APPARATUS AND PROCESS FOR EXPANDING A TUBULAR USING A CONE ASSEMBLY

Abstract

A cone assembly for use in expanding the diameter of a pipe has a rigid cone adapted to be positioned adjacent to an end of the pipe, a flexible cone positioned adjacent an end of the rigid cone and being movable between an expanded diameter at a reduced diameter, and an actuator having an end in contact with the flexible cone. The actuator is movable between an extended position and a retracted position. The extended position is adapted to cause the rigid cone to expand the outer diameter of the pipe and causes the flexible cone to expand in diameter. The retracted position of the actuator removes the force applied to the flexible cone so as to cause the flexible cone to have the reduced diameter. The flexible cone is a ring having a continuous wall with a single slot therethrough.

Description

FIELD OF THE INVENTION

The present invention relates to the field of tubulars for oil and gas wells. More particularly, the present invention the relates to a cone assembly that has ability to flex under the application of the force in order to expand the diameter of the tubular. Moreover, the present invention relates to cone assemblies that are adapted to be removed from the pipe following the expansion of the end of the pipe.

BACKGROUND OF THE INVENTION

It is common in modern oilfield operations and completions to place expandable tubular components downhole in a subterranean well. The expandable components include expandable tubulars and expandable devices that are placed downhole and, once in place, expanded to a desired size. The expandable components can be a casing, a tubing, sand-control screen assemblies, and other tubulars known in the art. The tubulars can be perforated, slotted or blank (un-slotted) smoothbore. The expandable tubulars can be used to provide mechanical support to the borehole wall to prevent cave-ins or collapses. Multiple layers of expandable tubulars can be employed in a single borehole section.

In any completion, lengths of tubulars to be expanded may be separated by lengths of tubulars which are not to be expanded. Further, completions may employ seal bores or fixed diameter tubular sections, such as for installation of isolation devices. There may also be other areas along the wellbore which do not readily expand, are not designed to expand, or will not expand to the same inner diameter as other sections of tubulars, such that it has areas where the borehole is narrow or has collapsed and will not readily allow for expansion, at joints where tubular sections are joined together, at seal bores where selected isolation devices were deployed, an annular barrier tools, blank pipe, smooth bore pipe sections, restrictions, swollen or narrow borehole areas where debris, junk or trash is encountered, or any other area or section which will not or is not designed to expand, readily expand or expand to the same degree as other tubular sections.

Radially expandable components are typically expanded by drawing a mechanical expansion tool through the tubular. The mechanical expansion tool can be pushed or pulled through the component. The component can be expanded from the top downward or from the bottom upward. There are several problems attendant with the apparatus and methods known in the art. Expansion tools are typically in the form of a rigid mandrel introduced into the component to be expanded. The mandrel is dragged or pushed through the component, causing radial expansion by the application of brute force. The expansion cone or tool may have a run-in position, in which the cone is collapsed or retracted to a smaller size to allow passage through the unexpanded components, and then enlarged to a run position to facilitate expansion of the components as the tool is dragged through the components.

Many expansion tools known in the art are of a fixed diameter or are designed to have a single expanded diameter for use in expansion. Commonly, the fixed-diameter expansion tool is introduced into the wellbore and positioned downhole, below the targeted production zone of the formation. The expandable component is then positioned adjacent to the targeted production zone, above the expansion tool, which is then drawn through the component to cause radial expansion. In such an operation, the fixed diameter of the expansion tool is required to be approximately equal to the desired size of the expanded tubular. This requirement also presents difficulty in positioning the tool. Some radially expandable expansion tools are designed for introduction into the wellbore in a contracted state, and then expanded then expanded for use.

FIGS. 1A and 1B show cone assemblies that can be used for the expanding of a pipe or tubular. As can be seen in FIG. 1A, there is a rigid cone 1, an expandable pipe 2, an actuator 3 and a piston 4 that is used to drive the actuator 3. In particular, the piston 4 extends through the interior of the rigid cone 1 so as to protrude outwardly of the end 5 of the rigid cone 1 and into the interior of the pipe 2. A selective anchor 6 is affixed to the end of the piston 4 and has teeth 6a extending outwardly therefrom, and provides a means of anchoring the pipe 2 to the assembly. The actuator 3, along with the piston 4, is configured to urge the end 7 of the rigid cone 1 toward the end 8 of the pipe 2 such that the tapered outer surface 9 of the rigid cone 1 will bear against the inner wall 10 of the pipe 2. A simpler design may provide an abutment member in lieu of the selective anchor 6. A pressure line 13 is provided in the assembly, and has pressure ports 14 and 15, which drive the actuator 3 and the teeth 6a of the selective anchor 6, respectively.

FIG. 1B shows how the prior art system expands the diameter of the pipe 2 under the application of internal pressure to line 13. As can be seen, the piston 4 moves the actuator 3 to an extended position so as to force the rigid cone 1 into the end 8 of the pipe 2. The tapered outer wall 9 of the rigid cone 1 will travel along the inner wall 10 of the pipe 2 and, as a result, expand the diameter of the pipe 10. The rigid cone 1 will be urged by the actuator 3 until it reaches the selective anchor 6. The selective anchor 6 expands such that the teeth 6a contact the inner surface 10 of the pipe 2.

Referring to FIG. 1C, after the pipe 2 has been expanded and creates the expansion portion 11, there is a ledge 12 that is formed at the end 8 of the pipe 2. The ledge 12 and the end 8 of the pipe portion 11 will have an inner diameter less than the maximum outer diameter of the rigid cone 1. As a result, because of the interference between the end 8 of the pipe and the end of the rigid cone 1, removal of the rigid cone 1 requires a large force. Large forces would be required to be applied to the piston 4 in order to urge the end 7 of the rigid cone 1 outwardly of the end 8 of the formed expanded diameter of the pipe. As such, a need has developed so as to provide a cone assembly which avoids the problems associated with the overhanging ledge 12 created from the formation of the expanded portion 11 of the pipe 2.

In the past, various patents have issued with respect to cone assemblies for use in the expansion of tubulars. For example, U.S. Pat. No. 7,048,067, issued on May 23, 2006 to Cook et al., describes an apparatus and method for repairing a wellbore casing. This apparatus has an opening in a wellbore casing located using a logging tool. An expandable tubular member is then positioned in opposition to the opening in the wellbore casing. The expandable tubular member is then radially expanded into intimate contact with the wellbore casing.

U.S. Pat. No. 7,117,940, issued on Oct. 10, 2006 to D. B. Campo, discloses an expander for expanding a tubular element. The apparatus includes an expandable casing, a drill string extending within the casing, and an expansion cone suspended from the drill string. The expansion cone has an expanded state and a collapsed state. The expansion cone is deformable to the expanded state and is relaxed in the collapsed state. A seal bushing seals an annulus between the drillstring and the expandable casing. A downward expansion flow path is formed wherein fluid communication is provided between the inside of the drill string and the annulus between the drill string and the expandable casing above the expansion cone. An upward expansion flow path is provided between the inside of the drill string and the inside of the expandable casing for upward expansion by the expansion cone.

U.S. Pat. No. 7,117,941, issued on Oct. 10, 2006 to Gano et al., shows a variable diameter expansion tool. This expansion tool has a variable-diameter cone movable between an expanded position and a retracted position. The cone is enlarged to an expanded position and advanced through expandable components until a restriction is released. At the restriction, the variable-diameter cone automatically retracts enough to allow the tool to continue advancing through the wellbore. When the restriction is passed, the variable-diameter cone enlarges again to its expanded position.

U.S. Pat. No. 7,255,177, issued on Aug. 14, 2007 to Duggan et al., describes a method of expanding tubing. This method provides an assembly having a section of expandable tubing and an expansion device in the form of an expansion mandrel located at least partially externally of the tubing. The method includes running the assembly into a bore and translating the expansion mandrel relative to the tubing so as to expand an end section of the tubing. The expansion mandrel is further translated relative to the tubing to expand the further section of the tubing.

U.S. Pat. No. 7,779,923, issued on Oct. 24, 2010 to Holland et al., describes a method and apparatus for anchoring and expanding tubular members. In particular, a downward force is applied to an expansion cone through a work string in order to anchor the tubular member in the wellbore and then pull upwardly on the expansion cone with the work string in order to expand the tubular member. The expansion cone is disposed in a launcher portion connected to the tubular member being expanded.

U.S. Pat. No. 8,100,186, issued on Jan. 24, 2012 to G. M. Noel, describes a method and apparatus for radially expanding and plastically deforming an expandable tubular member using a lower expansion cone and an upper expandable cone. The apparatus includes an expandable tubular, a support member releasably secured to the expandable member, and an extendable section below where the support member is releasably anchored. An upper expandable cone is attached to the extendable section in a retracted state. An anchor is releasable from below the upper expandable cone. The lower expansion cone is disposed below the anchor. An expansion sleeve is disposed in the lower end of the expandable tubular. The lower expansion cone is configured to expand the expansion sleeve radially outwardly to an outer diameter greater than the inside diameter of the expandable tubular when axially displaced downward by the extendable section.

U.S. Pat. No. 9,085,967, issued on Jul. 21, 2015 to F. C. Bennett, teaches an adjustable cone expansion system. This expansion system includes a mandrel slidably coupled to a plurality of primary cone segments that are interleaved with a plurality of secondary cone sections. The expansion system has a first position wherein the primary cone segments and the secondary cone segments are in a retracted position. The expansion system has a second position wherein the primary cone segments are in an expanded position and the secondary cone segments are in a retracted position. The expansion system has a third position wherein the primary cone segments and the secondary cone segments are in an expanded position. When the expansion assembly is displaced within a tubular member and in the second position, the primary cone segments expand the tubular member into a tri-lobe cross-sectional shape.

U.S. Pat. No. 10,641,067, issued on May 5, 2020 to Xu et al., provides a mechanical and hydraulic dual-defect expansion device with expandable tubular technology. This device has an anchor having a lower end coupled to an upper end of an insertion connection via a coupling, a hydraulic cylinder assembly movably disposed within an inner cavity of a hydraulic cylinder, and a variable-diameter expansion cone assembly. The variable-diameter expansion cone assembly comprises a sealing cone portion and a variable-diameter expansion cone portion. The sealing cone portion has an upper end connected to a lower end of the piston tube and a lower end connected to an upper end of the variable-diameter expansion cone portion.

U.S. Patent Application Publication No. 2013/0319692, published on Dec. 5, 2013 to Abedrabbo et al., provides a compliant cone system having a cone segment capable of deflecting in response to a restriction or obstruction encountered while expanding a tubular. The expansion cone system includes a mandrel and two or more pockets disposed circumferentially around the mandrel. Each pocket is at least partially defined by a fin member. The expansion cone system further includes a cone segment coupled to each pocket. The expansion cone system has a biasing member disposed between the mandrel and the respective cone segment.

U.S. Pat. No. 7,681,636, issued on Mar. 23, 2010 to Roggeband et al., discloses another pipe expander which may be used in the industry. The expander has an axially forward direction and a thrust means for exerting a thrust force to the expander to move the expander in the axially forward direction through the pipe. The expander has an adjustable rear cone with an expander surface tapering radially inward in the axially forward direction. The adjustable cone is movable between a radially expanded mode and a radially collapsed mode. Adjusting means are provided for moving the adjustable cone from the collapsed mode to the expanded mode by the action of the thrust force exerted by the thrust means. A front cone is positioned axially forward of the rear cone. The front cone has an expander surface that tapers radially inward in the axially forward direction, a rear surface that tapers radially inward in a direction opposite to the axially forward direction, and a largest diameter smaller than the largest diameter of the rear cone.

Referring to FIGS. 8 and 9 of the U.S. Pat. No. 7,681,636 patent, there are shown cross sections of the expander units utilized in this pipe expander. Notably, the expander units of the '636 patent are essentially flexible cones and have a number of fingers. These are discontinuous and render the pipe expander relatively fragile. Under normal conditions, individual cone segments may break off in the pipe, requiring the pipe expander to be replaced and also limiting the effectiveness of the pipe expander.

It is an object of the present invention to provide a cone assembly that has the ability to flex under a compressive load.

It is another object of the present invention to provide a cone assembly that gives the ability to pass by restrictions.

It is another object of the present invention to provide a cone assembly that is retrievable with zero force.

It is another object of the present invention to provide a cone assembly which avoids interference between the cone and the pipe end under no compressive loads.

It is a further object of the present invention to provide a cone assembly which is easy-to-use and relatively inexpensive.

These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims.

BRIEF SUMMARY OF THE INVENTION

The present invention is a cone assembly for use in expanding the diameter of a pipe. The cone assembly includes a rigid cone adapted to be positioned adjacent to an end of the pipe, and a flexible cone positioned adjacent an end of the rigid cone. The flexible cone is movable between an expanded diameter and a reduced diameter. The flexible cone having an internal taper and is preferably a ring with a continuous wall having a single slot therethrough. An actuator has an end in contact with the flexible cone. The actuator is movable between an extended position and a retracted position. The extended position is adapted to cause the rigid cone to expand the diameter of the pipe and to cause the flexible cone to have the expanded diameter. The retracted position of the actuator removes or releases a force applied to the flexible cone so as to cause the flexible cone to have the reduced diameter.

In an embodiment, the slot of the flexible cone extends longitudinally through the wall of the flexible cone, the slot widening in the expanded diameter of said flexible cone, the slot narrowing in the reduced diameter of said flexible cone.

In an embodiment, the actuator has a piston with an end bearing adjacent the opposite end of the flexible cone when the flexible cone has the expanded diameter.

In an embodiment, the slot is positioned at an angle with respect to a center axis of the flexible cone.

In an embodiment, the end of the actuator has a tapered outer diameter that corresponds to the internal taper of the flexible cone. The tapered outer diameter of the actuator may be slidable along the internal taper of the flexible cone.

In an embodiment, the internal taper of the flexible cone is slidable along an external taper of the rigid cone.

The present invention is also an assembly including a pipe having an end and an inner diameter, and a rigid cone positioned adjacent the end of the pipe. The rigid cone has a tapered outer diameter that reduces from one end of the rigid cone toward an opposite end of the rigid cone. The opposite end of the rigid cone has an outer diameter less than an inner diameter of the end of the pipe. The end of the rigid cone has an outer diameter greater than the inner diameter of the end of the pipe. A flexible cone includes a ring with a continuous wall having a single slot therethrough. The flexible cone has an end at the end of the rigid cone and an opposite end. The flexible cone has a tapered inner diameter. The flexible cone has an expanded diameter upon an application of force and a reduced diameter when no force or a minimal force is applied to the flexible cone. An actuator is provided, having an end facing the opposite end of the flexible cone. The end of the actuator is in contact with the flexible cone, the actuator movable between an extended position and a retracted position, wherein the extended position causes the flexible cone to have the expanded diameter and to urges the flexible cone and the rigid cone to expand the diameter of the pipe. The retracted position allows the flexible cone and the rigid cone to be removed from the inner diameter at the end of the pipe.

In an embodiment, the flexible cone has a slot extending axially through the wall of said flexible cone from the end of said flexible cone to the opposite end of said flexible cone.

In an embodiment, the reduced diameter of the flexible cone is less than the inner diameter of the pipe when the actuator is in the retracted position.

In an embodiment, the actuator has a tapered outer diameter at an end thereof, the tapered outer diameter of the actuator generally matching the tapered inner diameter of the flexible cone. The tapered outer diameter of the actuator is slidable with respect to the tapered inner diameter of said flexible cone as said actuator moves between the extended position and the retracted position.

In an embodiment, the slot is positioned at an angle with respect to a center axis of the flexible cone.

In an embodiment, the internal taper of the flexible cone is slidable along an external taper of the rigid cone.

The present invention is also a method for expanding the diameter of a pipe, the method comprising the steps of: (1) positioning a rigid cone and a flexible cone adjacent the end of the pipe such that the rigid cone has a narrow diameter end adjacent the end of the pipe, the flexible cone being positioned adjacent a wide diameter end of said rigid cone, the flexible cone comprising a ring with a continuous wall having a single slot therethrough; (2) applying a force to the flexible cone so as to translate the flexible cone and the rigid cone into the end of the pipe; (3) expanding the diameter of the pipe by sliding an outer diameter of the rigid cone along an inner diameter of the pipe; (4) expanding a diameter of the flexible cone during the application of force to the flexible cone; (5) releasing or reducing the force on the flexible cone after the end of the pipe has a desired expanded diameter so as to cause the flexible cone to reduce the outer diameter of the flexible cone; and (6) removing the flexible cone and the rigid cone from the end of the pipe after the force is reduced or released.

In an embodiment, the rigid cone has a tapered outer diameter, the tapered outer diameter having a large diameter greater than an inner diameter of the end of the pipe prior to the step of expanding the outer diameter of the pipe and a small diameter less than the inner diameter of the end of the pipe prior to the step of expanding the outer diameter of the pipe. The large diameter of the rigid cone may be less than an inner diameter of the end of the pipe following the steps of expanding the outer diameter of the pipe.

In an embodiment, the step of applying the force includes actuating an actuator so as to move from a retracted position to an extended position, the extended position bearing against an end of the flexible cone. The step of expanding the outer diameter of the flexible cone may include sliding a tapered surface of the actuator or a tapered outer surface of the rigid cone along the tapered inner diameter of the flexible cone such that the slot formed in the outer wall of the flexible cone widens.

In an embodiment, the step of removing includes retracting the actuator so as to pull the rigid cone and the flexible cone from the end of the pipe, and retrieving the flexible cone and the rigid cone to a remote location.

This foregoing Section is intended to describe, with particularity, the preferred embodiments of the present invention. It is understood that modifications to this preferred embodiment can be made within the scope of the present claims. As such, this Section should not to be construed, in any way, as limiting of the broad scope of the present invention. The present invention should only be limited by the following claims and their legal equivalents.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIGS. 1A, 1B and 1C show a cone assembly of the prior art as used for the expansion of a pipe or tubular.

FIG. 2 is a side elevational view showing the cone assembly of the present invention prior to the expansion of the tubular.

FIG. 2A is a perspective view showing the flexible cone of the present invention.

FIGS. 3A and 3B illustrates the various steps of the method of the present invention for the expansion of the tubular and for the removal of the cone assembly from the tubular.

FIGS. 4A, 4B and 4C show the various steps of the method of the present invention for forming the expanded outer diameter of the tubing.

FIGS. 5A, 5B and 5C illustrate a cone assembly of another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 2, there is shown the cone assembly 20 for use in the expansion of a tubular 22. The tubular 22 is in the nature of a pipe having an end 24 and an inner diameter 26. A rigid cone 28 is positioned adjacent to the end 24 of the pipe 22. The rigid cone 28 has a tapered outer diameter 30 that reduces in diameter from end 32 toward end 33. The end 33 of the rigid cone 28 has an outer diameter less than the inner diameter 26 at the end of the pipe 22. The end 32 of the rigid cone 28 has an outer diameter greater than the inner diameter 26 of the pipe 22. A flexible cone 34 has an end 36 at the end 32 of the rigid cone 28. The flexible cone 34 will preferably have a tapered inner diameter which widens from the end 36 to the opposite end 38. The flexible cone 34 has an expandable diameter when a force is applied to the end 38 of the flexible cone 34 and a reduced diameter when no force or minimal force is applied to the flexible cone. In FIG. 2, the reduced diameter of the flexible cone 34 is particularly illustrated.

An actuator 40 has an end received within the flexible cone 34. As will be described hereinafter, the end of the actuator 40 is receivable within the tapered inner diameter of the flexible cone 34. The actuator 40 is movable between an extended position and a retracted position (shown in FIG. 2). In the extended position, the flexible cone has an expanded diameter which urges the flexible cone and the rigid cone to expand the diameter of the pipe 22. The retracted position allows the flexible cone 34 and the rigid cone 28 to be removed from the inner diameter 26 of the pipe 22.

As can be seen in FIG. 2A, the flexible cone 34 has a slot 43 extending axially through a wall of the flexible cone 34 from one end of the flexible cone 34 to an opposite end of the flexible cone. As will be described hereinafter, the reduced diameter of the flexible cone 34 will be less than the inner diameter 26 of the pipe 22 (after expansion) when the actuator 40 is in the retracted position. The actuator 40 will preferably have a tapered outer diameter at an end thereof. In an embodiment, the tapered outer diameter of the actuator 40 generally matches the tapered inner diameter of the flexible cone 34. The tapered outer diameter of the actuator 40 is slidable with respect to the tapered inner diameter of the flexible cone 34 as the actuator 40 moves between the extended position and the retracted position.

Preferably, the flexible cone 34 is in the form of a ring with a continuous outer wall with a single slot therethrough. This construction is advantageous compared to the relatively fragile expander units of the U.S. Pat. No. 7,681,636 patent. The flexible cone 34 of the present invention is stronger and provides more continuous pressure on the pipe than those of the prior art.

In FIG. 2, it can be seen that there is a piston 42 that is the actuator 40 or acts upon the actuator 40. The piston has a portion received within the inner diameter of the flexible cone 34 and within the interior of the rigid cone 28. The piston 42 has a selective anchor 44 at an end thereof. The selective anchor 44 has a plurality of teeth 45 thereon. The selective anchor 44 will bear against the end 33 of the rigid cone 28 when the actuator 40 moves from the retracted position to the extended position. Each of the rigid cone 28 and the flexible cone 34 is preferably of a frustoconical shape. A pressure line 80 is provided with a pressure port 82 that drives the piston 42 of the actuator 40. The pressure line 80 is also connected to a pressure port 84, which expands the selective anchor 44 such that the teeth 45 engage the pipe.

FIG. 2A is an isolated view of the flexible cone 34. FIG. 2A illustrates the flexible cone 34 as a ring, wherein the slot 43 cuts through the ring shape from end 38 to end 36. The slot 43 is preferably cut at an angle with respect to the axial direction of the pipe (rather than straight across from end 38 to end 36). An angled cut is preferable because this prevents a gap in the flexible cone where pressure would not be applied to the pipe upon expansion.

FIG. 3A illustrates the flexible cone in the expanded configuration. Dashed line 41 shows the lack of a gap due to the angled cut, whereas a straight or axially-cut flexible cone would have a gap where pressure would not be applied to the pipe, thereby not expanding the pipe all around.

FIGS. 3A and 3B show the process of the present invention. In particular, in FIG. 3A, it can be seen that the actuator 40 urges against the flexible cone 34 so as to push the flexible cone 34 and the rigid cone 28 into the inner diameter 26 of the pipe 22. In particular, the tapered outer diameter 30 of the rigid cone 28 will form the desired tapered section 46 of the pipe 22. Similarly, the tapered outer diameter of the flexible cone 34 will further serve to shape the expanded diameter section of the pipe 22. In FIG. 3A, it can be seen that when the actuator 40 applies a force against the flexible cone 34, the slot 43 will expand so as to expand the outer diameter of the flexible cone 34. In this configuration, it can be seen that there is a ledge 50 that is formed at the end of the pipe. The rigid cone 28 moves so as to approach the selective anchor 44.

Under normal circumstances, it would be difficult to remove the cone assembly from the interior diameter 26 of the pipe 22. However, because of the use of the flexible cone 34, in combination with the rigid cone 28, removal becomes simplified. In FIG. 3B, it can be seen that the actuator 40 removes its force from the flexible cone 34 and also to the rigid cone 28. Because the flexible cone 34 is suitably flexible and it is biased to the non-expanded diameter, the slot 43 will narrow in width so as to reduce the outer diameter of the flexible cone 34. The selective anchor 44 can bear against the rigid cone 28 so that the piston 42 can draw or pull the rigid cone 28 and the flexible cone 34 from the inner diameter 26 of the pipe 22. As such, the expanded section 46 of the pipe 22 is created. The ledge 50 will not interfere with the removal of the flexible cone 34 or the rigid cone 28.

FIG. 4A shows, in particular, the configuration on the interior of each of the rigid cone 28 and the flexible cone 34 in relation to the actuator 40. It can be seen that a portion 42 of the actuator 40 extends through the interior of the rigid cone 28 and the flexible cone 34. The flexible cone 34 has a tapered inner diameter 54 which widens from the end 36 which abuts the rigid cone 24 toward the opposite end 38 of the flexible cone. The actuator 40 has a tapered outer diameter 56 which will slide along the tapered inner diameter 54 of the flexible cone 34 as the actuator 40 translates through the interior of the flexible cone 34. As the actuator 40 moves in the direction toward the rigid cone 28, the outer diameter of the flexible cone 34 will expand by the widening of the slot 43. This will further urge the rigid cone 28 into the inner diameter 26 of the pipe 22. A spring 49 urges the flexible cone 34 toward the rigid cone 28. The portion 42 of the actuator 40 has an abutment surface 51. The actuator 40 has a wall 41. In FIG. 4A, the rigid cone 28 has an end bearing against the surface 51, and the flexible cone has an end spaced from the wall 41.

FIG. 4B shows that the actuator 40 has moved to its extended position. In this configuration, the wall 41 of the actuator 40 will abuts the rigid cone 28 so as to fully urge the rigid cone 28 into the inner diameter 26 of the pipe 22 in order to create the expanded section 46 and the ledge 50 of the pipe 22. In this configuration, the tapered inner diameter 54 of the flexible cone 34 will slide along the tapered outer diameter 56 of the actuator 40. The spring 49 is compressed and the flexible cone 34 is fully positioned over the surface of the actuator 40. The end of the rigid cone 28 will bear against the wall 41. As such, the actuator 40 will cause the outer surface of the rigid cone 28 and the flexible cone 34 to form the expanded section 46 of the pipe 22. The end 47 of the rigid cone 28 will be spaced from the selective anchor 44.

FIG. 4C shows the circumstances in which the force is removed from the actuator 40. In this configuration, the actuator 40 will move rearwardly within the interior of the flexible cone 34. Similarly, the abutment surface 51 at the end of the portion 42 of the actuator 40 will bear against the end 47 of the rigid cone 28 so as to draw or pull the rigid cone 28 and the flexible cone 34 from the inner diameter 26 of the pipe 22. Since the wide outer diameter of the flexible cone 34 is less than the inner diameter of the pipe 22 at the end of the ledge 50, there will be no restriction against the removal of the rigid cone 28 and the flexible cone 34 from the interior diameter 26 of the pipe 22 after expansion. This assembly can then be easily retrieved to a remote location for further use. The spring 49 assists the rigid cone 28 and the flexible cone 34 back to the position shown in FIG. 4A.

Referring to FIGS. 5A-5C, there is shown an alternative embodiment of the cone assembly of the present invention. The cone assembly 100 includes an actuator 102 and rigid cone 104. As with the previous embodiment, a flexible cone 106 is in contact with both the actuator and the rigid code 104.

In FIG. 5A it can been seen that there is an axially forward direction 108 with respect to the pipe 120. The rigid cone 104 has two sections divided by a ledge 110. In the forward section, the diameter of the rigid cone decreases in the axially forward direction 108. Opposite the ledge 110, the diameter of the rigid cone increases in the axially forward direction 108. This area of increasing diameter is illustrated by reference number 112. The flexible cone has a corresponding increase in diameter moving in the axially forward direction 108 from the actuator 102.

As can be seen in FIG. 5A, the actuator 102 is in contact with the flexible cone 106 such the flexible cone 106 slides along the sloped portion 112 of the rigid cone 104. FIG. 5A also illustrates a spring 116 positioned between actuator 102 and the rigid cone 104. A selective anchor or other abutment number 118 is also shown in FIG. 5A.

FIG. 5B illustrates the cone assembly 100 in the extended position. As can be seen at FIG. 5B, the actuator 102 has moved the flexible cone 106 up the sloped portion 112 of the rigid cone 104 so as to cause the flexible and rigid cone to expand the diameter of the pipe 120. As we see in FIG. 5B, the flexible cone has been moved along the slope 112 of the rigid code 114 until it abuts the ledge 110. FIG. 5B illustrates how the pipe has been expanded and a ledge 122 is present.

In FIG. 5C, the cone assembly 100 has been retracted. The flexible cone 106 has moved axially rearwardly along the sloped portion 112 of the rigid cone 104 back to its original position as shown in FIG. 5A. In this position, it can be seen how there is a gap between the bottom portion of the ledge 122 and the top of both the rigid cone 104 and the flexible cone 106. As with the previous embodiments, this allows for easy extraction of the cone assembly from the expanded pipe.

The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction can be made is the scope of the present invention without departing from the true spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.

Claims

1. A cone assembly for use in expanding the diameter of a pipe, the cone assembly comprising: a rigid cone adapted to be positioned adjacent to an end of the pipe;a flexible cone positioned adjacent an end of said rigid cone, said flexible cone movable between an expanded diameter and a reduced diameter, said flexible cone having an internal taper, the flexible cone comprising a ring with a continuous wall having a single slot therethrough; andan actuator having an end in contact with said flexible cone, said actuator movable between an extended position and a retracted position, the extended position adapted to cause said rigid cone to expand a diameter of the pipe and to cause said flexible cone to have the expanded diameter, the retracted position of said actuator removing or releasing a force applied to said flexible cone so as to cause said flexible cone to have the reduced diameter.

2. The cone assembly of claim 1, the slot of the flexible cone extending longitudinally through the wall of said flexible cone, the slot widening in the expanded diameter of said flexible cone, the slot narrowing in the reduced diameter of said flexible cone.

3. The cone assembly of claim 1, said actuator comprising a piston having an end bearing adjacent the opposite end of said flexible cone when said flexible cone has the expanded diameter.

4. The cone assembly of claim 1, said slot positioned at an angle with respect to a center axis of the flexible cone.

5. The cone assembly of claim 1, the end of said actuator having a tapered outer diameter that corresponds to the internal taper of said flexible cone.

6. The cone assembly of claim 5, wherein the tapered outer diameter of said actuator is slidable along the internal taper of said flexible cone.

7. The cone assembly of claim 1, wherein the internal taper of said flexible cone is slidable along an external taper of said rigid cone.

8. An assembly comprising: a pipe having an end and an inner diameter;a rigid cone positioned adjacent the end of the pipe, said rigid cone having a tapered outer diameter that reduces from one end of the rigid cone toward an opposite end of said rigid cone, the opposite end of said rigid cone having an outer diameter less than an inner diameter of the end of said pipe, the end of said rigid cone having an outer diameter greater than the inner diameter of the end of said pipe;a flexible cone comprising a ring with a continuous wall having a single slot therethrough, the flexible cone having an end at the end of said rigid cone and an opposite end, said flexible cone having a tapered inner diameter, said flexible cone having an expanded diameter upon an application of force and a reduced diameter when no force or a minimal force is applied to said flexible cone; andan actuator having an end facing the opposite end of said flexible cone, the end of said actuator being in contact with the flexible cone, said actuator movable between an extended position and a retracted position, the extended position causing the flexible cone to have the expanded diameter and to urge said flexible cone and said rigid cone to expand the diameter of said pipe, the retracted position allowing said flexible cone and said rigid cone to be removed from the inner diameter at the end of said pipe.

9. The assembly of claim 8, wherein the flexible cone has a slot extending axially through the wall of said flexible cone from the end of said flexible cone to the opposite end of said flexible cone.

10. The assembly of claim 8, wherein the reduced diameter of said flexible cone is less than the inner diameter of said pipe when the actuator is in the retracted position.

11. The assembly of claim 8, wherein the actuator has a tapered outer diameter at an end thereof, the tapered outer diameter of said actuator generally matching the tapered inner diameter of said flexible cone.

12. The assembly of claim 11, wherein the tapered outer diameter of said actuator is slidable with respect to the tapered inner diameter of said flexible cone as said actuator moves between the extended position and the retracted position.

13. The assembly of claim 8, said slot positioned at an angle with respect to a center axis of the flexible cone.

14. The assembly of claim 8, wherein the internal taper of said flexible cone is slidable along an external taper of said rigid cone.

15. A method for expanding the diameter of a pipe, the method comprising: positioning a rigid cone and a flexible cone adjacent the end of the pipe such that the rigid cone has a narrow diameter end adjacent the end of the pipe, the flexible cone being positioned adjacent a wide diameter end of said rigid cone, the flexible cone comprising a ring with a continuous wall having a single slot therethrough;applying a force to the flexible cone so as to translate the flexible cone and the rigid cone into the end of the pipe;expanding the diameter of the pipe by sliding an outer diameter of said rigid cone along an inner diameter of said pipe;expanding a diameter of said flexible cone during the application of force to the flexible cone;releasing or reducing the force on the flexible cone after the end of the pipe has a desired expanded diameter so as to cause the flexible cone to reduce the outer diameter of the flexible cone; andremoving the flexible cone and the rigid cone from the end of the pipe after the force is reduced or released.

16. The method of claim 15, wherein the rigid cone has a tapered outer diameter, the tapered outer diameter having a large diameter greater than an inner diameter of the end of the pipe prior to the step of expanding the outer diameter of the pipe and a small diameter less than the inner diameter of the end of the pipe prior to the step of expanding the outer diameter of the pipe.

17. the method of claim 16, wherein the large diameter of the rigid cone is less than an inner diameter of the end of the pipe following the steps of expanding the outer diameter of the pipe.

18. The method of claim 15, wherein the step of applying the force comprises: actuating an actuator so as to move from a retracted position to an extended position, the extended position bearing against an end of the flexible cone.

19. The method of claim 18, the step of expanding the outer diameter of the flexible cone comprising: sliding a tapered surface of the actuator or a tapered outer surface of the rigid cone along the tapered inner diameter of the flexible cone such that the slot formed in the outer wall of the flexible cone widens.

20. The method of claim 18, wherein the step of removing comprises: retracting the actuator so as to pull the rigid cone and the flexible cone from the end of the pipe; andretrieving the flexible cone and the rigid cone to a remote location.