Filament wound composite ball

• US 9,187,975 B2
• Filed: 10/23/2013
• Issued: 11/17/2015
• Est. Priority Date: 10/26/2012
• Status: Expired due to Fees

• Current Assignee: Weatherford Technology Holdings, LLC (Weatherford International PLC)
• Original Assignee: Weatherford Technology Holdings, LLC (Weatherford International PLC)
• Inventors: Rochen, James
• Primary Examiner(s): Aftergut, Jeff
• Application Number:
  US14/061,346
• Publication Number:
  US 20140120346A1
• Time in Patent Office: 755 Days
• Field of Search: 156/170, 156/169, 156/172, 156/173
• US Class Current: 1/1
• CPC Class Codes: B29C 53/76 about more than one axis , e.g. T-pieces, balls
• CPC Class Codes: B29D 99/0042 Producing plain balls hollow balls B29D22/04
• CPC Class Codes: E21B 33/12 Packers; Plugs used for cementing E21B33/134, E21B33/16
• CPC Class Codes: Y10T 428/2922 Nonlinear [e.g., crimped, coiled, etc.]

Abstract

A composite ball is formed with wound filament in a winding machine by winding the filament on a core, which can be permanent and form part of the finished ball. Alternatively, the core can be temporary. When winding is completed, the wound body is removed from the winding machine, an exterior of the wound body is finished, and the wound body is cured. When the core is permanent, at least a portion of the core is removed from the winding machine along with the wound body so any excess of the permanent core can be removed. The temporary core, however, is removed from the wound body, and the void is filled with filler material.

Claims

1. A method of forming a composite ball with filament in a winding machine, comprising not necessarily in order:

forming a wound body by winding the filament on a core in the winding machine, the core having at least a core portion to be removed from the wound body;

removing the wound body from the winding machine;

curing the wound body; and

finishing an exterior of the wound body by filling a void resulting in the wound body from removal of the core portion from the wound body or removing excess of the core portion left outside the wound body.

2. The method of claim 1, wherein removing the wound body from the winding machine comprises removing the wound body and at least a permanent core portion of the core from the winding machine.

3. The method of claim 1, wherein forming the wound body by winding the filament on the core in the winding machine comprises one or more of:

articulating the filament relative to the core about a plurality of axes;

wet winding the filament around the core;

winding the filament in one or more patterns around the core;

wet winding the filament coated in a matrix material; and

winding the filament pre-impregnated with a matrix material.

4. The method of claim 1, wherein finishing the exterior of the wound body comprises machining the exterior of the wound body.

5. The method of claim 1, wherein curing the wound body comprises heating the wound body.

6. A method of forming a composite ball with filament in a winding machine, comprising not necessarily in order:

forming a wound body by winding the filament on a core in the winding machine, wherein the core comprises a permanent core;

removing the wound body from the winding machine;

curing the wound body; and

finishing an exterior of the wound body by removing excess of the permanent core from the exterior of the wound body.

7. The method of claim 6, wherein the permanent core is composed of a composite material.

8. A method of forming a composite ball with filament in a winding machine, comprising not necessarily in order:

forming a wound body by winding the filament on a core in the winding machine, wherein the core comprises a temporary core;

removing the wound body from the winding machine;

curing the wound body; and

finishing an exterior of the wound body by removing the temporary core from the wound body and filling a remaining void of the wound body with a filler material.

9. The method of claim 8, wherein the filler material is composed of a composite material.

10. A method of forming a composite ball with filament in a winding machine, comprising not necessarily in order:

forming a wound body by winding the filament on a core in the winding machine;

removing the wound body from the winding machine;

removing the wound body from the core;

curing the wound body; and

finishing an exterior of the wound body.

11. The method of claim 10, wherein finishing the exterior of the wound body comprises filing a resulting void in the wound body with a filler material.

12. A method of forming a composite ball with filament in a winding machine, comprising not necessarily in order:

forming a wound body by winding the filament on a core in the winding machine, wherein the core comprises a temporary core portion and a permanent core portion;

removing the wound body from the winding machine;

curing the wound body; and

finishing an exterior of the wound body by removing the temporary core portion from the wound body and the permanent core portion and filling a remaining void of the wound body with a filler material.

13. The method of claim 12, wherein the filler material is composed of a composite material, and wherein the permanent core portion is composed of a composite material.

14. A composite ball formed with filament in a winding machine by a method, comprising not necessarily in order:

forming a wound body by winding the filament on a core in the winding machine, the core having at least a core portion to be removed from the wound body;

removing the wound body from the winding machine;

curing the wound body; and

finishing an exterior of the wound body by filling a void resulting in the wound body from removal of the core portion from the wound body or removing excess of the core portion left outside the wound body.

15. The composite ball of claim 14, wherein removing the wound body from the winding machine comprises removing the wound body and at least a portion of the core from the winding machine.

16. The composite ball of claim 14, wherein forming the wound body by winding the filament on the core in the winding machine comprises one or more of:

articulating the filament relative to the core about a plurality of axes;

wet winding the filament around the core;

winding the filament in one or more patterns around the core;

wet winding the filament coated in a matrix material; and

winding the filament pre-impregnated with a matrix material.

17. The composite ball of claim 14, wherein finishing the exterior of the wound body comprises machining the exterior of the wound body.

18. The composite ball of claim 14, wherein curing the wound body comprises heating the wound body.

19. A method of forming a composite ball with filament in a winding machine, comprising not necessarily in order:

forming a wound body by winding the filament on a permanent core in the winding machine;

removing the wound body and at least a portion of the permanent core from the winding machine;

curing the wound body; and

finishing an exterior of the wound body by at least partially removing excess of the permanent core.

20. The method of claim 19, wherein the permanent core is composed of a composite material.

21. A method of forming a composite ball with filament in a winding machine, comprising not necessarily in order:

forming a wound body by winding the filament on a temporary core in the winding machine;

removing the wound body from the temporary core;

curing the wound body; and

finishing an exterior of the wound body by filing a resulting void in the wound body from the removed temporary core.

22. The method of claim 21, wherein filling the resulting void comprises filling with a filler material composed of a composite material.

23. A composite ball formed with filament in a winding machine by a method, comprising not necessarily in order:

forming a wound body by winding the filament on a permanent core in the winding machine;

removing the wound body and at least a portion of the permanent core from the winding machine;

curing the wound body; and

finishing an exterior of the wound body by at least partially removing excess of the permanent core.

24. The composite ball of claim 23, wherein the permanent core is composed of a composite material.

25. A composite ball formed with filament in a winding machine by a method, comprising not necessarily in order:

forming a wound body by winding the filament on a temporary core in the winding machine;

removing the wound body from the temporary core;

curing the wound body; and

finishing an exterior of the wound body by filing a resulting void in the wound body from the removed temporary core.

26. The composite ball of claim 25, wherein filing the resulting void comprises filling with a filler material composed of a composite material.