# US 11,441,399 B2 · Downhole conformable screen system and method of making a conformable screen for downhole use > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,441,399 B2 - Document ID: US11441399B2 - Status: Granted - Kind: B2 - Application number: 16/942,131 - Filed: 2020-07-29 - Published: 2022-02-03 - Granted: 2022-09-13 - Earliest claimed: 2020-07-29 - Assignees: Baker Hughes Oilfield Operations LLC - Applicants: Sean Gaudette - Inventors: Sean Gaudette - Web page: https://patentgrep.com/patent/US11441399B2 ## CPC - E21B 43/108: {Expandable screens or perforated liners} - E21B 43/082: {Screens comprising porous materials, e.g. prepacked screens} - E21B 2200/08: Down-hole devices using materials which decompose under well-bore conditions - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS ## Abstract A system of a downhole conformable screen system including a tubular, and a screen defined by a plurality of 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 after the tubular and screen have been positioned within the wellbore. A method of making a conformable screen for downhole use including forming a plurality of screen segments out of a porous foam, and attaching the plurality of screen segments to a tubular to form a screen around the tubular. ## Claims ### Claim 1 A downhole conformable screen system comprising: a tubular having a longitudinal axis; and a screen defined by a plurality of longitudinally extending 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 filtration material of each screen segment abuts filtration material of the next adjacent screen segment both before and after expansion of the screen system. ### Claim 2 (depends on 1) The downhole conformable screen system of claim 1, wherein the tubular defines a wall having a plurality of openings that extend radially through the wall, the openings being configured to allow fluid flowing through the screen to flow through the openings into an inner bore of the tubular. ### Claim 3 (depends on 1) The downhole conformable screen system of claim 1, further comprising a retainer positioned at an axial end of the screen, the retainer being configured to hold the screen segments together. ### Claim 4 (depends on 1) The downhole conformable screen system of claim 1, wherein the screen segments have trapezoidal cross-sectional shapes. ### Claim 5 (depends on 1) The downhole conformable screen system of claim 1, wherein a first longitudinal protrusion that extends in a direction tangential to the tubular longitudinal axis of one screen segments overlaps a second longitudinal protrusion that extends in a direction tangential to the tubular longitudinal axis of another screen segment. ### Claim 6 (depends on 1) The downhole conformable screen system of claim 1, further comprising an adhesive configured to hold adjacent screen segments to one another. ### Claim 7 (depends on 6) The downhole conformable screen system of claim 6, wherein the adhesive is configured to degrade when exposed to an agent. ### Claim 8 (depends on 6) The downhole conformable screen system of claim 6, wherein the adhesive is sufficiently weak so as not to damage the screen segments when they expand. ### Claim 9 (depends on 1) The downhole conformable screen system of claim 1, further comprising one or more standoffs positioned in an annular space between the tubular and the screen. ### Claim 10 (depends on 9) The downhole conformable screen system of claim 9, wherein the one or more standoffs are an integral part of the screen segments. ### Claim 11 (depends on 1) The downhole conformable screen system of claim 1, wherein the plurality of screen segments includes twelve of the screen segments each covering an arc of 30 degrees. ### Claim 12 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. ### Claim 13 (depends on 12) The method of making a conformable screen for downhole use of claim 12, further comprising positioning one end of the plurality of screen segments in an annular gap defined between the tubular and a collar. ### Claim 14 (depends on 12) The method of making a conformable screen for downhole use of claim 12, further comprising retaining the plurality of screen segments to the tubular with a retainer. ### Claim 15 (depends on 12) The method of making a conformable screen for downhole use of claim 12, further comprising adhering each of the plurality of screen segments to perimetrically adjacent ones of the screen segments with adhesive. ### Claim 16 (depends on 12) The method of making a conformable screen for downhole use of claim 12, further comprising forming a standoff on each of the plurality of screen segments. ### Claim 17 (depends on 12) The method of making a conformable screen for downhole use of claim 12, further comprising forming the plurality of screen segments so they have a trapezoid cross section. ### Claim 18 (depends on 12) The method of making a conformable screen for downhole use of claim 12, further comprising forming longitudinal protrusions on opposing perimetrical sides of each of the plurality of screen segments. ### Claim 19 (depends on 18) The method of making a conformable screen for downhole use of claim 18, further comprising overlapping the longitudinal protrusion of each of the plurality of screen segments with one the longitudinal protrusions of adjacent ones of the plurality of screen segments. ### Claim 20 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.