tubular
member diameter, a second tubular member comprising a maximum
second tubular member diameter, whereby the second tubular member
is positioned adjacent the first tubular member, and means for
allowing a connection member to be coupled to the first tubular
member and the second tubular without a maximum connection member
diameter being substantially greater than the maximum first tubular
member diameter and the maximum second tubular member diameter.
[0153] An expandable tubular member has been described that
includes a tubular member comprising an inner surface and an outer
surface, a thread member extending from the inner surface, and an
expansion channel defined by the tubular member and located on the
outer surface and adjacent the thread member. In an exemplary
embodiment, a plurality of thread members extend from the inner
surface, and an expansion channel is defined by the tubular member
and located on the outer surface and adjacent each of the plurality
of thread members. In an exemplary embodiment, the expansion
channel is located radially adjacent the thread member. In an
exemplary embodiment, the expansion channel comprises a helical
channel on the outer surface of the tubular member. In an exemplary
embodiment, the expansion channel provides a stress concentration
in the thread member during radial expansion and plastic
deformation of the tubular member.
[0154] An expandable tubular member has been described that
includes a tubular member comprising an inner surface and an outer
surface, a thread member extending from the inner surface, and
means for providing a stress concentration in the thread member
during radial expansion and plastic deformation of the tubular
member. In an exemplary embodiment, the means for providing a
stress concentration comprises a helical groove on the outer
surface of the tubular member. In an exemplary embodiment, the
means for providing a stress concentration comprises means for
providing a stress concentration along the length of the thread
member.
[0155] An expandable tubular member has been described that
includes a first tubular member comprising an inner surface and an
outer surface, a thread member extending from the inner surface, an
expansion channel defined by the first tubular member and located
on the outer surface and adjacent the thread member, and a second
tubular member coupled the first tubular member and engaging the
thread member. In an exemplary embodiment, a plurality of thread
members extend from the inner surface, whereby the second tubular
member is coupled to the first tubular member and engaging the
plurality of thread members, and an expansion channel is defined by
the first tubular member and located on the outer surface and
adjacent each of the plurality of thread members. In an exemplary
embodiment, the expansion channel is located radially adjacent the
thread member. In an exemplary embodiment, the first tubular member
and the second tubular member are positioned in a wellbore. In an
exemplary embodiment, the expansion channel comprises a helical
channel on the outer surface of the first tubular member. In an
exemplary embodiment, the expansion channel provides a stress
concentration in the thread member during radial expansion and
plastic deformation of the tubular member. In an exemplary
embodiment, a tubular connection sleeve is positioned on the first
tubular member, and an expansion slot is defined by the tubular
connection sleeve in a substantially axial orientation with respect
to the tubular connection sleeve and located adjacent the expansion
channel. In an exemplary embodiment, the expansion slot is oriented
substantially perpendicularly with respect to the expansion
channel. In an exemplary embodiment, a plurality of spaced apart
expansion slots are defined by the tubular connection sleeve in a
substantially axial orientation with respect to the tubular
connection sleeve and located adjacent the expansion channel. In an
exemplary embodiment, the plurality of spaced apart expansion slots
are oriented substantially perpendicularly with respect to the
expansion channel. In an exemplary embodiment, the plurality of
spaced apart expansion slots are spaced apart about the
circumference of the tubular connection sleeve. In an exemplary
embodiment, the first tubular member the second tubular member, and
the tubular connection sleeve are positioned in a wellbore. In an
exemplary embodiment, the expansion slot on the tubular connection
sleeve provides at least one discrete point stress concentration on
the thread member during radial expansion and plastic deformation
of the first tubular member.
[0156] An expandable tubular member has been described that
includes a first tubular member comprising an inner surface and an
outer surface, a thread member extending from the inner surface, an
expansion channel defined by the first tubular member and located
on the outer surface and adjacent the thread member, a tubular
connection sleeve positioned on the first tubular member, an
expansion slot defined by the tubular connection sleeve in a
substantially axial orientation with respect to the tubular
connection sleeve and located adjacent the expansion channel, and a
second tubular member coupled the first tubular member and engaging
the thread member, whereby upon radial expansion and plastic
deformation of the first tubular member and the second tubular
member, the first tubular member and the second tubular member can
withstand a pressure of up to approximately 4000 pounds per square
inch.
[0157] An expandable tubular member has been described that
includes a first tubular member defining a flange channel on a
first surface of the first tubular member, and resilient means
positioned in the flange channel for forming a seal between the
first tubular member and a second tubular member. In an exemplary
embodiment, the resilient means for forming a seal comprises means
for forming a metal to metal seal. In an exemplary embodiment, the
resilient means comprises a wave spring. In an exemplary
embodiment, the resilient means comprises an O-ring.
[0158] An expandable tubular member has been described that
includes a first tubular member comprising a flange member
extending from a surface on the first tubular member, the flange
member comprising a resilient beam extending from a distal end of
the flange member for forming a seal between the first tubular
member and a second tubular member.
[0159] An expandable tubular member has been described that
includes a first tubular member defining a flange channel on a
surface of the first tubular member, a second tubular member
comprising a flange member extending from a surface on the second
tubular member, the second tubular member coupled to the first
tubular member with the flange member positioned in the flange
channel, whereby a sealing passageway is defined between the flange
member and the flange channel, and resilient means for forming a
seal between the first tubular member and the second tubular member
positioned in the sealing passageway. In an exemplary embodiment,
the resilient means for forming a seal comprises means for forming
a metal to metal seal. In an exemplary embodiment, the resilient
member comprises a wave spring. In an exemplary embodiment, the
wave spring is positioned in the sealing passageway and
circumferentially between the flange member and the flange channel.
In an exemplary embodiment, the first tubular member, the second
tubular member, and the wave spring are positioned in a wellbore.
In an exemplary embodiment, the resilient member comprises an
O-ring. In an exemplary embodiment, the O-ring is positioned in the
sealing passageway and circumferentially between the flange member
and the flange channel. In an exemplary embodiment, the first
tubular member, the second tubular member, and the O-ring are
positioned in a wellbore. In an exemplary embodiment, the resilient
member comprises a resilient beam extending from a distal end of
the flange member. In an exemplary embodiment, the resilient beam
is located in the sealing passageway and circumferentially between
the flange member and the flange channel. In an exemplary
embodiment, the first tubular member, the second tubular member,
and the resilient beam are positioned in a wellbore.
[0160] A connection member for coupling expandable tubular members
has been described that includes a tubular connection member
comprising an inner surface and an outer surface, a primary sealing
member having a substantially diamond shaped cross section and
extending from a substantially central location on the inner
surface, a reinforced section located on the outer surface and
adjacent the primary sealing member, and a plurality of secondary
sealing surfaces located on opposite distal ends of the tubular
connection member and on opposite sides of the primary sealing
member. In an exemplary embodiment, the primary sealing member is
deformable to provide a metal to metal seal between the tubular
connection member and an expandable tubular member. In an exemplary
embodiment, the plurality of secondary sealing surfaces are
deformable to provide a metal to metal seal between the tubular
connection member and an expandable tubular member.
[0161] A connection member for coupling expandable tubular members
has been described that includes a tubular connection member, and
means for providing a primary and secondary metal to metal seal
between the tubular connection member and an expandable tubular
member.
[0162] An expandable tubular member has been described that
includes a first tubular member comprising a first connection end,
a second tubular member comprising a second connection end, and a
connection member coupling together the first tubular member and
the second tubular member, the connection member including a
tubular connection member comprising an inner surface and an outer
surface, the inner surface engaging the first tubular member and
the second tubular member, a primary sealing member having a
substantially diamond shaped cross section, extending from a
substantially central location on the inner surface, and positioned
between the first connection end and the second connection end, a
reinforced section located on the outer surface and adjacent the
primary sealing member, and a plurality of secondary sealing
surfaces located on opposite distal ends of the tubular connection
member and on opposite sides of the primary sealing member, the
secondary sealing surfaces coupled to the first connection end and
the second connection end. In an exemplary embodiment, the primary
sealing member is deformable to provide a metal to metal seal
between the connection member and the first tubular member and the
second tubular member. In an exemplary embodiment, the plurality of
secondary sealing surfaces are deformable to provide a metal to
metal seal between the connection member and the first tubular
member and the second tubular member. In an exemplary embodiment,
the first tubular member, the second tubular member, and the
connection member are positioned in a wellbore.
[0163] An expandable tubular member has been described that
includes a first tubular member comprising a first connection end,
a second tubular member comprising a second connection end, a
connection member coupled to the first connection end and the
second connection end, and means for providing a primary and
secondary metal to metal seal between the connection member and the
first tubular member and the second tubular member.
[0164] A method for coupling expandable tubular members has been
described that includes providing a first tubular member comprising
a maximum first tubular member diameter, providing a second tubular
comprising a maximum second tubular member diameter, and coupling
the first tubular member to the second tubular member with a
connection member comprising a maximum connection member diameter
which is not substantially greater than the maximum first tubular
member diameter and the maximum second tubular member diameter. In
an exemplary embodiment, the method further includes coupling a
protective sleeve adjacent the connection member. In an exemplary
embodiment, the method further includes positioning the first
tubular member, the second tubular member, and the connection
member in a wellbore. In an exemplary embodiment, the method
further includes radially expanding and plastically deforming the
first tubular member and the second tubular member. In an exemplary
embodiment, the radially expanding and plastically deforming
comprises radially expanding and plastically deforming a first
reduced diameter section on the first tubular member to
substantially the maximum first tubular member diameter and
radially expanding and plastically deforming a second reduced
diameter section on the second tubular member to substantially the
maximum second tubular member diameter. In an exemplary embodiment,
the radially expanding and plastically deforming comprises radially
expanding and plastically deforming the first tubular member and
the second tubular member into engagement with the wellbore.
[0165] A method for coupling expandable tubular members has been
described that includes providing a first tubular member comprising
a thread member extending from an inner surface and defining a
expansion channel on the outer surface which is located adjacent
the thread member, and coupling a second tubular member to the
first tubular member by engaging the thread member with a thread
channel in the second tubular member. In an exemplary embodiment,
the method further includes positioning the first tubular member
and the second tubular member in a wellbore. In an exemplary
embodiment, the method further includes radially expanding and
plastically deforming the first tubular member and the second
tubular member, whereby the expansion channel provides a stress
concentration in the thread member which increases the deformation
of the thread member in the thread channel during the radially
expanding and plastically deforming. In an exemplary embodiment,
the radially expanding and plastically deforming provides a metal
to metal seal between the thread member and the thread channel. In
an exemplary embodiment, the method further includes coupling a
connection sleeve to the outer surface of the of the first tubular
member, the connection sleeve defining an expansion slot oriented
axially with respect the connection sleeve and which is positioned
substantially perpendicularly to the expansion channel. In an
exemplary embodiment, the method further includes positioning the
first tubular member, the second tubular member, and the connection
sleeve in a wellbore. In an exemplary embodiment, the method
further includes radially expanding and plastically deforming the
first tubular member, the second tubular member, and the connection
sleeve, whereby the expansion slot and the expansion channel
provide a stress concentration which increases the deformation of
the thread member in the thread channel during the radially
expanding and plastically deforming. In an exemplary embodiment,
the radially expanding and plastically deforming provides a metal
to metal seal between the thread member and the thread channel.
[0166] A method for coupling expandable tubular members has been
described that includes providing a first tubular member comprising
a flange member extending from an inner surface, providing a second
tubular member defining a flange channel on an outer surface,
positioning a resilient member in the flange channel, and coupling
the first tubular member to the second tubular member by
positioning the flange member in the flange channel and adjacent
the resilient member. In an exemplary embodiment, the method
further includes positioning the first tubular member and the
second tubular member in a wellbore. In an exemplary embodiment,
the method further includes radially expanding and plastically
deforming the first tubular member and the second tubular member,
whereby the radially expanding and plastically deforming compresses
the resilient member and provides a seal between the flange member
and the flange channel. In an exemplary embodiment, the radially
expanding and plastically deforming provides a metal to metal seal
between the flange member and the flange channel.
[0167] A method for coupling expandable tubular members has been
described that includes providing a first tubular member comprising
a first connection end, providing a second tubular member
comprising a second connection end, positioning a connection member
adjacent the first connection end and the second connection end
such that a primary sealing member on the connection member is
positioned between the first connection end and the second
connection end, and a plurality of secondary sealing surfaces are
positioned adjacent the first tubular member and the second tubular
member, and coupling the first tubular member to the second tubular
member using the connection member. In an exemplary embodiment, the
coupling includes providing a metal sealing member between the
first tubular member, the second tubular member, and the secondary
sealing surfaces. In an exemplary embodiment, the method further
includes positioning the first tubular member, the second tubular
member, and the connection member in a wellbore. In an exemplary
embodiment, the method further includes radially expanding and
plastically deforming the first tubular member and the second
tubular member, whereby the radially expanding and plastically
deforming provides a primary seal between the primary sealing
member and the first tubular member and the second tubular member,
and the radially expanding and plastically deforming provides a
secondary seal between the secondary sealing surfaces and the first
tubular member and the second tubular member.
[0168] An expandable tubular member has been described that
includes a first tubular member, a second tubular member coupled to
the first tubular member, and means for effecting a gas and fluid
tight seal between the first tubular member and the second tubular
member before, during, and after radial expansion and plastic
deformation of the first tubular member and the second tubular
member, the means providing a seal which can withstand a pressure
of up to 4000 pounds per square inch.
[0169] An expandable tubular member has been described that
includes a first tubular member comprising a first tubular member
diameter which decreases from a first outside diameter along the
length of the first tubular member to a second outside diameter
adjacent a first tubular member connection end on the first tubular
member, a second tubular member comprising a second tubular member
diameter which decreases from first outside diameter along the
length of the second tubular member to the second outside diameter
adjacent a second tubular member connection end on the second
tubular member, whereby the second tubular member connection end is
coupled to the first tubular member connection end, and a
connection member coupled to the second outside diameter, whereby
the connection member comprises a connection member diameter which
is less than or equal to the first outside diameter.
[0170] An expandable tubular member has been described that
includes a tubular member comprising an inner surface and an outer
surface, a plurality of thread members extending from the inner
surface, and a helical expansion channel defined by the tubular
member and located on the outer surface and radially adjacent each
of the plurality of thread members, whereby the expansion channel
provides a stress concentration in the thread member during radial
expansion and plastic deformation of the tubular member.
[0171] An expandable tubular member has been described that
includes a first tubular member comprising an inner surface and an
outer surface, a plurality of thread member extending from the
inner surface, a helical expansion channel defined by the first
tubular member and located on the outer surface and radially
adjacent each of the plurality of thread members, a second tubular
member coupled the first tubular member and engaging the plurality
of thread members, whereby the expansion channel provides a stress
concentration in the thread member during radial expansion and
plastic deformation of the first tubular member and the second
tubular member, a tubular connection sleeve positioned on the first
tubular member, and a plurality of spaced apart expansion slots
defined by the tubular connection sleeve in a substantially axial
orientation with respect to the tubular connection sleeve and
oriented substantially perpendicularly adjacent to and with respect
to the expansion channel; whereby the plurality of expansion slots
on the tubular connection sleeve provides a plurality of discrete
point stress concentrations on the thread member during radial
expansion and plastic deformation of the first tubular member, the
second tubular member, and the connection sleeve.
[0172] A connection member for coupling expandable tubular members
has been described that includes a tubular connection member
comprising an inner surface and an outer surface, a primary sealing
member having a substantially diamond shaped cross section,
extending from a substantially central location on the inner
surface, and deformable to provide a metal to metal seal between
the tubular connection member and an expandable tubular member, a
reinforced section located on the outer surface and adjacent the
primary sealing member, and a plurality of secondary sealing
surfaces located on opposite distal ends of the tubular connection
member on opposite sides of the primary sealing member, and
deformable to provide a metal to metal seal between the tubular
connection member and an expandable tubular member.
[0173] An expandable tubular member has been described that
includes a first tubular member comprising a first connection end,
a second tubular member comprising a second connection end, and a
connection member coupling together the first tubular member and
the second tubular member, the connection member including a
tubular connection member comprising an inner surface and an outer
surface, the inner surface engaging the first tubular member and
the second tubular member, a primary sealing member having a
substantially diamond shaped cross section, extending from a
substantially central location on the inner surface, positioned
between the first connection end and the second connection end, and
deformable to provide a metal to metal seal between the connection
member and the first tubular member and the second tubular member,
a reinforced section located on the outer surface and adjacent the
primary sealing member, and a plurality of secondary sealing
surfaces located on opposite distal ends of the tubular connection
member and on opposite sides of the primary sealing member, the
secondary sealing surfaces coupled to the first connection end and
the second connection end and deformable to provide a metal to
metal seal between the connection member and the first tubular
member and the second tubular member.
[0174] A method for coupling expandable tubular members has been
described that includes providing a first tubular member comprising
a maximum first tubular member diameter, providing a second tubular
comprising a maximum second tubular member diameter, coupling the
first tubular member to the second tubular member with a connection
member comprising a maximum connection member diameter which is not
substantially greater than the maximum first tubular member
diameter and the maximum second tubular member diameter,
positioning the first tubular member, the second tubular member,
and the connection member in a wellbore, and radially expanding and
plastically deforming the first tubular member and the second
tubular member, wherein the radially expanding and plastically
deforming comprises one of either radially expanding and
plastically deforming a first reduced diameter section on the first
tubular member to substantially the maximum first tubular member
diameter and radially expanding and plastically deforming a second
reduced diameter section on the second tubular member to
substantially the maximum second tubular member diameter or
radially expanding and plastically deforming the first tubular
member and the second tubular member into engagement with the
wellbore.
[0175] A method for coupling expandable tubular members has been
described that includes providing a first tubular member comprising
a thread member extending from an inner surface and defining a
expansion channel on the outer surface which is located adjacent
the thread member, coupling a connection sleeve to the outer
surface of the of the first tubular member, the connection sleeve
defining an expansion slot oriented axially with respect the
connection sleeve and which is positioned substantially
perpendicularly to the expansion channel, coupling a second tubular
member to the first tubular member by engaging the thread member
with a thread channel in the second tubular member, positioning the
first tubular member, the second tubular member, and the connection
sleeve in a wellbore, and radially expanding and plastically
deforming the first tubular member, the second tubular member, and
the connection sleeve, whereby the expansion slot and the expansion
channel provide a stress concentration which increases the
deformation of the thread member in the thread channel during the
radially expanding and plastically deforming and provides a metal
to metal seal between the thread member and the thread channel.
[0176] A method for coupling expandable tubular members has been
described that includes providing a first tubular member comprising
a flange member extending from an inner surface, providing a second
tubular member defining a flange channel on an outer surface,
positioning a resilient member in the flange channel, coupling the
first tubular member to the second tubular member by positioning
the flange member in the flange channel and adjacent the resilient
member, positioning the first tubular member and the second tubular
member in a wellbore, and radially expanding and plastically
deforming the first tubular member and the second tubular member,
whereby the radially expanding and plastically deforming compresses
the resilient member and provides a seal between the flange member
and the flange channel; whereby the radially expanding and
plastically deforming provides a metal to metal seal between the
flange member and the flange channel.
[0177] A method for coupling expandable tubular members has been
described that includes providing a first tubular member comprising
a first connection end, providing a second tubular member
comprising a second connection end, positioning a connection member
adjacent the first connection end and the second connection end
such that a primary sealing member on the connection member is
positioned between the first connection end and the second
connection end, and a plurality of secondary sealing surfaces are
positioned adjacent the first tubular member and the second tubular
member, coupling the first tubular member to the second tubular
member using the connection member, whereby the coupling includes
providing a metal sealing member between the first tubular member,
the second tubular member, and the secondary sealing surfaces,
positioning the first tubular member, the second tubular member,
and the connection member in a wellbore, and radially expanding and
plastically deforming the first tubular member and the second
tubular member, whereby the radially expanding and plastically
deforming provides a primary seal between the primary sealing
member and the first tubular member and the second tubular member,
and the radially expanding and plastically deforming provides a
secondary seal between the secondary sealing surfaces and the first
tubular member and the second tubular member.
[0178] It is understood that variations may be made in the
foregoing without departing from the scope of the invention.
Furthermore, the elements and teachings of the various illustrative
embodiments may be combined in whole or in part in some or all of
the illustrative embodiments. In addition, one or more of the
elements and teachings of the various illustrative embodiments may
be omitted, at least in part, and/or combined, at least in part,
with one or more of the other elements and teachings of the various
illustrative embodiments.
[0179] Although illustrative embodiments of the invention have been
shown and described, a wide range of modification, changes and
substitution is contemplated in the foregoing disclosure. In some
instances, some features of the present invention may be employed
without a corresponding use of the other features. Accordingly, it
is appropriate that the appended claims be construed broadly and in
a manner consistent with the scope of the invention.
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