Downhole conformable screen system and method of making a conformable screen for downhole use

A method of making a conformable screen for downhole use comprising:

• forming a plurality of screen segments out of a porous foam, each segment having perimetrical sides;
• and
• attaching the plurality of screen segments to a tubular to form a screen around the tubular, wherein perimetrical sides of each screen segment remains in contact with a perimetrical side segment of a next adjacent screen segment both before and after expansion of the screen.

A downhole conformable screen system comprising:

• a tubular having a longitudinal axis;
• and
• a screen defined by a plurality of longitudinally extending foam screen segments positioned radially outward of the tubular, each of the plurality of screen segments being positioned perimetrically between two other of the screen segments, the screen being configured to expand radially to engage with an inner surface of a wellbore and have opposing perimetrical sides of each screen segment abutting perimetrical sides of the next adjacent screen segment, such that foam material of each screen segment abuts the foam material of the next adjacent screen segment both before and after expansion of the screen system.