Note: Descriptions are shown in the official language in which they were submitted.
SETTING TOOL FOR SETTING A DOWNHOLE TOOL
Cross-Reference to Related Applications
[0001] This application claims the benefit of U.S. Provisional Application
Serial No. 63/017,471, filed
April 29, 2020, the content of which is hereby incorporated by reference in
its entirety.
Field
[0002] The invention relates to a tool for performing downhole operations, and
in particular to
a setting tool for setting downhole tools.
Background
[0003] A conventional setting tool for setting downhole tools, such as bridge
plugs, frac plugs,
packers, composite plugs, cement retainers, etc., uses an explosive power
charge within the
setting tool to create pressure that is then converted into the mechanical
force required to set
the downhole tool. The conventional setting tool also uses hydraulic oil
located between a first
piston disposed In a first cylinder and a second piston disposed in a second
cylinder. The first
piston in the first cylinder is pushed directly by power charge gases
resulting from the ignition
and explosion of the power charge and in turn pushes the hydraulic oil, which
then pushes the
second piston in the second cylinder. The second piston is then typically
connected by a rod and
linkage to a setting sleeve for pushing against and setting the downhole tool
in the wellbore
casing.
[0004] The downhole tool typically has a central mandrel that is attached to a
fixed portion of
the setting tool and is stationary relative to the fixed portion of the
setting tool. The setting sleeve
usually extends around the outer circumference of the downhole tool central
mandrel and the
=
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Date Recue/Date Received 2021:04-29
setting tool operates to stroke the setting sleeve downward relative to the
fixed portion and the
central mandrel against an uppermost sleeve of the downhole tool. The
uppermost sleeve then
moves downward relative to the central mandrel toward a lower end of the
mandrel and sets the
downhole tool by, for example, pushing anchor slips over conical elements and
pressing an
eiastomeric seal element between the mandrel and the casing. During setting of
the downhole
tool, a shear pin is sheared to release the setting tool from the downhole
tool so that the setting
tool may be retrieved from the well and be redressed for repeated later use.
[0005] The conventional setting tool has seven sets of seals that protect the
inner workings of
the tool from the well environment. Also, the hydraulic oil is placed in an
oil chamber which must
be filled properly depending on the temperature in the well, Leakage of any of
the seals and/or
improper filling of the hydraulic oil in the oil chamber can negatively impact
the setting tool's
performance and the entire completion operation. For example, if the seals in
the oil chamber
fail, the hydrostatic pressure will work against the second piston to pre-
stroke the setting tool. In
a further example, if there is too much hydraulic oil in the oil chamber,
temperature in the well
can cause the hydraulic oil to expand, which exerts an unwanted force on the
piston and
prematurely stroking the setting tool. Still further, too little hydraulic oil
may limit the required
stroke, thereby possibly keeping the setting tool from fully setting the
downhole tool. Further,
leakage of any seal may lead to wetting of the power charge, which may prevent
the power
charge from igniting as intended.
[0006] To reuse the conventional setting tool, the setting tool needs to be
redressed in between
runs. There are risks and labour costs associated with redressing the setting
tool. If the setting
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Date Recue/Date Received 2021-04-29
tool is not rebuilt properly, the setting tool may set prematurely or not at
all, as described above.
Further, to dispose of the conventional setting tool, the setting tool is
usually taken apart to
retrieve the hydraulic fluids prior to the disposal of the other components
thereof.
[0007] The present disclosure thus aims to address the above-mentioned
shortcomings of the
conventional setting tool.
Summary
[0008] According to a broad aspect of the present disclosure, there is
provided a setting tool for
use with a down hole tool, the setting tool having a run-in position and a set
position, the setting
tool comprising: a housing having a housing upper end, a housing lower end, a
housing wall
having a housing inner surface defining an axially extending housing inner
bore; a setting mandrel
having a mandrel upper end, a mandrel lower end, a mandrel wall having a
mandrel outer surface
and a mandrel inner surface, the mandrel inner surface defining an axially
extending mandrel
inner bore, the mandrel upper end being connected to the housing lower end; a
piston
comprising an upper open end and a lower closed end, at least a portion of the
piston being'
disposed in the housing inner bore, and the at least a portion of the piston
comprising a piston
head in sealing engagement with the inner surface of the housing wall, the
piston having defined
therein a power charge chamber extending between the upper open end and the
lower closed
end, the power charge chamber being in fluid communication with the housing
inner bore via
the upper open end, the piston configured to be slidably movable axially
relative to the housing
and the setting mandrel; a power charge, at least a portion of the power
charge being disposed
in the power charge chamber; and a crosslink sleeve supported about the
mandrel outer surface,
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Date Recue/Date Received 2021-04-29
wherein the setting tool is actuated upon ignition of the power charge to
transition from the run-
in position to the set position; in the run-in position, the crosslink sleeve
is secured to the setting
mandrel such that the crosslink sleeve is stationary relative to the setting
mandrel; and in the set
position, the piston is moved axially relative to the housing towards the
mandrel lower end, and
the crosslink sleeve is shifted axially, by the axial movement of the piston,
relative to the setting
mandrel towards the mandrel lower end.
[0009] In some embodiments, the piston head comprises an upper piston face and
a lower piston
face, and the piston comprises a piston rod extending axially from the lower
piston face to the
lower closed end, at least a portion of the piston rod configured to be
slidably movable axially in
the mandrel inner bore.
[0010] In some embodiments, an upper pressure chamber and a lower pressure
chamber are
defined in the housing inner bore, the upper pressure chamber being adjacent
to the upper
piston face and the lower pressure chamber being adjacent to the lower piston
face, and the
volume of the upper pressure chamber in the set position is greater than that
in the run-position,
and the volume of the lower pressure chamber in the set position is less than
that in the run-
position.
[0011] In some embodiments, the housing wall has defined therethrough a vent
port to allow
fluid communication between the housing inner bore and the exterior of the
housing, and in the
run-in position, the vent port is in fluid communication with the lower
pressure chamber,
[0012] In some embodiments, in the set position, the vent port is in fluid
communication with
the upper pressure chamber.
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Date Recue/Date Received 2021-04-29
[00131 In some embodiments, upon the ignition of the power charge, a gas in
the power charge
chamber is released into the upper pressure chamber via the upper open end.
[0014] In some embodiments, in the run-in position, the setting tool comprises
a breakable seal
disposed in the vent port to block fluid flow through the vent port, and in
the set position, the
breakable seal is broken to permit fluid flow through the vent port.
(0015] In some embodiments, the setting tool comprises an annular plug sea
lingly attached to
the housing inner surface below the vent port, the annular plug having a
central aperture through
which a portion of the piston rod is scalingly received,
[0015] In some embodiments, the setting tool comprises a crosslink key coupled
to the crosslink
sleeve, and the mandrel wall has defined therethrough an axially extending
slot in which a portion
of the crosslink key is received, the portion of the crosslink key being
slidably movable along the
length of the axially extending slot, and the piston is configured to directly
engage the crosslink
key,
[0017] In some embodiments, the setting tool comprises a retainer for securing
the crosslink key
to the crosslink sleeve and the portion of the crosslink key in the axially
extending slot.
[0018] In some embodiments, the setting tool comprises a shear screw, and
wherein in the run-
in position, the crosslink sleeve is secured to the setting mandrel by the
shear screw, and in the
set-position, the shear screw is broken to permit axial movement of the
crosslink sleeve relative
to the setting mandrel.
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Date Recue/Date Received 2021-04-29
[0019] In some embodiments, one or both of: the setting mandrel is configured
to connect to a
mandrel of the downhole tool; and the crosslink sleeve is configured to
connect to a setting
=
sleeve of the downhole tool.
(0020] In some embodiments, one or both of: the setting mandrel is a mandrel
of the downhole
tool; and the crosslink sleeve is a setting sleeve of the downhole tool.
[0021] In some embodiments, the setting tool is free of hydraulic fluid.
[0022] In some embodiments, in the run-in position, the lower pressure chamber
contains a
liquid.
[00231 In some embodiments, the piston rod comprises a piston rod wall, and
the housing wall
has a thickness in the range of 0.5" and 0.9" and the piston rod wall has a
thickness in the range
of 0.2" and 0.5".
[0024] According to another broad aspect of the present disclosure, there is
provided a method
for setting a downhole tool in a weilbore, the downhole tool being attached to
a setting tool, the
method comprising: igniting a power charge disposed in a power charge chamber
defined in a
piston disposed in a housing of the setting tool, to release a gas from an
upper open end of the
power charge chamber; increasing, by the gas, a first pressure in an upper
pressure chamber in
the housing above the piston to provide an increased first pressure in the
upper pressure
chamber, the upper pressure chamber being in fluid communication with the
upper open end of
the power charge chamber; exerting an axial force on the piston by the
increased first pressure
in the upper pressure chamber; engaging, by the piston, a crosslink key
coupled to a crosslink
sleeve supported on an outer surface of a setting mandrel connected a lower
end of the housing,
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Date Recue/Date Received 2021-04-29
the crosslink sleeve being axially locked to the setting mandrel; releasing,
by the axial force, the
crosslink sleeve from the setting mandrel; shifting, by the axial force, the
piston axially in a
downhole direction relative to the housing; pushing, by the piston, the
crosslink key axially in the
downhole direction relative to the setting mandrel to shift the crosslink
sleeve downward relative
to the housing; and shifting, by the crosslink sleeve, a setting sleeve of the
downhole tool.
[0025] In some embodiments, the method comprises, while shifting the piston,
releasing a
second pressure in a lower pressure chamber in the housing through a vent port
in a wall of the
housing, the lower pressure chamber being below the upper pressure chamber.
[0026] In some embodiments, the method comprises, after shifting the setting
sleeve of the
downhole tool, releasing at least some of the increased first pressure through
the vent port.
[0027] In some embodiments, a portion of the crosslink key is received in an
axially extending
= slot defined through a wall of the setting mandrel, and pushing the
crosslink key comprises
pushing the crosslink key downward along a length of the axially extending
slot,
[0028] In some embodiments, the method comprises one or both of: while
releasing the crosslink
sleeve, absorbing shock by a plug secured to an inner surface of the housing;
and absorbing shock
by the plug when the piston reaches the end of a downward stroke, wherein a
portion of the
piston is received through the plug.
[0029] In some embodiments, the method comprises retrieving the setting tool
from the
wellbore by wireline.
.. Brief Description of the Drawings
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Date Recue/Date Received 2021-04-29
[0030] The invention will now be described by way of an exemplary embodiment
with reference
to the accompanying simplified, diagrammatic, not-to-scale drawings. Any
dimensions provided
in the drawings are provided only for illustrative purposes, and .do not limit
the invention as
defined by the claims. In the drawings:
[0031] FIG. 1 is a perspective view of a setting tool, shown in a run-in
position, according to
embodiments of the present disclosure.
[0032] FIG. 2 is a longitudinal cross-sectional view of the setting tool of
FIG. 1.
[0033] FIG. 3 is a longitudinal cross-sectional view of the setting tool of
FIG. 1, shown in a set
position, according to embodiments of the present disclosure.
[0034] FIG. 4 is a perspective longitudinal cross-sectional view of the
setting tool of FIG. 1.
Detailed Description of the Invention
[0035] When describing the present invention, all terms not defined herein
have their common
art-recognized meanings. To the extent that the following description is of a
specific embodiment
or a particular use of the invention, it is intended to be illustrative only,
and not limiting of the
claimed invention. The following description is intended to cover all
alternatives, modifications
and equivalents that are included in the spirit and scope of the invention, as
defined in the
appended claims.
[0036] In some embodiments, the setting tool of the present disclosure is
configured to: have
fewer seals than the conventional setting tool; be dry fired, without the use
of hydraulic oil; and
be disposable after one use, if desired.
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Date Recue/Date Received 2021-04-29
[0037] FIGs, 1 to 4 illustrate a setting tool 20 that can be attached to a
downhole tool to be set
(not shown) such as a bridge plug, frac plug, packer, composite plug, cement
retainer, etc., and
the setting tool 20 is configured to be run into a wellbore with the downhole
tool attached
thereto, for selectively setting the downhole tool when the downhole tool is
in a desired location
in the welibore. In FIGs, 1, 2, and 4, the setting tool 20 is shown in a run-
in position. In FIG. 3, the
setting tool 20 is shown in a set position.
[0038] With reference to FIGs. 1 to 4, the setting tool 20 generally comprises
a housing 22, a
piston 24, a power charge 26, a setting mandrel 28, a crosslink sleeve 30, and
a crosslink key 32,
all between a first end 40 and a second end 42 of the setting tool 20. In some
embodiments, the
setting tool 20 has a central longitudinal axis x about which the housing 22,
the piston 24, the
setting mandrel 28, and the crosslink sleeve 30 coaxially extend.
[0039] In some embodiments, the housing 22 is a generally tubular member
having a wall with
an inner surface defining an inner axial bore 34 extending from a first end 36
to a second end 38
of housing 22. In some embodiments, the housing 22 may be generally
cylindrical in shape. In the
illustrated embodiment, the first end 36 of housing 22 coincides with the
first end 40 of the
setting tool 20. In some embodiments, the first end 36 and/or the first end 40
is a pin end
configured to receive a setting tool firing head (not shown) and may be
externally threaded for
threaded connection with the firing head. The second end 38 of housing 22 is
opposite the first
end 36 and is closer to second end 42 of the tool 20 than the first end 36. In
some embodiments,
the second end 38 is a box end for receiving a first end 72 of the setting
mandrel 28. The box end
38 may be internally threaded for threaded connection with the first end 72 of
the setting
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Date Recue/Date Received 2021-04-29
mandrel 28. In some embodiments, the interface between the housing 22 and
setting mandrel
28 may be fluidly sealed when the housing 22 is connected to the mandrel 28.
[0040] In the illustrated embodiment, the piston 24 comprises a piston head 46
having a first
piston face 47 and a second piston face opposite the first piston face 47. The
piston 24 also
comprises a piston rod 48 extending laterally from and substantially
orthogonal to the second
piston face of the piston head 46. The piston rod 48 has a first end that is
affixed to the second
piston face of the piston head 46 and a free end 68 opposite the first end. In
the illustrated
embodiment, the piston rod 48 has a substantially uniform outer diameter along
its length and
the piston rod's outer diameter is smaller than the outer diameter of the
piston head 46. The
piston rod 48 may be generally cylindrical in shape.
[0041] The piston 24 is configured to be slidably movable axially in inner
bore 34, along axis x,
relative to housing 22. In some embodiments, at least a portion of the piston
24 is disposed in
housing 22. In the illustrated embodiment, the piston head 46 and at least a
portion of the piston
rod 48 are disposed in inner bore 34 of the housing 22, with the piston head
46 being closer to
the first end 40 than the piston rod 48. In some embodiments, the piston rod
48 extends axially
in inner bore 34, from the second piston face to and through the second end 38
of the housing
22.
[0042] In some embodiments, the setting tool 20 comprises an annular plug 54
positioned in the
inner bore 34. In some embodiments, the plug 54 is fixedly coupled to the
inner surface of
housing 22 so that the plug 54 is stationary relative to the housing 22. Plug
54 may be coupled to
the housing 22 by interference fit, threaded connection, or other methods
known to those skilled
Date Recue/Date Received 2021-04-29
in the art. In some embodiments, the plug 54 is sealingly coupled to the inner
surface of housing
22. The plug 54 has a central aperture for slidably receiving an axial portion
of the piston rod 48
therethrough. When the piston 24 is disposed in the housing 22, piston rod 48
extends through
the central aperture of the plug 54 and the free end 68 of the piston rod 48
may extend into an
inner bore 70 of the setting mandrel 28 via the first end 72 of the mandrel
28. The piston rod 48
and the inner bore 70 are sized such that the piston rod 48 is slidably
movable axially along axis
x, through plug 54, in inner bore 70 relative to the setting mandrel 28.
In'some embodiments,
the plug 54 is configured to support the piston rod 48, to help keep the
piston rod 48
concentrically situated relative to the housing 22 and/or the setting mandrel
28. In some
embodiments, the outer surface of piston rod 48 is in sealing engagement with
the plug 54 while
the piston rod 48 moves through the central aperture of the plug 54.
[0043] The outer diameter of the piston head 46 is larger than the diameters
of the central
aperture of plug 54 such that the piston head 46 cannot fit through plug 54.
The plug 54 acts as
a stop to limit the axial movement of the piston head 46 within housing 22
towards the second
end 42, to help maintain the piston head 46 within housing 22. In some
embodiments, the inner
surface of the housing 22 has an inwardly radially extending shoulder 66 near
the first end 36.
The shoulder 66 is configured to limit the axial movement of the piston 24
towards the first end
36. The shoulder 66 reduces the diameter of a portion of inner bore 34, near
first end 36, such
that the outer diameter of the piston head 46 is greater than the reduced
diameter, thus
preventing the piston head 46 from moving past first end 36.
11
Date Recue/Date Received 2021-04-29
[0044] The piston 24 functions to fluidly separate the inner bore 34 into a
first pressure chamber
SO and a second pressure chamber 52. The first pressure chamber SO is defined
adjacent the first
end 40, between the inner surface of the housing 22 and the first piston face
47. The first pressure
chamber 50 provides a space for receiving a power charge ignitor (not shown).
The second
pressure chamber 52 is defined between the second piston face of the piston
head 46, the inner
surface of housing 22, the outer surface of the piston rod 48, and the annular
plug 54. In some
ern bodirnents, to fluidly separate the pressure chambers 50, 52, the piston
head 46 is configured
to sealingly engage an axial portion of the Inner surface of the housing 22.
In some embodiments,
the piston head 46 has a groove defined on its outer surface and a seal 62 is
received in the
groove to sealingly engage the inner surface of the housing 22. The seal 62
may be an annular
seal, such as an 0-ring.
[0045] When the setting tool 20 is in the set position shown in FIG. 3, the
piston 24 is shifted
towards the second end 42 compared to the run-in position shown in FIGs. 2 and
4. The piston
head 46 in the set position (FIG. 3) is closer to the annular plug 54 than in
the run-in position
(FIG. 2 and 4). Accordingly, the volume of the first pressure chamber 50 is
greater in the set
position than that in the run-in position, and the volume of the second
pressure chamber 52 in
the set position is less than that in the run-in position. The volume of the
first pressure chamber
50 increases and the volume of the second pressure chamber 52 correspondingly
decreases
during the setting tool's transition from the run-position to the set
position.
[0046] The housing 22 has a vent port 56 extending through its wall to allow
fluid communication
between the inner bore 34 and the exterior of the housing 22. In the
illustrated embodiment, the
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Date Recue/Date Received 2021-04-29
vent port 56 is positioned axially between the first end 36 of housing 22 and
the annular plug 54.
In some embodiments, the vent port 56 may be covered by a breakable seal such
as a burst disc
or blowout plug, when the setting tool 20 is in the run-in position, to block
fluid flow through the
vent port. The vent port 56 is unsealed after the setting tool 20 is actuated
to allow fluid flow
through the vent port during the transition between the run-in position to the
set position (the
"setting process"). ,
[00471 When the tool 20 is in the run-in position, as shown in FIGs. 2 and 4,
the vent port 56 is in
fluid communication with the second pressure chamber 52. In embodiments where
the
breakable seal is included, the breakable seal helps prevent wellbore fluids
from entering the
second pressure chamber 52 during running in of the setting tool 20. In some
embodiments, in
the run-in position, where the vent port 56 includes the breakable seal, the
second pressure
chamber 52 may be filled with a compressible or incompressible fluid. Filling
the second pressure
chamber 52 with liquid, especially an incompressible liquid, may help maintain
the setting tool
in the run-in position prior to actuation, which will be described in more
detail below. The
15 compressibility of the fluid in the second pressure chamber 52 in the
run-in position may affect
the amount of resistance encountered by the piston 24 when the setting tool is
actuated. For
example, the piston 24 may move towards the second end 42 with little
resistance at actuation
if the second pressure chamber 52 is filled with a compressible gas in the run-
in position, which
may help prevent excessive pressure buildup in the first pressure chamber 50
that can cause
20 damage to the housing 22 and/or the piston 24. When the tool 20 is in
the set position, as shown
in FIG. 3, the vent port 56 is in fluid communication with the first pressure
chamber 50. The vent
=
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Date Recuetate Received 2021-04-29
port 56 allows the setting tool 20 to self-vent during use, which will be
described in more detail
below.
100481 The piston 24 has a first open end 59 at or adjacent to the first
piston face 47 and a second
closed end 61 which may be adjacent to or coincide with the free end 68 of the
piston rod 48.
The piston 24 has define therein a power charge chamber 58, extending from the
first open end
59 to the second closed end 61. The power charge chamber 58 is in fluid
communication with
the first pressure chamber 50 via the first open end 59. In the illustrated
embodiment, the
chamber 58 is fully enclosed along the length of the piston rod 48 and the
second end 61 is also
fully enclosed such that the chamber 58 is not in fluid communication with the
second pressure
chamber 52, i.e., fluid communication is restricted between the chamber 58 and
the exterior of
the piston 24 below the second piston face or at or near the second closed end
61. Accordingly,
fluid communication between the chamber 58 and the exterior of the piston 241s
only permitted
through the first open end 59. In some embodiments, the power charge chamber
58 has an inner
diameter that is about 40% or less of the outer diameter of the piston rod 48.
If the interior of
.. .the power charge chamber 58 is not round, then a ratio of effective cross-
sectional areas
calculated from the cross-sectional areas of the power charge chamber 58 or
the piston rod
48 can be used to determine that the size of the power charge chamber 58 as
compared to the
exterior of the piston rod 48.
[0049] At least a portion of the power charge 26 is disposed in power charge
chamber 58. A
portion of the power charge 26 may extend axially outwardly beyond the first
open end 59 of the
power charge chamber 58. In Some embodiments, the power charge 26 extends
substantially the
14
Date Recue/Date Received 2021-04-29
full length of the power charge chamber 58. In some embodiments, the power
charge 26 extends
about 90% or more of the length of the power charge chamber 58. In some
embodiments, the
power charge 26 has an outer diameter which is about 75% or more of the inner
diameter of the
power charge chamber 58. If the power charge chamber 58 or the power charge 26
are of a
shape that is not generally cylindrical, then the effective diameter of the
power charge 26 can be
compared to the effective diameter of the power charge chamber 58, with the
effective
diameters determined by calculation from the cross-sectional areas of the
power charge
chamber 58 and the power charge 26. In other embodiments, which are not shown,
the power
charge 26 maybe disposed outside piston 24, for example, in the first pressure
chamber 50
adjacent the first piston face 47 of the piston head 46. In some embodiments,
the power
charge 26 is selected such that the power charge burns at a rate that results
in the combustion
of the power charge in about 15 seconds to about 60 seconds. The power charge
26 may be a
pyrotechnic explosive power source or a non-explosive gas-generating power
source, known to
'those skilled in the art.
[0050] In some embodiments, the setting mandrel 28 is a tubular member having
a wall with an
inner surface that defines the inner bore 70. In some embodiments, the setting
mandrel 28 may
be generally cylindrical in shape. Inner bore 70 extends from the first end 72
to a second end 73
of the mandrel 28. In the illustrated embodiment, the second end 73 of the
mandrel 28 coincides
with the second end 42 of the setting tool 20. In the illustrated embodiment,
the mandrel 28 is
shown as a separate component from the housing 22. In other embodiments, which
are not
shown herein, the mandrel 28 and the housing 22 may be integrally formed such
that they are
one and the same.
Date Recue/Date Received 2021-04-29
[0051] In some embodiments, the setting mandrel 28 has an annular protrusion
44 that extends
radially outwardly from the outer surface of the setting mandrel 28. In some
embodiments, the
annular protrusion 44 is positioned closer to the first end 72 than to the
second end 73 of the
mandrel 28. In some embodiments, when the first end 72 of mandrel 28 is
received in the box
end 38, the second end of the housing 22 abuts against the annular protrusion
44.
[0052] In some embodiments, the wall of the setting mandrel 28 has. at least
one axially
extending slot 74 defined therein, for receiving a portion of the crosslink
key 32. The slot 74 has
a first end (not shown) and a second end 80, the second end 80 being closer to
the second end
42 of the setting tool and the second end 73 of the mandrel 28 than the first
end of the slot 74,
and the first end of the slot 74 being closer to the first end 40 than the
second end 80. In the
illustrated embodiment, the setting mandrel 28 has two slots 74 extending
through its wall and
the two slots are substantially parallel to one another (and/or to the central
longitudinal axis x)
and are azimuthally separated about axis x by about 1800. In some embodiments,
the axial
location of at least a portion of one of the slots 74 is the same as the axial
location of at least a
portion of the other slot 74, so that at least a portion of each slot 74
overlaps axially with the
other slot.
[0053] In the illustrated embodiment, the crosslink sleeve 30 is supported
about the outer
surface of the setting mandrel 28 and is configured to be slidably movable
axially relative to the
= setting mandrel 28. In other embodiments, which are not shown herein, at
leasta portion of the
crosslink sleeve 30 may be supported about the outer surface of the housing
22. In the illustrated
embodiment, the length of the setting mandrel 28 is greater than that of the
crosslink sleeve 30.
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Date Recue/Date Received 2021-04-29
When the setting tool 20 is in the run-in position, as shown in FIGs. 2 and 4,
the crosslink sleeve
30 is secured to the mandrel 28 by at least one intact shear screw 60. In the
illustrated
embodiment shown in FIGs. 2 and 4, the intact shear screw GO extends from the
wall of the
crosslink sleeve 30 into the wall of the setting mandrel 28 to maintain the
crosslink sleeve's axial
position relative to the mandrel 28. When intact, shear screw 60 prevents the
weight of the
downhole tool from prematurely placing the setting tool into the set position
by pulling the
crosslink sleeve axially relative to the mandrel 28 toward the second end 42
of the setting tool
20. In some embodiments, in the run-in position, the crosslink sleeve 30 may
be close to or abut
against the annular protrusion 44.
[0054] When the setting tool 20 is actuated, as described in more detail
below, the intact shear
screw 60 is broken to release the crosslink sleeve 30 to allow the sleeve 30
move axially relative
to the setting mandrel 28 in the direction of the second end 42 of the setting
tool 20. In a sample
embodiment, the force required to break the shear screw 60 ranges from about
2000 lbs to about
10000 lbs. Once the shear screw 60 is broken, the setting tool 20 can
transition to the set position
=
as shown in FIG. 3. With reference to FIG. 3, in the set position, the broken
shear screw 60' no
longer axially locks the crosslink sleeve 30 to the mandrel 28 and the axial
location of the=crosslink
sleeve 30 is closer to the second end 42 of the tool 20 than that in the run-
in position (FIG. 2).
The axial location of the crosslink sleeve 30 in the run-in position may be
referred to herein as
. the "run-in location" of the sleeve 30 and the axial location of the
cross-link sleeve 30 in the set
position may be referred to herein as the "set locatibn" of the sleeve 30.
=
17
Date Recue/Date Received 2021-04-29
[0055] In some embodiments, the crosslink key 32 extends from at feast the
inner surface of the
crosslink sleeve 30 into at least one slot 74 of the setting mandrel 28. The
crosslink key 32 is
configured to be slidably movable in slot(s) 74, along the axial length of the
slot(s) 74. In some
embodiments, the crosslink key 32 may be integral with the crosslink sleeve 30
such that the
crosslink key 32 and the crosslink sleeve 30 are formed as a single component.
In other
embodiments, as shown for example in FIGs. 2 to 4, the crosslink key 32 is a
separate component
from the crosslink sleeve 30. In further embodiments, the crosslink sleeve 30
has at least one
aperture 76 in its wall for receiving one end of the crosslink key 32. The
aperture 76 may be sized
to be slightly larger than or about the same as the size of the end of the
crosslink key 32. In some
embodiments, the crosslink sleeve 30 has two apertures 76 extending through
its wall and the
two apertures 76 are at about the same axial location in the crosslink sleeve
30 and are
azimuthally separated about axis x by about 1800. In some embodiments, the
crosslink key 32 is
an elongated member that extends laterally inside the crosslink sleeve 30,
substantially
orthogonal to the axis x, with each end of the crosslink key 32 received in a
respective aperture
.. 76 defined in the wall of the crosslink sleeve 30. In some embodiments, the
crosslink key 32
extends across the inner diameter of the crosslink sleeve 30,
100563 Each aperture 76 in crosslink sleeve 30 is aligned with a respective
slot 74 and a portion
of the crosslink key 32 is received in both the aperture 76 and the slot 74.
The length of aperture
76 is less than that of the slot 74. In some embodiments, the crosslink sleeve
30 has two apertures
76, each aligned with a respective slot 74, such that the crosslink key 32,
with each end received
in a respective aperture 76, extends laterally through both slots 74 across
inner bore 70 of the
mandrel 28. In some embodiments, the crosslink key 32, when extended through
both slots 74,
18
Date Recue/Date Received 2021-04-29
is centrally positioned such that the crosslink key 32 (orthogonally)
intersects the central
longitudinal axis x. In some embodiments, at least a portion of the inner
surface of the crosslink
sleeve 30 abuts against the outer surface of the setting mandrel 28, as shown
in the illustrated
embodiment. In other embodiments, the length of the crosslink key 32, the
inner diameter of the
crosslink sleeve 30, and/or the outer diameter of the setting mandrel 28 may
be selected such
that the inner surface of the crosslink sleeve 30 is spaced apart from the
outer surface of the
mandrel 28. In such embodiments where the crosslink sleeve 30 is spaced apart
from the mandrel
28, the crosslink sleeve 30 may or may not be concentric with the mandrel 28.
[00571 In some embodiments, the setting tool 20 comprises a retainer 78 for
keeping the
.. crosslink key 32 in apertures 76 and slots 74, thereby coupling the
crosslink key 32 to the crosslink
sleeve 30 via apertures 76, without restricting the crosslink key's ability to
slide axially along the
slots 74. For example, as illustrated in FIGs. 1 to 4, the retainer 78 is a
retainer sleeve supported
on the outer surface of the crosslink sleeve 30 and is sized to be adjacent to
or abut against the
apertures 76 to substantially cover the apertures 76, thereby keeping the
crosslink key 32 within
the apertures 76 between the inner surface of the retainer sleeve 78. The
retainer 78 may be
secured to crosslink sleeve 30 by a fastener and/or friction-fitting. As a
person skilled in the art
can appreciate, other ways of securing the crosslink key 32 in the setting
tool 20 are possible.
[00581 When the setting tool 20 is in the run-in position shown in FIGs. 2 and
4, with shear screw
60 intact, the crosslink sleeve 30 is at its run-in location wherein the
crosslink key 32 and as a
result the crosslink sleeve 30 are at or near a first end of the slot(s) 74.
Further, in the run-in
position, the free end 68 of the piston rod 48 is close to or abuts against
the crosslink key 32.
19
Date Recue/Date Received 2021-04-29
Once the setting tool 20 is actuated and the shear screw 60 is broken, the
crosslink sleeve 30 and
the crosslink key 32 coupled to the crosslink sleeve 30 are free to move
axially relative to the
setting mandrel 28 but the extent of the axial movement of the crosslink key
32 (and thus the
crosslink sleeve 30) is limited by the axial length of the slot(s) 74. In the
set position shown in
.. FIG. 3, the piston 24 has pushed the crosslink key 32 to the second end 80
of the slot(s) 74,
thereby placing the crosslink sleeve 30 in its set location (i.e., the
furthest position away from the
first end 40 of the setting tool 20). The crosslink key 32 thus prevents the
entirety of the crosslink
sleeve 30 from sliding axially past the second end 73 of the setting mandrel
28.
[0059] The crosslink sleeve 30 may be securely coupled to a setting sleeve
(not shown) of the
downhole tool to be set, for example by threaded connection. For example, a
second end 33 of
the crosslink sleeve 30 may be an externally threaded pin end for connection
to a box end of the
setting sleeve of the downhole tool to be set. Alternatively, the crosslink
sleeve 30 is the setting
sleeve of the downhole tool. The second end 73 of the setting mandrel 28 may
be securely
coupled to a mandrel of the down hole tool to be set, for example by threaded
connection.
Alternatively, the setting mandrel 28 is the mandrel of the downhole tool to
be set.
[0060] Various components of the setting tool 20 may be formed of steel and/or
composite
materials. In some embodiments, one or more components of the setting tool 20
are made of
lower cost steel, which may reduce the overall cost of the setting tool 20. In
some embodiments,
one or more components of the setting tool 20 are made of AISI 4140.
[0061] In some embodiments, the setting tool 20 is initially assembled in the
run-in position
shown for example in FIGs.1., 2, and 4. in sample embodiments, to assemble the
tool 20, at least
=
Date Recue/Date Received 2021-04-29
a portion of the power charge 26 is disposed in the power charge chamber 58 of
the piston 24.
Then, the piston rod 48 is inserted into the aperture of the annular plug 54
via the free end 68.
The piston 24 is then inserted into inner bore 34 of housing 22 via the second
end 38, with the
first piston face 47 of the piston head 46 and the open end 59 of the chamber
58 facing towards
the first end 36 of the housing 22. The inner bore 34 may have a reduced
diameter section and/or
a radially inwardly extending shoulder for catching the plug 54 so that the
plug 54 is secured
within the housing 22 at an axial location that is closer to the second end 38
than the vent port
56,
[0062] In some embodiments, as described above, a breakable seal may be added
to the setting =
JO tool 20 to block the vent port 56 in the run-in position. In sonic
embodiments, prior to installing
the breakable seal into vent port 56, a fluid may be injected into the second
pressure chamber
52 via the vent port 56.
[0063] In some embodiments, the setting mandrel 28 is inserted, second end 73
first, through
the crosslink sleeve 30 so that the crosslink sleeve 30 is supported about the
outer surface of the
mandrel 28. The crosslink sleeve 30 is then rotated about the axis x until
each aperture 76 is
aligned with one of the slots 74. The crosslink key 32 is inserted laterally
across the crosslink
sleeve 30 and the setting mandrel 28, through apertures 76 and slots 74,
respectively. The
retainer 78 is then placed on to the sleeve 30 to keep the crosslink key 32 in
the apertures 76 and
slots 74. The crosslink sleeve 30 is then moved to its run-in location on the
mandrel 28 and one
or more shear screws 60 are inserted to hold the crosslink sleeve 30 in place
(i.e., to axially lock
the crosslink sleeve 30 to the mandrel 28).
21
Date Recue/Date Received 2021-04-29
[0064J The setting mandrel 28 is.threadedly connected at its first end 72 to
the box end 38 of
the housing 22.1n some embodiments, the remaining portion of the piston 24 is
slidably inserted
into inner bore 70 of the setting mandrel 28 as the mandrel 28 is being
connected to the housing
22. When the mandrel 28 is coupled to the housing 22, the free end 68 of the
piston 24 is close
to or abuts against the crosslink key 32. In the run-in position, the
crosslink key 32 is held in place
at the run-in location by the shear screw 60 via the sleeve 30, which helps
maintain the piston 24
in the run-in position by restricting the piston's axial movement towards the
second end 73 of
the mandrel 28. The shear screw 60 thus prevents premature actuation of the
setting tool 20,
i.e., premature shifting of the piston 24 and/or the crosslink sleeve 30
towards the second end
42 of the setting tool. In embodiments where the second pressure chamber 52 is
filled with a
fluid and the vent port is blocked by the breakable seal in, the run-in
position, the fluid in the
second pressure chamber 52 may also help prevent premature setting of the
setting tool 20 by
restricting axial movement of the piston 24 relative to the housing 22 and the
setting mandrel
28.
[0065] Thus configured, the setting tool 20 has fewer parts and seals; is free
of hydraulic oil; and
is easier to assemble than the conventional setting tool. The setting tool 20
may be pre-
assembled in a controlled environment, such as a factory, or assembled onsite.
[0066] In operation, the downhole tool to be set is attached to the setting
tool 20 before run in.
In some embodiments, the setting sleeve of the downhole tool is connected to
the crosslink
sleeve 30. Alternatively, the setting sleeve of the downhole tool is the
crosslink sleeve 30. The
mandrel of the downhole tool is connected to the setting mandrel 28.
Alternatively, the mandrel
22
Date Recue/Date Received 2021-04-29 =
of the downhole tool is the setting mandrel 28. The setting tool 20 is
initially in the run-in position
as shown in FIGs. 2 and 4.
[0067] The setting tool 20 in its initial run-in position, along with the
downhole tool attached
thereto, is run into the wellbore, with the downhole tool entering the
wellbore first such that the
setting tool 20 is uphole from the downhole tool. In this description, the
terms "downhole",
"downward", "down", "lower", and the like refer to the direction in the
wellbore away from the
surface opening of the wellbore. The downhole direction is denoted by arrow
"D" in FIGs. 2 and
3. The terms "uphole", "upward", "up", "upper", and the like refer to the
direction in the wellbore
toward the surface opening of the wellbore. When the setting tool 20 is run
into the wellbore,
the first end 40 is uphole relative to the second end 42. Accordingly, the
above-mentioned terms
"first" and "second" may be referred to as "upper" and "lower," respectively.
For example, the
first end 40 may be referred to as the "upper end 40"; the second end 42 may
be referred to as
the "lower end 42"; the first piston face 47 may be referred to as the "upper
piston face 47," etc.
Further, a "downward movement" and the like of a first part refer to the
relative movement of
the first part in reference to a second part and does not necessarily mean
that the first part has
actually moved downward relative to the wellbere, but rather that the first
part has moved
downwards relative to the second part, which may include, for example, the
scenario where the
second part has physically moved upwards in the wellbore while the first part
remained
substantially stationary. The same principle applies to an "upward movement"
and the like.
[00681 When the downhole tool reaches a desired location in the wellbore, the
setting tool 20
can be actuated. In some embodiments, to actuate the setting tool 20 to
transition the tool 20
23
Date Recue/Date Received 2021-04-29
from the run-in position to the set position, the power charge 26 is ignited
to generate high
pressure gas. The power charge 26 may be ignited by an ignitor (not shown) or
by any technique
known to those skilled in the art. Since the power charge chamber 58 is fully
enclosed along the
length of the piston rod 48 and at the lower closed end 61, the high pressure
gas in the chamber
58 is released into the upper pressure chamber 50 via the upper open end 59.
As the power
charge 26 combusts, the pressure in the upper pressure chamber 50 increases,
The increase in
pressure in the upper pressure chamber 50 exerts an axial force on the upper
piston face 47 of
the piston head 46 in the direction of the lower end 42 (i.e., the downhole
direction D), or on the
housing 22 in the direction of the upper end 40, If, in the run-in position,
the free end 68 of piston
rod 48 abuts against the crosslink key 32, then the force exerted on the
piston 24 is transferred
to the crosslink key 32, If, in the run-in position, the free-end 68 does not
abut against the
crosslink key 32, then the force exerted on the piston head 46 causes the
piston 24 to shift
downwards relative to the setting mandrel 28 towards the crosslink key 32
until the free-end 68
abuts against the crosslink key 32 and transfers the force exerted thereon to
the crosslink key 32.
The downward force exerted on the crosslink key 32 is in turn transferred to
the crosslink sleeve
30 via aperture(s) 76. In alternative embodiments, the upward force on the
housing 22 is
translated to the setting mandrel 28 and crosslink sleeve 30, thus pulling the
crosslink key 32 to
meet the free-end 68 if the crosslink key 32 is not already abutting the free-
end 68 in the run-in
position. The engagement of the free-end 68 with the crosslink key 32 exerts a
downward force
on the crosslink sleeve 30 via aperture(s) 76.
[0069] Once the downward force on the crosslink sleeve 30 is sufficient to
break the shear screw
60, the shear screw 60 is. broken (shown in FIG. 3 as broken shear screw 601,
which allows the
24
Date Recue/Date Received 2021-04-29
axial force exerted on the piston 24 and the housing 22 to move the piston 24
(further)
downwards relative to the housing 22 (or to move the housing 22 (further)
upwards relative to
the piston 24), whereby the piston rod 48 slides further into inner bore 70 of
the setting mandrel
28. As the piston 24 moves down relative to the housing 22 and setting mandrel
28, pressure in
the lower pressure chamber 52 increases and the breakable seal, if included in
the vent port 56,
eventually breaks as a result of the increased pressure to allow fluid to flow
through the vent
port 56. If the breakable seal is not included or when the breakable seal is
broken, fluid in the
lower pressure chamber 52 is vented to the exterior of the setting tool 20
through the vent port
56, thereby allowing the piston 24 to move downwards. In some embodiments, the
vent port 56
may serve to control the speed of the setting process (i.e., the time it takes
the tool 20 to arrive
at the set position from actuation), e.g, to slaw the stroke speed of the
piston 24, upon initiation
of power charge 26 regardless of the type of power charge used to actuate the
setting tool 20.
Therefore, the vent port 56 may be sized accordingly to provide a metering
function to control
the setting rate of the setting tool 20. For example, the larger the vent port
56, the quicker the
setting speed of the setting 20.
[0070] The downward movement of the piston 24 relative to the housing 22 and
mandrel 28
pushes the crosslink key 32 downwards along slot(s) 74 relative to the setting
mandrel 28.
Because the crosslink key 32 is coupled to the crosslink sleeve 30 and the
aperture(s) 76 is shorter
than slot(s) 74, the downward movement of the crosslink key 32 also moves
crosslink sleeve 30
downwards relative to the setting mandrel 28. The configuration of the setting
tool 20 allows
direct physical contact between piston 24 and the crosslink key 32 during the
transition of the
setting tool, so that the piston 24 to can directly exert a downward force on
the crosslink key 32,
=
Date Recue/Date Received 2021-04-29
without using any intermediary components or hydraulic fluids. In some
embodiments, during
the transition from the run-in position to the set position, the piston 24 and
crosslink sleeve 30
shift downwards in direction D relative to the housing 22 and mandrel 28 (or
the housing 22 and
setting mandrel 28 shift upwards opposite direction D relative to the piston
24 and crosslink
sleeve 30). The extent to which piston head 46 can move axially in the
downhoie direction D
relative to the housing 22 and setting mandrel 28 is restricted by the plug
54. As a result, the
piston stroke of piston 24 is limited by the plug 54 and the maximum piston
stroke length
depends on the initial uphole position of the piston head 46 in the run-in
position and the position
of the plug 54 in housing 22. Plug 54 may be configured to absorb shock when
the shear screw
60 is broken and the piston head 46 bottoms out on the upper face of the plug
54.
[0071] The extent to which the crosslink key 32. (and the crosslink sleeve 30)
can move axially in
the downhole direction D relative to the setting mandrel 28 is limited by the
length of the slot(s)
74. When the crosslink key 32 reaches the lower end 80 of the slot(s) 74, the
crosslink sleeve 30
cannot move further down relative to the mandrel 28. Further, the stroke
length of the piston 24
may be less than the maximum piston stroke length if the distance between the
crosslink key 32
and the lower end 80 of the slot 74 is less than the distance between the
lower piston face of the
piston head 46 and the plug 54.
[0072] In some embodiments, the piston head 46 sealingly engages the inner
surface of housing
- 22 for substantially the entire stroke of the piston 24. The setting tool 20
is placed in the set
position, as shown in FIG. 3, when the piston 24 reaches the end of its
downward stroke (i.e.,
when the lower piston face of the piston head 46 abuts against the upper face
of the plug 54
26
Date Recue/Date Received 2021-04-29
and/or when the crosslink key 32 abuts against the lower end BO of the slot
74). In the set
position, the crosslink sleeve 30 is pushed downwards to its set location by
the piston 24 via the
crosslink key 32. The setting tool 20 is configured such that the shifting of
the crosslink sleeve 30
in the downhoie direction D, initiated and caused by the combustion of the
power charge 26, is
sufficient to set the downhole tool that is attached to the setting tool 20.
[00731 In the illustrated embodiment shown in HG. 3, when the setting. tool 20
is in the set
position, the upper piston face 47 is below the vent port 56 so that the vent
port 56 is in fluid
communication with the upper pressure chamber 50, thereby allowing the high
pressure gas in
the upper pressure chamber 50 resulting from the power charge combustion to
exit setting tool
20 via vent port 56. therefore, in the set position, little or no residual
pressure from the power
charge combustion remains inside the setting tool 20.
[0074] After the downhole tool is set, the setting tool 20 or components
thereof may be
retrieved from the wellbore and brought to surface by wireline. In some
embodiments, at least
the housing 22 and the piston 24 are configured to be disposable after a
single run of the setting
tool 20. In some embodiments, some or all of the components of the setting
tool 20 are
disposable after a single use, which may reduce errors during subsequent
setting operations
related to material fatigue.
[0075] In some embodiments, at actuation, the setting tool 20Is configured to
provide a pressure
differential between the upper pressure chamber 50 and the lower pressure
chamber 52 in the
range of about 10,000 psi and 40,000 psi. In one embodiment, the setting tool
20 provides a
pressure differential of about 20,000 psi. In some embodiments, at least some
components of
27
Date Recue/Date Received 2021-04-29
the setting tool 20, such as the housing 22 and the piston 24, are selected
and configured to
withstand such high pressure differentials with little or no damage thereto,
for at least the time
period of the power charge combustion (e.g., about 20 seconds,) such that
these components
can be reused after the setting tool is retrieved from the wellbore, for
example, for the
.. subsequent setting of another downhole tool.
[0076] In some embodiments, the housing 22 may have an outer diameter of about
3.8", with
an overall wall thickness in the range of about 0.5" and about 0.9". In one
embodiment, the
overall thickness of the housing wall is about 0.8". In some embodiments,
where the pressure
differential is about 20,000 psi, the housing 22 is configured to withstand a
minimum hoop stress
of about 38 ksi at its outer surface. For example, the housing 22 may be made
of a material having
a yield strength of about 100 ksi and a hardness of about 28 Rc or greater. In
some embodiments,
the piston rod 48 may have an outer diameter of the about 13", with an overall
wall thickness in
the range of about 0.2" and 0.5", In one embodiment, the overall thickness of
the piston rod wall
is about 0.5". In some embodiments, the piston 24 is configured to withstand a
minimum hoop
stress of about 25 ksi. For example, the piston 24 may be made of a material
having a yield
strength of about 110 ksi and a hardness greater than about 28 Rc or greater.
In embodiments
where the lower pressure chamber 52 is filled with a liquid in the run-in
position, the wall
thickness of the housing 22 and/or the piston rod 48 may be selected to be
thicker than that of
embodiments where the lower pressure chamber 52 is filled with a gas, so that
the housing and
piston may better withstand the pressures in the upper pressure chamber 50
while the power
charge combusts.
28
Date Recue/Date Received 2021-04-29
[0077] The setting tool 20 described herein is gas operated and dry fired,
using only a power
charge, in the absence of any hydraulic fluid, such as hydraulic oil. Since
the setting tool 20 is dry
fired, the setting tool may be disposed of when desired, without the need to
tear down the
setting tool to retrieve hydraulic fluids. The setting tool 20 also eliminates
the need to redress
the setting tool for subsequent use, thereby reducing the risks associated
with improper
rebuilding of the setting tool and eliminating the labour costs of redressing
the setting tool in
between runs. Further, in the absence of hydraulic oil, damage to the parts of
the setting tool 20
may be reduced during setting, which may render some parts of the setting tool
reusable
thereafter,
[0078] Interpretation of Terms
[0079] Unless the context clearly requires otherwise, throughout the
description and the
"comprise", "comprising", and the like are to be construed in an inclusive
sense, as opposed to
an exclusive or exhaustive sense; that is to say, in the sense of "including,
but not limited to";
"connected", "coupled", or any variant thereof, means any connection or
coupling, either direct
or indirect, between two or more elements; the coupling or connection between
the elements
can be physical, logical, or a combination thereof; "herein", "above",
"below", and words of
similar import, when used to describe this specification, shall refer to this
specification as a
whole, and not to any particular portions of this specification; "or', in
reference to a list of two
or more items, covers all of the following interpretations of the word: any of
the items in the list,
29
Date Recue/Date Received 2021-04-29
all of the items in the list, and any combination of the items in the list;
the singular forms "a",
"an", and "the" also include the meaning of any appropriate plural forms.
[0080] Where a component is referred to above, unless otherwise indicated,
reference to that
component should be interpreted as including as equivalents of that component
any component
which performs the function of the described component (i.e., that is
functionally equivalent),
including components -which are not structurally equivalent to the disclosed
structure which
performs the function in the illustrated exemplary embodiments.
[00811 The previous description of the disclosed embodiments is provided to
enable any person
skilled in the art to make or use the present invention. Various modifications
to those
embodiments will be readily apparent to those skilled in the art, and the
generic principles
defined herein may be applied to other embodiments without departing from the
spirit or scope
of the invention. Thus, the present invention is not intended to be limited to
the embodiments
shown herein, but is to be accorded the full scope consistent with the claims.
Moreover, nothing
disclosed herein is intended to be dedicated to the public regardless of
whether such disclosure
is explicitly recited in the claims. It is therefore intended that the
following appended claims and
claims hereafter introduced are interpreted to include all such modifications,
permutations,
additions, omissions, and sub-combinations as may reasonably be inferred. the
scope of the
claims should not be limited by the preferred embodiments set forth in the
examples but should
be given the broadest interpretation consistent with the description as a
whole.
Date Recue/Date Received 2021-04-29
