Multi-Piece Packing Element Containment System

A packer device for forming a fluid seal within a wellbore, comprising:

• a central packer mandrel;
• a deformable packer element radially surrounding the mandrel, the packer element being axially compressible between an unset position wherein the element has a radially reduced condition, and a set position wherein the element has a radially expanded condition to form a fluid seal against a surrounding surface;
• a setting sleeve that is moveable axially with respect to the mandrel for selectively axially compressing the packer element into its set position;
• a packer element containment system to limit axial deformation of the packer element, the containment system comprising:
• a) a backup ring which partially encases the packer element;
• and
• b) a plurality of support rings adjacent the backup ring to prevent deformation of the backup ring.

A method of containing a packer element against axial extrusion, the method comprising the steps of:

• a) assembling a packer device having:
• a central packer mandrel;
• a deformable packer element radially surrounding the mandrel, the packer element being axially compressible between an unset position wherein the element has a radially reduced condition, and a set position wherein the element has a radially expanded condition to form a fluid seal against a surrounding surface;
• a setting sleeve that is moveable axially with respect to the mandrel for selectively axially compressing the packer element into its set position;
• a packer element containment system to limit axial deformation of the packer element, the containment system comprising a backup ring which partially encases the packer element;
• and a plurality of generally conically-shaped support rings adjacent the backup ring to prevent deformation of the backup ring;
• b) moving the setting sleeve axially with respect to the packer mandrel to compress the packer element to its set position;
• and
• c) axially flattening the support rings to form an axial structural barrier against extrusion of the packer element.