Large format diverter materials, methods of manufacture and uses of same

Abstract

Devices, materials, and compositions of diverting material, and related methods and systems for making same and using same to divert a fluid in an underground formation such as a wellbore. The diverter devices, material, and compositions may be manufactured by various methods, including 3-D printing using a variety of polymers.

Description

LARGE FORMAT DIVERTER MATERIALS, METHODS OF MANUFACTUREAND USES OF SAMEInventors: Nicholas A. Koster, Denver, CO, U.S.A.Michael A. Bernich, II, Ellisville, MO, U.S.A.CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority pursuant to 35 U.S.C. § 119(e) of U.S Provisional Patent Application No. 63 / 659,965, filed June 14, 2025, entitled “Large Format Diverter Materials, Methods of Manufacture and Uses of Same,” which is hereby incorporated by reference herein in its entirety.BACKGROUND

[0002] Wellbores allow access to subterranean formations for extraction of various fluids, such as hydrocarbons (oil, natural gas, etc.). Wellbores may also be used in geothermal applications. In many cases, fluids travel through the wellbore, from the wellbore into the formation, and / or to the wellbore from the formation. In some cases, these distances can be significant.

[0003] Well stimulation is a term covering various techniques designed to control exchange of fluids between wellbores and the surrounding formations. One particular well-stimulation technique is hydraulic fracturing. This technique is typically used to increase / enhance flow of geologic fluids, for example natural gas, petroleum, etc. from subsurface reservoirs into wellbores, where the fluids may be directed to the surface for capture and processing. Briefly, fracturing may involve the introduction of pressurized liquids into the wellbore. These liquids are forced into formations at high pressure to aid in breaking and / or fracturing low-permeability formations such as low or non-permeable rock formations. Fracturing these formations may aid in producing channels through the formation or rock. These new channels allow the geologic fluids, that may be located at some distance from the wellbore and / or blocked by the non- permeable formation, a flowpath toward and into the wellbore.

[0004] Hydraulic fracturing is often performed multiple times or at multiple locations along a length of a wellbore. In other cases, hydraulic fracturing may be performed in and / or nearpreviously depleted zones. In such cases it may be useful to isolate specific zones, such as a previously fractured zone, or confine fractures to particular zones.

[0005] Isolating specific zones in a wellbore may be accomplished with the use of diverter materials. Diverter materials may be useful in temporarily or permanently sealing or plugging permeable zones that have fractures, fissures, etc. that my allow fluid to enter the permeable zone. This temporary sealing helps to divert fluid flow from those zones (especially previously fractured and / or depleted zones) or region to another. In one example, diverter materials may be used to divert fluid from from a high permeability region to a lower permeability region. However, many variables make selecting the diverter material to use in a given situation (i.e. target zone’s position in wellbore, temperature, and fluid characteristics) difficult.

[0006] What is needed is a diverter material that with tunable characteristics that can be quickly manufactured for deployment.SUMMARY

[0007] Disclosed herein are particles, devices, materials, compositions, methods, and systems for diverting fluid. The disclosed diverting particles are sized to be capable of targeting large holes and / or voids, bridging and sealing those holes. The diverter particles may have various shapes and sizes. In many embodiments, the particles may be disc-shaped or spherical, the height and / or profile of the disc may be selected based on its ability to bridge / seal the hole or void. The disclosed particles are engineered to deform after placement at the hole / void in response to pressure, while maintaining its position at / in the hold and maintain the seal of the hole / void after deformation. The disclosed materials and particles may be engineered, in part, to deform at specific temperatures and pressures encountered in specific wellbores and specific locations within those wellbores. In many embodiments, the particle’s size, shape, diameter, profile, and / or composition may be selected based on the target hole’s size and or shape, for one example the particle may have at least one measurable dimension that is about 50% to about 150% of diameter of the hole to be sealed. In various embodiments, the hole or perforation may be a casing breach, and / or the particle may contact one surface of the hole, flatten and / or deform, but not traverse the hole and / or a channel or tunnel defined by the hole. In many embodiments, the flattened / deformed particle may not protrude from the hole to extend above an opposite surface. This ability to resist protruding from the other side of th hole may help prevent removal or displacement of the flattened / deformed particle when or if an object or fluid exerts a force against, over, or across the flattened particle.

[0008] The disclosed particles may include one or more structures positioned at or near the particle’s center or core. In various embodiments, the particle may define a central volume rendering the particle at least partially hollow, in some embodiments the central volume may be separated or in fluid communication with the particles’ exterior environment. In many embodiments, the disclosed particles may define a surface area that may improve transport within the fluid flow and / or prevent settling of particles out of the fluid flow. In many embodiments, the disclosed particles may further or separately possess relatively low density. The disclosed materials and particles may allow for sealing and diversion without the use of specialty devices, such as a launcher. In many embodiments, the disclosed material and particles may be preloaded into typical frac iron, which may be isolated behind valves, in anticipation of deployment.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figures of various embodiments of the disclosed particles are provided at the Examples.

[0010] FIG. 1 shows graphs with hydrolysis characteristics of various embodiments of the disclosed particles comprising various polymeric compositions at various temperatures.

[0011] FIG. 2 is one embodiment of the disclosed diverter particle with a globe or spherical shape.

[0012] FIG. 3 is one embodiment of the disclosed diverter particle with a disc shape.

[0013] FIG. 4 shows results from testing of one embodiment of the disclosed diverter particle with a disc shape.

[0014] FIG. 5 shows a plurality of disclosed diverter particle embodiments.

[0015] FIG. 6 shows one embodiment of the disclosed disc shaped diverter particle.

[0016] FIG. 7 shows one embodiment of the disclosed globe shaped diverter particle.

[0017] FIG. 8 shows forces on one embodiment of the disclosed particle.

[0018] FIG. 9 shows one method for using the disclosed diverter particles.DETAILED DESCRIPTION

[0019] Disclosed herein are compositions, methods, devices, and systems for deformable diverter products with enhanced sealing behavior. In many embodiments, the disclosed subject matter may deform and / or flatten upon encountering a hole or void, in many embodiments, for example, where the hole or void is in a cylinder with walls of a given thickness the disclosed devices and materials may flow to the hole and substantially seal the hole, whereupon thedevice and material my be partially inserted into the hole, but the deformed device / material, or any substantial portion thereof, will not extend beyond the opposite surface of the cylinder. This ability to avoid substantially traversing the hole / void may aid in preventing the device or material from interacting with fluid and / or fluid-borne components passing near the sealed hole. This may increase the longevity of the device’s residence at the hole or void.

[0020] The disclosed diverter materials may be produced by various methods. In many embodiments, the disclosed materials may be produced by additive or non-additive manufacturing processes. Additive manufacturing may, in some cases, provide for greater design flexibility than other methods. In some embodiments, the additive manufacturing may be, without limitation, 3D printing, selective laser sintering, electron beam melting, resin printing, electrophotographic deposition. Non-additive manufacturing methods may include molding, for example compression or injection molding, subtractive manufacturing (i.e. chemically or physically removing material from other processes). In some embodiments, the materials may be manufactured by combining one or more techniques.

[0021] The disclosed materials may have various shapes, sizes, and characteristics. In some embodiments, the materials may be comprised of a plurality of particles. In many embodiments, the particles generally spherical, flat, discoid, etc. In some embodiments, the particles may comprise a core or center that does not include material, and or generally defines a void in the material comprising the particle. In some embodiments, the core or center may be in fluid communication with the exterior of the particle. In various embodiments, the strength and rigidity of the particle may vary and / or be tuned (i.e. selected during manufacture). In these cases, the strength and rigidity may vary independently along multiple axes. In various embodiments, the particle’s density may be altered and / or tuned prior to or during manufacture by altering the shape and or material used to form the particle.

[0022] The disclosed particles may be of various sizes. In many embodiments, the particle may have at least one measurable dimension from about 0.1 cm to about 10 cm, for one example from about 0.6 cm to about 5 cm. In many embodiments, the diameter is the measurable dimension, and is greater than about 0.10 cm, 0.15 cm, 0.20 cm, 0.25 cm, 0.30 cm, 0.35 cm, 0.40 cm, 0.45 cm, 0.50 cm, 0.55 cm, 0.60 cm, 0.65 cm, 0.70 cm, 0.75 cm, 0.80 cm,0.85 cm, 0.90 cm, 0.95 cm, 1.00 cm, 1 .05 cm, 1.10 cm, 1.15 cm, 1 .20 cm, 1 .25 cm, 1.30 cm,1 .35 cm, 1 .40 cm, 1 .45 cm, 1 .50 cm, 1 .55 cm, 1 .60 cm, 1 .65 cm, 1 .70 cm, 1 .75 cm, 1 .80 cm,1 .85 cm, 1 .90 cm, 1 .95 cm, 2.00 cm, 2.05 cm, 2.10 cm, 2.15 cm, 2.20 cm, 2.25 cm, 2.30 cm,2.35 cm, 2.40 cm, 2.45 cm, 2.50 cm, 2.55 cm, 2.60 cm, 2.65 cm, 2.70 cm, 2.75 cm, 2.80 cm,2.85 cm, 2.90 cm, 2.95 cm, 3.00 cm, 3.05 cm, 3.10 cm, 3.15 cm, 3.20 cm, 3.25 cm, 3.30 cm,3.35 cm, 3.40 cm, 3.45 cm, 3.50 cm, 3.55 cm, 3.60 cm, 3.65 cm, 3.70 cm, 3.75 cm, 3.80 cm,3.85 cm, 3.90 cm, 3.95 cm, 4.00 cm, 4.05 cm, 4.10 cm, 4.15 cm, 4.20 cm, 4.25 cm, 4.30 cm,4.35 cm, 4.40 cm, 4.45 cm, 4.50 cm, 4.55 cm, 4.60 cm, 4.65 cm, 4.70 cm, 4.75 cm, 4.80 cm,4.85 cm, 4.90 cm, 4.95 cm, 5.00 cm, 5.05 cm, 5.10 cm, 5.15 cm, 5.20 cm, 5.25 cm, 5.30 cm,5.35 cm, 5.40 cm, 5.45 cm, 5.50 cm, 5.55 cm, 5.60 cm, 5.65 cm, 5.70 cm, 5.75 cm, 5.80 cm,5.85 cm, 5.90 cm, 5.95 cm, 6.0 cm, 6.2 cm, 6.4 cm, 6.6 cm, 6.8 cm, 7.0 cm, 7.2 cm, 7.4 cm, 7.6 cm, 7.8 cm, 8.0 cm, 8.2 cm, 8.4 cm, 8.6 cm, 8.8 cm, 9.0 cm, 9.2 cm, 9.4 cm, 9.6 cm, 9.8 cm, and 10.0 cm, and less than about 10.5 cm, 10.0 cm, 9.8 cm, 9.6 cm, 9.4 cm, 9.2 cm, 9 cm, 8.8 cm, 8.6 cm, 8.4 cm, 8.2 cm, 8 cm, 7.8 cm, 7.6 cm, 7.4 cm, 7.2 cm, 7 cm, 6.8 cm, 6.6 cm, 6.4 cm, 6.2 cm, 6 cm, 5.95 cm, 5.9 cm, 5.85 cm, 5.8 cm, 5.75 cm, 5.7 cm, 5.65 cm, 5.6 cm, 5.55 cm, 5.5 cm, 5.45 cm, 5.4 cm, 5.35 cm, 5.3 cm, 5.25 cm, 5.2 cm, 5.15 cm, 5.1 cm, 5.05 cm, 5 cm, 4.95 cm, 4.9 cm, 4.85 cm, 4.8 cm, 4.75 cm, 4.7 cm, 4.65 cm, 4.6 cm, 4.55 cm, 4.5 cm, 4.45 cm, 4.4 cm, 4.35 cm, 4.3 cm, 4.25 cm, 4.2 cm, 4.15 cm, 4.1 cm, 4.05 cm, 4 cm, 3.95 cm, 3.9 cm, 3.85 cm, 3.8 cm, 3.75 cm, 3.7 cm, 3.65 cm, 3.6 cm, 3.55 cm, 3.5 cm, 3.45 cm, 3.4 cm, 3.35 cm, 3.3 cm, 3.25 cm, 3.2 cm, 3.15 cm, 3.1 cm, 3.05 cm, 3 cm, 2.95 cm, 2.9 cm, 2.85 cm, 2.8 cm, 2.75 cm, 2.7 cm, 2.65 cm, 2.6 cm, 2.55 cm, 2.5 cm, 2.45 cm, 2.4 cm, 2.35 cm, 2.3 cm, 2.25 cm, 2.2 cm, 2.15 cm, 2.1 cm, 2.05 cm, 2 cm, 1 .95 cm, 1 .9 cm, 1 .85 cm, 1 .8 cm, 1 .75 cm, 1 .7 cm, 1 .65 cm, 1 .6 cm, 1 .55 cm, 1 .5 cm, 1.45 cm, 1 .4 cm, 1 .35 cm, 1 .3 cm, 1 .25 cm, 1 .2 cm, 1.15 cm, 1.1 cm, 1 .05 cm, 1 cm, 0.95 cm, 0.9 cm, 0.85 cm, 0.8 cm, 0.75 cm, 0.7 cm, 0.65 cm, 0.6 cm, 0.55 cm, 0.5 cm, 0.45 cm, 0.4 cm, 0.35 cm, 0.3 cm, 0.25 cm, 0.2 cm, 0.15 cm, 0.1 cm, and 0.05 cm.

[0023] The specific gravity of the disclosed particles may vary. In many embodiments, the specific gravity may be from about 1.01 to about 1.5, for example about 1.14 to about 1.3. In many embodiments, the specific gravity is greater than about 1.00, 1.05, 1.10, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21 , 1.22, 1.23, 1.24, 1.25, 1.26, 1.27, 1.28, 1.29, 1.30, 1.35, 1.40, 1.45, or 1 .50 and less than about 1 .55, 1 .50, 1 .45, 1 .40, 1 .35, 1 .30, 1 .29, 1 .28, 1 .27, 1 .26, 1 .25, 1 .24, 1.23, 1.22, 1.21 , 1.20, 1.19, 1.18, 1.17, 1.16, 1.15, 1.10, and 1.05, wherein the reference fluid / substance may be water, fracturing fluid, or other substance to which the particles are added.

[0024] The disclosed particles may be comprised of various degradable and / or non- degradable materials. In many embodiments, the material is selected, without limitation, from thermoplastics, resins, metals, polymers, etc. In some embodiments, the material is selected from poly lactic acid (PLA), polyethylene terephthalate (PET), PET glycol (PETg), acrylonitrile butadiene styrene (ABS), amide based polymers (such as nylon), polyurethane (for examplethermoplastic polyurethane or TPU), acrylate polymers (polyacrylate or Acrylic), Poly(methyl methacrylate) or PMA, acrylonitrile styrene acrylate (ASA), polycaprolactone (PCL), poly carbonate (PC), polyphenylsulfone (PPSU), polysulfone (PSU), polyether ether ketone (PEEK), Polytetrafluoroethylene (PTFE or Teflon), polyvinyl alcohol (PVOH), polyglycolide (PGA), polyoxymethylene (POM or acetal), glass, carbon, and combinations thereof.

[0025] The disclosed diverter particles may be substantially resistant to heat. In many embodiments, the devices, particles, and materials may have a service temperature between about 60 and 180°C, for example greater than about 60°C, 65°C, 70°C, 75°C, 80°C, 85°C, 90°C, 95°C, 100°C, 105°C, 110°C, 115°C, 120°C, 125°C, 130°C, 135°C, 140°C, 145°C, 150°C, 155°C, 160°C, 165°C, 170°C, and 175°C, and less than about 180°C, 175°C, 170°C, 165°C, 160°C, 155°C, 150°C, 145°C, 140°C, 135°C, 130°C, 125°C, 120°C, 115°C, 110°C, 105°C, 100°C, 98°C, 90°C, 85°C, 80°C, 75°C, 70°C, and 65°C. The disclosed material may be stable at various wellbore temperatures. In many embodiments, the disclosed material and particles may be stable up to about 180°C, for one example 60°C-107°C.

[0026] Figure 1 shows hydrolysis data for the presently disclosed diverter particles comprised of various polymers with differing characteristics at different temperatures. From these graphs, one may select the period of time the diverter may be resident in a given hole or void. From less than about 10 days, to several months. In some embodiments, the diverter material may be substantially permanent within the wellbore at a given temperature (See for example CemVert+ D800 at 190°F and CemVert+ D500 at 120°F.

[0027] The disclosed diverter material may be useful for various situations. In some embodiments the material is useful in wellbore diversion, sealing, etc. In some embodiments the disclosed material may be used for near wellbore diversion. In some embodiments, the disclosed material may be useful in sealing leaks, for one example leaks and / or perforations in casing. The disclosed material may be useful in sealing large void spaces.

[0028] The disclosed diverter material may be deployed in various ways. In most embodiments, the material may be deployed downstream of pumps, in one example on the high pressure side. In some embodiments, the material may be deployed via preloaded iron, for one example behind valves.

[0029] The disclosed diverter material may be engineered for use with and transport within various fluids and fluid systems. In some embodiments, without limitation, the system or fluid may be acid systems, slickwater, high viscosity friction reducer (HVFR), etc. In various embodiment, the fluid may be a relatively high or low viscosity fluid. In low viscosity fluids, thedisclosed material may not settle out of the fluid or may display very little settling out in the fluid compared to existing materials and particles.

[0030] The disclosed material may be engineered for beneficial characteristics at the placement site, for example a hole or perforation. For example, in many embodiments, the disclosed particles may first contact the area surrounding the hole, and seal the hole, the particles are then partially drawn into the hole to complete the seal, while additional material deforms and substantially flattens against the surface surrounding the hole. This deformation / flattening aids in maintaining the seal by reducing the amount of particle material that sits proud the surface of the hole. In some embodiments, this may be referred to as “pancaking.”

[0031] The disclosed materials may aid in sealing the placement site while minimizing at least one dimension, such a height that may intrude into the wellbore. In many embodiments, after deformation the disclosed 3-dimensional particles may substantially flatten (or “pancake”) to a single plane, such that the thickness of the flattened particle may be less than about 60% of one measurable dimension of the unflattened particle, for example less than about 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, or 5%. As one example, wherein the particle’s shape is substantially spherical, for example with a radius of about 3.5 cm (i.e. a diameter of about 7 cm), the unflattened sphere when first contacting the hole may have a height, that is the distance the sphere extends above and beyond the surface through which the hole is formed, by about 7 cm. After finalizing deployment, the particle may deform and substantially flatten to achieve a height that is substantially less than 7 cm, for example the flattened height may be less than about 3 cm, 2 cm, or 1 cm. In some embodiments, the particle may be disc shaped prior to flattening or deforming. In embodiments wherein the hole to be plugged is in a casing, and the flattened particle is applied and positioned to the exterior surface of the casing, the flattened particle may not protrude through the channel, or tunnel, of the hole and beyond the inner surface of the casing. In many cases, the channel defining the hole and connecting the two surfaces (exterior and interior, in the case of a casing) may be from about 1 cm to about 10 cm (or in some cases about 0.5” to about 3.0”). While the disclosed particles may enter the channel / tunnel defined by the hole the particle will deform / collapse against one surface of the hole and not protrude substantially, or at all, from the channel / tunnel to the opposite surface. In many embodiments, the (1 ) deformation / flattening of the disclosed particles and (2) the presence of a substantial portion of diverter material positioned within the channel of the hole, may resist removal or displacement if an object or fluid exerts a force against, over, or across the flattened particle.

[0032] Use of the disclosed materials may minimize or eliminate the need for mechanical blocking and / or diverting systems. The disclosed materials may be used in various wellbores, for example boreholes with eroded perforations and / or large casing leaks.

[0033] Two particular embodiments of the disclosed diverter particles are shown in FIGs. 2 and 3. As depicted in Figure 2, one embodiment of the disclosed diverter particles may define a disc 100, having a radius R and a height H. These embodiments may be referred to as FlowDiscs, Discs, or FlowDisc+s. The disc 100 may have an upper surface 110 and a lower surface 130, not shown, and an edge 120. In most embodiments, the upper 110 and lower surface 120 may be substantially planer. In this embodiment, the disc 100 may further include a raised portion 150, which may extend from the upper surface 1 10 to a height h. In many embodiments, the lower surface 120 may also include a raised portion 150. In this embodiment, the raised portion 150 may define a “+” symbol comprising arms 155 having a length I and width w. In many embodiments, after deployment, placement, and deformation / flattening, the height H is substantially reduced to 0.9X, 0.8X, 0.7X, 0.6X, 0.5X, 0.4X, 0.3X, 0.2X, 0.1X or less of beginning height H. The height h of the raised portion may also be substantially reduced. In many embodiments, the raised portion 150 may aid in increasing the amount of material inserted into the hole’s channel.

[0034] Figure 3 shows an embodiment of the disclosed particles which may be referred to as FlowGlobes, globes, or FlowGlobe+s. The globe 200 may define a substantially spherical shape defined by an outer surface 210. The outer surface may comprise a plurality of windows 215 which may allow for fluid communication between the globe’s interior or core 230 and its external environment. In other embodiments, the core 230 may be solid and / or may not be in fluid communication with the external environment. In this embodiment, the windows 215 of the globe 200 may be separated by a plurality of circumferential ribs 211 , 212, and 213 having a width Wsand may extend toward a center of the globe into the interior by a distance ts,, in some embodiments, there may be a second set of ribs 220 with a distance tS2, such that the distance may be ts+ tS2.

[0035] Various methods may employ the disclosed particles to seal a hole in or near a wellbore. In one embodiment, the method may include identifying a wellbore with at least one hole or void amenable to sealing with diverter particles; selecting a diverter particle for sealing the hole, wherein the diverter particle comprises at least one measurable dimension at least as large as the hole’s average diameter and the particle is comprised of a material whose hydrolysis time is selected based on the operating temperature of the wellbore and the desired operating lifespan ranging from 24 hours to a permanent blockage; deploying the diverterparticle(s) down stream of the wellbore pumps; allowing the diverter particle(s) to contact at least one surface at or near the hole; allowing the diverter particle(s) to deform to at least partially enter a channel formed by the hole; allowing the diverter particle(s) to flatten against at least one surface at or near the hole; and thereby sealing the hole with minimal protrusion into the interior of the wellbore. In many embodiments, the hole may be in a casing in the wellbore. In some embodiments, identifying the hole may include inferring the existence of the hole from loss of a fluid or pressure within the wellbore.EXAMPLESExample 1 - Deformation and flattening of a FlowGlobe

[0036] Applicant tested the ability of the disclosed particles to deploy, place at a hole, deform, flatten and seal the hole. In these experiments, a 1 .9 cm (3 / 4 inch) diameter globe was deployed to seal a 1.27 cm (0.5 in) hole in a metal surface. As shown in Figure 3, after deformation and flattening, the globe’s material is distributed around the surface surrounding the hole (top), and extends substantially less than 1 .9 cm above that surface. Indeed, the globe’s flattened material extends less that about 3 mm, and in some areas less than 1 mm above the surface. This flattening substantially decreases the chance that the flattened material will be removed from the hole.Example 2 - Various views of embodiments of the disclosed particles.

[0037] FIG. 5 shows a plurality of FlowDisc+ comprising various polymer materials. FIG. 6 shows one embodiment of the disclosed particle having a disc shape and an open interior with a spiral internal structure. FIG. 7 is a perspective view of spherical shaped particle having an open interior with a spiral internal structure. FIG 8 showing forces within an embodiment of the particle.

[0038] All references disclosed herein, whether patent or non-patent, are hereby incorporated by reference as if each was included at its citation, in its entirety. In case of conflict between reference and specification, the present specification, including definitions, will control.

[0039] While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description. As will be apparent, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the detailed description is to be regarded as illustrative in nature and not restrictive.

[0040] The description of certain embodiments included herein is merely exemplary in nature and is in no way intended to limit the scope of the disclosure or its applications or uses. In the included detailed description of embodiments of the present systems and methods, reference is made to the accompanying drawings which form a part hereof, and which are shown by way of illustration specific to embodiments in which the described systems and methods may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice presently disclosed systems and methods, and it is to be understood that other embodiments may be utilized, and that structural and logical changes may be made without departing from the spirit and scope of the disclosure. Moreover, for the purpose of clarity, detailed descriptions of certain features will not be discussed when they would be apparent to those with skill in the art so as not to obscure the description of embodiments of the disclosure. The included detailed description is therefore not to be taken in a limiting sense, and the scope of the disclosure is defined only by the appended claims.

[0041] From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention.

[0042] The particulars shown herein are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of various embodiments of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for the fundamental understanding of the invention, the description taken with the drawings and / or examples making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.

[0043] As used herein and unless otherwise indicated, the terms “a” and “an” are taken to mean “one”, “at least one” or “one or more”. Unless otherwise required by context, singular terms used herein shall include pluralities and plural terms shall include the singular.

[0044] Unless the context clearly requires otherwise, throughout the description and the claims, the words ‘comprise’, ‘comprising’, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”. Words using the singular or plural number also include the plural and singular number, respectively. Additionally, the words “herein,” “above,” and “below” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of the application.

[0045] Of course, it is to be appreciated that any one of the examples, embodiments or processes described herein may be combined with one or more other examples, embodiments and / or processes or be separated and / or performed amongst separate devices or device portions in accordance with the present systems, devices and methods.

[0046] Finally, the above discussion is intended to be merely illustrative of the present system and should not be construed as limiting the appended claims to any particular embodiment or group of embodiments. Thus, while the present system has been described in particular detail with reference to exemplary embodiments, it should also be appreciated that numerous modifications and alternative embodiments may be devised by those having ordinary skill in the art without departing from the broader and intended spirit and scope of the present system as set forth in the claims that follow. Accordingly, the specification and drawings are to be regarded in an illustrative manner and are not intended to limit the scope of the appended claims.

Claims

CLAIMSWe claim:1 . A particle for use in fluid diversion, comprising: a particle surface; and a particle core.

2. The particle of claim 1 , wherein the particle core includes at least one void.

3. The particle of claim 2, wherein the void is in fluid communication with an external environment of the particle.

4. The particle of claim 2, wherein the particle core is solid.

5. The particle of claim 1 , wherein the particle core is in fluid communication with the particle surface.

6. The particle of any one of claims 1 to 5, wherein the particle is substantially spherical.

7. The particle of any one of claims 1 to 5, wherein the particle is substantially disc-shaped.

8. The particle of any one of claims 1 to 5, for use in fluid diversion.

9. The particle of any one of claims 1-8, wherein the particle comprises one or more of a thermoplastic, resin, metal, polymer, poly lactic acid (PLA), polyethylene terephthalate (PET), PET glycol (PETg), acrylonitrile butadiene styrene (ABS), amide based polymers (such as nylon), polyurethane (for example thermoplastic polyurethane or TPU), acrylate polymers (polyacrylate or Acrylic), Poly(methyl methacrylate) or PMA, acrylonitrile styrene acrylate (ASA), polycaprolactone (PCL), poly carbonate (PC), polyphenylsulfone (PPSU), polysulfone (PSU), polyether ether ketone (PEEK), Polytetrafluoroethylene (PTFE or Teflon), polyvinyl alcohol (PVOH), polyglycolide (PGA), polyoxymethylene (POM or acetal), glass, and carbon fiber.

10. The particle of any one of claims 1-9, wherein the particle has at least one measurable dimension between about 0.1 and 10.0 cm.11 . The particle of claim 10, wherein the particle has a radius of about 1 .0-3.0 cm.

12. A method of manufacturing the particle of any of claims 1 -1 1 , comprising: an additive process.

13. The method of claim 12, where in the additive process is 3-D printing.

14. A method of sealing a hole in a surface of a device carrying a fluid, comprising: adding the particle of any one of claims 1 -13 to the fluid; flowing the fluid comprising the particle to the hole; allowing the particle to contact surfaces surrounding the hole; allowing fluid pressure on the particle to increase, wherein the pressure increase deforms the particle and seals the hole.

15. A method for using a particle of any one of claims 1 -13, comprising: identifying a wellbore with at least one hole or void amenable to sealing with diverter particles; selecting the diverter particle for sealing the hole, wherein the diverter particle comprises at least one measurable dimension at least as large as the hole’s average diameter and the particle is comprised of a material whose hydrolysis time is selected based on the operating temperature of the wellbore and the desired operating lifespan ranging from 24 hours to a permanent blockage; deploying the diverter particle into a fluid down stream of the wellbore pumps; allowing the diverter particle(s) to contact at least one surface at or near the hole; allowing the diverter particle(s) to deform to at least partially enter a channel formed by the hole; allowing the diverter particle(s) to flatten against at least one surface at or near the hole; and thereby sealing the hole with minimal protrusion into the interior of the wellbore.

16. The method of claim 15, wherein the hole is in a casing in the wellbore.

17. The method of claim 15 or 16, wherein identifying the hole may include inferring the existence of the hole from loss of a fluid or pressure within the wellbore.

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