Connecting member including shape memory material, downhole tool including connecting member, and method of forming downhole tool

Abstract

A downhole valve system for use in a borehole is disclosed. The downhole valve system includes a first downhole component formed of a brittle material, a second downhole component, and a connecting member. The connecting member is formed of a shape memory material and includes: an outer surface having an outer diameter; an inner surface having an inner diameter, one of the outer diameter and the inner diameter being alterable by applying a stimulus to the shape memory material; and a connection feature complementary to a connection feature of the second downhole component, formed on one of the outer surface and the inner surface. The connection member is secured to the first downhole component at a respective surface of one of the inner diameter and the outer diameter and to the second downhole component via the first connection feature and the second connection feature to connect the second downhole component to the first downhole component.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Serial No. 63 / 374,190, filed on August 31, 2022, the disclosure of which is hereby incorporated by reference in its entirety. Technical Field

[0003] Embodiments of the present disclosure generally relate to shape memory materials. In particular, embodiments of the present disclosure relate to connecting members including shape memory materials, downhole tools including the connecting members, and methods of forming the downhole tools. Background Art

[0004] Wellbores are formed in underground formations for various purposes, including, for example, extracting oil and gas from underground formations and extracting geothermal energy from underground formations. Wellbores can be formed in underground formations using one or more earth-boring tools (such as earth-boring rotary drill bits) that are fixed to a series of elongated tubular segments connected end-to-end, which are referred to in the art as a "drill string." During drilling operations, the drill string extends downward from an uphole end located at the surface of the drilling rig to an earth-boring tool (e.g., a drill bit) located at the downhole end of the drill string. The earth-boring rotary drill bit is rotated and pushed into the underground formation. As the earth-boring rotary drill bit rotates, the cutting elements, cutters, or their grinding structures cut, crush, shear, and / or grind away formation material to form a wellbore. As formation material is removed from the wellbore, the wellbore lengthens. Additional tubular segments can be sequentially added to the uphole end of the drill string to maintain contact between the earth-boring tool and the bottom of the wellbore.

[0005] The downhole end of the drill string, located at the bottom of the wellbore being drilled, typically includes an assembly of components and tools, which is generally referred to in the art as a "bottom hole assembly" (BHA). The BHA typically includes one or more downhole tools to detect information about the drilling process, evaluate the formation being drilled, and transmit this information to the surface in real time. The downhole tools can be positioned inside and secured to a tubular element of the drill string, such as a drill collar. For example, the downhole tool can be positioned within a subassembly or drill collar, which can be coupled to additional tubular sections of the drill string, such as additional drill collars, subassemblies, drill pipe, a downhole motor, etc.

[0006] During drilling operations, drilling fluid is pumped from the drilling equipment down through the center of the drill string, typically through a downhole motor, out of the nozzle of the drill bit, and circulated back to the drilling equipment through the wellbore. Because downhole tools are typically positioned within the drill string and are in direct contact with the drilling fluid circulating through the drill string, downhole tools can be made of materials that are resistant to wear and corrosion. Summary of the Invention

[0007] Embodiments described herein include shape memory material structures, downhole tools including the shape memory material, and methods of forming downhole tools including the shape memory material.

[0008] In one illustrative embodiment, the present disclosure provides a connecting member comprising a body comprising a shape memory material configured to transition from a first state having a first configuration to a second state having a second configuration in response to application of a stimulus. The body comprises one or more sidewalls and a connecting feature. The one or more sidewalls define an opening extending between their ends. The connecting feature is located on at least a portion of the one or more sidewalls. The connecting feature comprises the shape memory material and is configured to couple the body to a component when in the first state.

[0009] In another illustrative embodiment, the present disclosure provides a downhole valve system for use in a borehole. The downhole valve system includes a first downhole component, a second downhole component, and a connecting member. The first downhole component, which is made of a brittle material, includes a longitudinal axis. The second downhole component includes a first connecting feature. The connecting member is formed of a shape memory material and includes: an outer surface having an outer diameter; an inner surface having an inner diameter, one of the outer diameter and the inner diameter being capable of being changed by applying a stimulus to the shape memory material; and a second connecting feature, which is complementary to the first connecting feature and is formed on one of the outer surface and the inner surface. The connecting member is fixed to the first downhole component at a corresponding surface of one of the inner diameter and the outer diameter, and is fixed to the second downhole component via the first connecting feature and the second connecting feature to connect the second downhole component to the first downhole component.

[0010] In another illustrative embodiment, the present disclosure provides a downhole valve system for use in a borehole. The downhole valve system includes a first downhole component, a second downhole component, and a connecting member. The first downhole component, which is made of a brittle material, includes a longitudinal axis. The connecting member is formed of a shape-memory material and includes an outer surface having an outer diameter and an inner surface having an inner diameter. By applying a stimulus to the shape-memory material, one of the outer diameter and the inner diameter can be changed. The connecting member is fixed to the first downhole component at a first corresponding surface of one of the inner diameter and the outer diameter, and the connecting member is fixed to the second downhole component at a second corresponding surface of one of the inner diameter and the outer diameter to connect the second downhole component to the first downhole component.

[0011] In another illustrative embodiment, the present disclosure provides a method for forming a downhole tool. The method includes providing a first downhole component and a second downhole component, the first downhole component being made of a brittle material and including a longitudinal axis, the second downhole component including a first connecting feature. The method also includes connecting the second downhole component to the first downhole component using a connecting member formed of a shape memory material. The connecting member includes: an outer surface having an outer diameter; an inner surface having an inner diameter, one of the inner diameter and the outer diameter being modifiable by applying a stimulus to the shape memory material; and a second connecting feature, the second connecting feature being complementary to the first connecting feature and formed on one of the outer surface and the inner surface, the connection being formed by fixing the connecting member to the first downhole component at a corresponding surface of one of the inner diameter and the outer diameter and connecting the connecting member to the second downhole component via the first connecting feature and the second connecting feature to connect the second downhole component to the first downhole component. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 and Figure 2 is a simplified diagram illustrating how the microstructure of a shape memory material according to an embodiment of the present disclosure may be changed;

[0013] Figure 3 is a simplified perspective view of a connecting member in a first state and unchanged configuration according to an embodiment of the present disclosure;

[0014] Figure 4 and Figure 5 According to an embodiment of the present disclosure Figure 3 The connecting member along the AA plane ( Figure 4 ) and along the BB plane ( Figure 5 ) a simplified cross-sectional view taken from FIG;

[0015] Figure 6 According to an embodiment of the present disclosure Figure 3 Simplified perspective views of the connecting member in a second different state and unchanged configuration;

[0016] Figure 7 According to an embodiment of the present disclosure Figure 6 A simplified cross-sectional view of the connecting member taken along the CC plane;

[0017] Figure 8 According to an embodiment of the present disclosure Figure 6 a simplified perspective view of the connected components in a changed configuration;

[0018] Figure 9 According to an embodiment of the present disclosure Figure 8 A simplified cross-sectional view of the connecting member taken along the DD plane;

[0019] Figure 10 is a brittle structure according to an embodiment of the present disclosure and two Figure 8 a perspective view of the connecting members of FIG. 1 , the two connecting members being in a second state and an altered configuration;

[0020] Figure 11 yes Figure 10 One of the connecting members is positioned in Figure 10 Simplified side cross-sectional views of corresponding portions of the brittle structure;

[0021] Figure 12 is a perspective view of a downhole tool component according to an embodiment of the present disclosure, the downhole tool component comprising Figure 10 a fragile structure and two connecting members, wherein the connecting members are in a first state, have not changed configuration, and are fixed to the fragile structure;

[0022] Figure 13 According to an embodiment of the present disclosure Figure 12 A simplified side cross-sectional view of a downhole tool component wherein a connecting member is secured to a corresponding portion of a fragile structure;

[0023] Figure 14 According to an embodiment of the present disclosure Figure 13 A side view of a downhole tool component comprising a connecting member having a connecting feature;

[0024] Figure 15 Two in a second state and a changed configuration positioned within a fragile structure according to additional embodiments of the present disclosure Figure 8 A simplified cross-sectional view of a connecting member;

[0025] Figure 16 According to an additional embodiment of the present disclosure Figure 15 A simplified cross-sectional view of a downhole tool component comprising Figure 10 a fragile structure and two connecting members in a first state, unchanged in configuration, and fixed within the fragile structure;

[0026] Figure 17 According to the embodiment of the appendix of the present disclosure Figure 15 and Figure 16 A simplified cross-sectional view of a downhole tool component having a connection feature on the connection component;

[0027] Figure 18 is a perspective view of a downhole tool according to an embodiment of the present disclosure, the downhole tool including a Figure 14 or Figure 17 Additional components for downhole tools;

[0028] Figure 19is a simplified schematic diagram of an earth-boring system according to an embodiment of the present disclosure, the earth-boring system comprising Figure 18 downhole tools;

[0029] Figure 20 is a simplified side cross-sectional view of the plunger system;

[0030] Figure 21 According to an embodiment of the present disclosure Figure 19 A simplified side cross-sectional view of another embodiment of a portion of a bottom hole assembly; and

[0031] Figure 22 yes Figure 20 A simplified side cross-sectional view of another embodiment of a plunger system. DETAILED DESCRIPTION

[0032] Certain structures (such as components of downhole tools) can be made of materials that are generally durable in terms of high hardness, resistant to erosion, corrosion and wear, and lightweight due to their relatively low density. Materials that exhibit ideal properties for certain downhole tool applications can also be relatively brittle and include materials such as ceramics or hard metals. Although the chemical and heat resistance of brittle materials (such as ceramics) make them attractive materials for many applications, brittle materials are generally difficult to machine compared to metals. In addition, it may be ideal to connect a brittle structure to one or more additional structures to form an assembly. For example, downhole tools typically include various components that are connected together before being positioned in a drill string. Therefore, the difficulty of machining brittle materials poses a challenge to connecting the brittle structure to other structures of the assembly. For example, it is difficult to make threads from brittle materials. Even if threads can be made in hard metals, the threads will not provide a reliable mechanical connection because hard metals lack the elastic material properties required in threaded connections. To address this issue, a metal connecting member, such as a sleeve or threaded sleeve, can be machined to size and then press-fitted onto the ceramic material by first heating the metal sleeve to thermally expand it. However, structures designed for a press or interference fit require precise machining and procedures that are prone to error.

[0033] Therefore, according to an embodiment of the present disclosure, a connecting member may include a shape memory material that is configured to transition from a first state having a first configuration to a second state having a second configuration, and vice versa, in response to the application of a stimulus such as temperature, stress (optical stress, magnetic stress, or mechanical stress), or electric current. The connecting member may exhibit superelastic properties, which may facilitate connections between brittle structures (e.g., ceramics, hard metals, glass, graphite, etc.) without the need for press-fit or gluing procedures. For example, the shape memory material of the connecting member may be in a second state below the transition temperature, and the opening within the connecting member may be enlarged so that the connecting member can be positioned on the brittle structure. Once positioned in the desired position, the connecting member may be exposed to a temperature above the transition temperature. Exposing the connecting member to a temperature above the transition temperature triggers a state change from the second state back to the first state, and results in a change in volume and configuration (e.g., shape, such as contraction or expansion) to secure the connecting member to the brittle structure. The connecting member may then be machined to form a connecting feature (e.g., a thread) that can be used to secure the brittle structure to another structure of the downhole tool. In some embodiments, the connecting member can be machined to form the connecting features before securing the connecting member to the fragile structure. In other embodiments, instead of exposing the connecting member to a temperature above the transition temperature, stress or current can be used to induce the change from the second state back to the first state.

[0034] The following description provides specific details (such as specific shapes, specific sizes, dimensions, specific material compositions, and specific processing conditions) in order to provide a thorough description of the embodiments of the present disclosure. However, it will be understood by those skilled in the art that the embodiments of the present disclosure can be practiced without employing these specific details. The embodiments of the present disclosure can be practiced in conjunction with conventional manufacturing techniques employed in the industry. In addition, the description provided below does not form a complete process flow for manufacturing a connecting member or a downhole tool. Only those process actions and structures necessary to understand the embodiments of the present disclosure are described in detail below. Additional actions to form a complete connecting member or a complete downhole tool from the structures described herein can be performed by conventional manufacturing processes and additive manufacturing processes.

[0035] The drawings presented herein are for illustrative purposes only and are not meant to be actual views of any particular material, component, structure, device, or system. Variations in the shapes shown in the drawings due to, for example, manufacturing techniques and / or tolerances are to be expected. Therefore, the embodiments described herein should not be interpreted as limited to the specific shapes or areas shown, but rather include deviations in shapes that result, for example, from manufacturing. For example, an area shown or described as box-shaped may have roughness and / or nonlinear features, and an area shown or described as circular may include some roughness and / or linear features. In addition, sharp angles shown may be rounded, and vice versa. Therefore, the areas shown in the drawings are schematic in nature, and their shapes are not intended to illustrate the precise shape of the areas and do not limit the scope of the claims. The drawings are not necessarily drawn to scale. In addition, common elements between the drawings may retain the same reference numerals.

[0036] As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0037] As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0038] As used herein, the term "substantially" with respect to a given parameter, characteristic, or condition means and includes to the extent that one of ordinary skill in the art would understand that the given parameter, characteristic, or condition is met to a certain degree (e.g., within an acceptable tolerance). For example, depending on a particular parameter, characteristic, or condition being substantially met, the parameter, characteristic, or condition may be at least 90.0% met, at least 95.0% met, at least 99.0% met, at least 99.9% met, or even 100.0% met.

[0039] As used herein, the term "about," when used with respect to a numerical value of a particular parameter, includes that numerical value, and the degree of deviation from that numerical value as would be understood by one of ordinary skill in the art is within an acceptable tolerance for that particular parameter. For example, with respect to a numerical value, "about" may include additional numerical values ​​within the range of 90.0% to 110.0% of that numerical value, such as within the range of 95.0% to 105.0% of that numerical value, within the range of 97.5% to 102.5% of that numerical value, within the range of 99.0% to 101.0% of that numerical value, within the range of 99.5% to 100.5% of that numerical value, or within the range of 99.9% to 100.1% of that numerical value.

[0040] As used herein, the term "shape memory material" includes any suitable shape memory material, including shape memory metal alloys and shape memory polymers. Shape memory metal alloys can include nickel-based alloys, copper-based alloys, cobalt-based alloys, iron-based alloys, titanium-based alloys, aluminum-based alloys, or any mixtures thereof. Shape memory metal alloys can additionally include additional elements, such as niobium (Nb), which can enhance the shape memory capabilities of such materials. For example, a shape memory metal alloy can include a 50:50 mixture of nickel and titanium by weight, a 55:45 mixture of nickel and titanium by weight, or a 60:40 mixture of nickel and titanium by weight. Many other compositions are possible and can be selected based on tool requirements and material properties known in the art. Shape memory polymers can include, for example, epoxy polymers, thermosetting polymers, thermoplastic polymers, or combinations or mixtures thereof. Other polymers that exhibit shape memory behavior can also be used. Shape memory materials are polymorphic and can exhibit two or more crystal structures or states (e.g., phases). Shape memory materials can further exhibit a shape memory effect associated with a state (e.g., phase) transition between two crystal structures or states (e.g., phases), such as austenite and martensite. The austenite phase exists at high temperatures, while the martensite phase exists at low temperatures. The shape memory effect can be triggered by a stimulus, which can be thermal, electrical, magnetic, or chemical, and which causes the transition from one solid state to another.

[0041] As used herein, the terms "brittle structure" and "brittle material" refer to materials that have low ductility and undergo an elongation of 5% or less (i.e., tensile plastic deformation) before fracture at 20°C when tested using a tensile testing machine according to ASTM test method ASTM E399. The definition of brittle material used in this application refers to a material having a fracture toughness or crack resistance K of less than 20. 1C Material MPa·m 1 / 2 As specific, non-limiting examples, "brittle structures" and "brittle materials" include ceramics, glass, graphite, certain metals (hard metals) and alloys, certain polymers, polycrystalline diamond, and the like. Ceramics may be silicon nitride, silicon carbide, aluminum oxide, zirconium oxide, or alternative technical ceramics. Hard metals may be tungsten carbide, titanium carbide, titanium nitride, or tantalum carbide.

[0042] Figure 1 and Figure 2 is a simplified diagram showing how the microstructure of a shape memory material can be changed. Figure 1 and 2Specifically shown are the microstructures of shape memory alloys, but shape memory polymers can exhibit similar shape memory effects, as described below. Shape memory materials typically exhibit both a "shape memory effect" and a "pseudoplastic effect." Briefly, the shape memory effect refers to the ability of a material to reverse deformation in response to a temperature-induced state (e.g., phase) change. The pseudoelastic effect refers to the ability of a material to reverse deformation in response to a stress-induced state (e.g., phase) change, such as that induced by the application of an external load.

[0043] Now refer to Figure 1 , the shape memory alloy can transform from the original austenite phase (i.e., the high temperature phase) to the martensite phase (i.e., the low temperature phase) when cooled. The phase transformation from austenite to martensite can be spontaneous, diffusionless, and temperature-dependent. For different shape memory alloy compositions, the transformation temperature from austenite to martensite and vice versa is different. For example, the material composition of the shape memory alloy can be selected and / or adjusted so that the first transformation temperature of the shape memory alloy (e.g., the martensite termination temperature (M f )) occurs in the range from about -140°C to about 0°C, and the second transformation temperature of the shape memory alloy (eg, austenite finish temperature (A f )) occurs in the range of from about 0° C. to about 200° C. Different material compositions and transformation temperatures of shape memory alloys are described in Minjuan Wang et al., Martensitic transformation involved mechanical behaviors and wide hysteresis of NiTiNb shape memory alloys, 22(2) Progress in Natural Science: Materials International 130-138 (2012), available at sciencedirect.com / science / article / pii / S1002007112000330, the entire contents of which are hereby incorporated herein by this reference.

[0044] The phase transformation from austenite to martensite occurs at the first temperature (M s ) and a lower second temperature (M f ) occurs between. Figure 1As shown, initially, the crystal structure of martensite is heavily twinned and can be deformed by an applied stress, causing the material to assume a new size and / or shape. After the applied stress is removed, the material retains the deformed size and / or shape. However, upon heating, the martensite can transform and return to austenite. The phase transformation occurs at the first temperature (A) at which martensite begins to transform into austenite. s ) and a higher second temperature (A f ) occurs between the first and second cooling steps. Upon complete transformation to austenite, the element returns to its original "memorized" size and / or shape. As used herein, the term "memorized" refers to a configuration to which a material spontaneously returns in response to a change in temperature. During the second cooling process and the transformation from austenite to martensite, the crystal structure of the martensite phase is heavily twinned and can be deformed by the applied stresses so that the material assumes at least one of a new size and / or shape. The size and / or shape of the material in the previously deformed martensite phase is not remembered from the initial cooling process. This shape memory effect may be referred to as a one-way shape memory effect, such that an element exhibits a shape memory effect only upon heating, as Figure 1 shown.

[0045] Other shape memory alloys have two-way shape memory, such that materials containing such shape memory alloys exhibit this shape memory effect when heated and cooled. Thus, a shape memory alloy with a two-way shape memory effect may include two memorized sizes and shapes: a martensitic (i.e., low temperature) shape and an austenitic (i.e., high temperature) shape. Such a two-way shape memory effect is achieved by "training." By way of example and not limitation, the memorized austenitic and martensitic shapes may be formed by inducing non-uniform plastic strain in either the martensitic or austenitic phases, by aging under applied stress, or by thermomechanical cycling. Figure 2 When a two-way shape memory alloy is cooled from the austenite phase to the martensite phase, some martensite configurations may be favorable, such that the material may tend to adopt a preferred shape. By way of further non-limiting example, and without being bound by any particular theory, the applied stress may create permanent defects such that the deformed crystal structure of the martensite phase is remembered. After the applied stress is removed, the element retains the deformed size and / or shape. Upon heating, the martensite may be at a first temperature (A s ) and a higher second temperature (A f ) and returns to austenite. Upon complete transformation to austenite, the element returns to its original, memorized size and / or shape. The heating and cooling process can be repeated, causing the material to repeatedly transform between the memorized martensite and memorized austenite shapes.

[0046] In some embodiments, the shape memory alloy material may include a nickel-titanium-niobium alloy including about 40% to about 60% nickel by atomic weight, about 30% to about 40% titanium by atomic weight, and about 5% to about 20% niobium by atomic weight. As a specific non-limiting example, the shape memory alloy may include Ni 47.5 Ti 47.5 Nb5、Ni 47 Ti 44 Nb9 and / or Ni 45 Ti 45 Nb 10 In some embodiments, the first temperature (M f ) can be around -40°C, and only the higher temperature at which austenite exists (A f ) can be approximately 10° C. By way of non-limiting example, the shape memory alloy or shape memory polymer in a downhole application is selected to ensure that the shape memory alloy or shape memory polymer is in the austenite phase for a typical downhole temperature range, such as approximately 1° C. to approximately 250° C. or 1° C. to approximately 350° C. The material properties of the shape memory alloy or shape memory polymer are selected to allow for the desired change in size of the martensite phase.

[0047] Shape memory polymers can exhibit similar shape memory effects. A heating and cooling process can be used to heat a polymer to, for example, the melting point or glass transition temperature (T g ) and cool the polymer to the melting point or glass transition temperature (T g ) to transition shape memory polymers between a hard solid state and a soft solid state, as taught, for example, in U.S. Patent No. 6,388,043, entitled “Shape Memory Polymers,” issued May 14, 2002, the entire disclosure of which is incorporated herein by reference. The shape memory effect can be triggered by a stimulus, which can be thermal, electrical, magnetic, or chemical.

[0048] Figure 3-Figure 5 is a simplified perspective view of a connection member 100A in a first state and a “permanent” or unaltered configuration according to an embodiment of the present disclosure ( Figure 3 ), Simplified Cross-Section View ( Figure 4 ) and another simplified cross-sectional view ( Figure 5 ). Figure 4 is a simplified cross-sectional view of the connection member 100A taken along the AA plane, and Figure 5 is a simplified cross-sectional view of the connection member 100A taken along the BB plane.

[0049] The connecting member 100A can be used to connect a fragile structure (eg, the fragile structure 210 ( Figure 10 ) or brittle structure 310( Figure 15 )) is fixed to one or more additional components to form a downhole tool. The brittle structure can be any structure made of a brittle material, such as a shaft, a housing, etc. The brittle structure can be a solid structure, such as a solid cylindrical structure made of a solid material, or can be a structure having an inner hole along the longitudinal axis, such as a tube-like structure. The diameter of the inner hole can be less than 30%, less than 20%, less than 10% or less than 5% of the outer diameter of the brittle structure. The connecting member 100A can be made of or include a shape memory material, and the brittle structure (for example, the brittle structure 210 ( Figure 10 ) and brittle structure 310( Figure 15 )) can be made of or include brittle materials, such as glass, ceramics, graphite, hard metals, etc. In some embodiments, such as in Figure 3-Figure 5 As shown in FIG, the connection member 100A can be in the form of a tubular structure that is configured (e.g., sized, shaped, oriented, and / or arranged) to surround at least a portion of a brittle material structure. Although a brittle structure is described, the present disclosure is not limited thereto. For example, the connection member 100A and process described herein can be used in conjunction with any type of material structure.

[0050] The connecting member 100A generally includes a body 102 that includes a shape memory material that is configured to transition from a first state (e.g., austenite for shape memory alloys, or a soft solid state for shape memory polymers) to a second state (e.g., martensite for shape memory alloys, or a hard solid state for shape memory polymers) in response to the application of a stimulus (e.g., temperature). The body 102 may include one or more side walls 104. In various embodiments, the one or more side walls 104 include a cylindrical shape having a single side wall (e.g., a hollow cylindrical shape, a perfect circular hollow cylindrical shape, a tapered cylindrical shape, but not limited thereto). The body 102 and the one or more side walls 104 in various embodiments define an opening 106 (e.g., a cavity, a through hole, etc.) within the body 102. Figure 3-Figure 5 In the illustrated embodiment, the opening 106 extends from a first end 108 of the body 102 through a second end 110 of the body 102 opposite the first end 108. In some embodiments, the opening 106 can be centered about a central longitudinal axis 111 of the body 102.

[0051] The length (L) of the connecting member 100A A) is defined by the distance from the first end 108 of the body 102 to the second end 110 of the body 102 opposite the first end 108. For example, the length L of the connecting member 100A is A The sidewalls 104 may include an outer surface 112 and an inner surface 114, the outer surface defining the outer dimensions (eg, outer diameter (D)) of the connecting member 100A. OA )), which defines the inner dimensions (eg, inner diameter (D) of the opening 106 within the body 102. IA )). The length (L) of the connecting member 100A may be selected and / or modified as desired. A ) and size (e.g. D OA and / or D IA ).

[0052] The edges of one or more side walls 104 of the body 102 may be chamfered, rounded, beveled, etc. at one or more ends thereof. For example, portions of one or more side walls 104 located proximal to the exterior surface 112 and / or interior surface 114 of the body 102 of the connecting member 100A may be chamfered, rounded, beveled, etc. at one or more ends thereof. Additionally, portions of one or more side walls 104 located at the first end 108 and / or the second end 110 of the body 102 may be chamfered, rounded, beveled, etc. The chamfered, beveled, and / or rounded edges may facilitate relative movement between the connecting member and another structure (e.g., a fragile structure) when the connecting member 100A is slid over a corresponding portion of the fragile structure (210, 310).

[0053] exist Figure 3-Figure 5 In the embodiment of the present invention, the connection member 100A can be in a first state (e.g., an austenite phase for a shape memory alloy, or a soft solid state for a shape memory polymer) and in a "permanent" or unchanged configuration. Although the following description primarily relates to shape memory alloys, the connection member 100A can be in a first state (e.g., an austenite phase for a shape memory alloy, or a soft solid state for a shape memory polymer) and in a "permanent" or unchanged configuration. g ) and cooled to below the glass transition temperature, rather than heating to the austenite finish temperature (A f ) and cooled to the martensite termination temperature (M f ) below, substantially the same behavior and process applies to shape memory polymers. For example, the austenite phase of the shape memory alloy can be analogous to the soft solid state of the shape memory polymer, the martensite phase of the shape memory alloy can be analogous to the hard solid state of the shape memory polymer, and the glass transition temperature (T g ) can be similar to the austenite termination temperature (A f ) and martensite termination temperature (Mf ) combination.

[0054] The connection member 100A may be at a temperature higher than the austenite finish temperature (A f ) temperature, so that the connection member 100A is in the austenite phase. The connection member 100A may be at about room temperature (about 20° C.), and the austenite finish temperature (A f ) may be approximately 5° C. In the austenite phase, the connection member 100A may exhibit one or more dimensions (eg, inner diameter (D IA ) or outer diameter (D OA )), the one or more dimensions will cause the connection member 100A and the fragile structure 210 ( Figure 10 ) or 310( Figure 15 As a non-limiting example, the connection member 100A (in the austenite phase) may exhibit an inner diameter (D) in a range from about 12 mm to about 20 mm (e.g., about 16 mm). IA ), an outer diameter (D ) in the range of about 17 mm to about 25 mm (eg, about 21 mm) OA ), and a length (L) in the range of from about 12 mm to about 20 mm (eg, about 16 mm) A ).

[0055] In embodiments where the connection member 100A comprises a shape memory polymer, the connection member 100A may be at a temperature above the glass transition temperature (T g ) temperature, so that the polymer is in a soft solid state. The connecting member 100A may similarly exhibit one or more dimensions (eg, inner diameter (D IA ) or outer diameter (D OA )), the one or more dimensions will cause the connection member 100A and the fragile structure 210 ( Figure 10 ) or brittle structure 310( Figure 15 ) has an interference fit between at least a portion of the ).

[0056] In some embodiments, the fragile structure 210 ( Figure 10 ) is approximately cylindrical, and the connecting member 100A forms a tubular structure (eg, a sleeve), and the inner diameter (D IA ) (before the downhole tool including the brittle structure 210 is assembled) can be slightly smaller than the outer diameter of the brittle structure 210 (eg, a ceramic shaft). For example, the inner diameter (D IA) may be about 0.005% to about 1% smaller than the outer diameter of the corresponding portion of the fragile structure 210, such as about 0.05% to about 0.5% smaller than the outer diameter of the corresponding portion of the fragile structure 210. As a non-limiting example of a value, the inner diameter (D IA ) can be about 0.001 inches (0.0254 mm) to about 0.1 inches (2.54 mm) smaller than the outer diameter of the corresponding portion of the brittle structure 210, such as about 0.02 inches (0.508 mm) to about 0.060 inches (1.524 mm) smaller than the outer diameter of the corresponding portion of the brittle structure 210. In some embodiments, the brittle structure 210 and / or the connecting member 100A can include ridges or other textured surfaces to improve retention or alignment between the brittle structure 210 and the connecting member 100A when the connecting member undergoes a phase transition. The inner diameter of the connecting member 100A defines a surface (a surface corresponding to the inner diameter). In the first state and unmodified configuration of the connecting member 100A, the surface is fixed to the corresponding portion of the brittle structure 210.

[0057] In another embodiment, the fragile structure 310 ( Figure 15 ) can be, for example, a brittle housing or shaft including a cavity on one or more ends of the housing or shaft. The cavity can be sized and shaped to receive the connecting member 100A, and the connecting member 100A forms a tubular structure (e.g., a sleeve) sized and shaped to fit within the cavity of the brittle structure 310, with the outer diameter (D) of the body 102 of the connecting member 100A being 100 mm. OA ) (before the downhole tool including the brittle structure 310 is assembled) may be slightly larger than the inner diameter of the cavity within the brittle structure 310. For example, the outer diameter (D OA ) may be about 0.005% to about 1% greater than the inner diameter of the cavity within the fragile structure 310, such as about 0.05% to about 0.5% greater than the cavity within the fragile structure 310. As a non-limiting example of a value, the outer diameter (D OA ) can be about 0.001 inches (0.0254 mm) to about 0.1 inches (2.54 mm) larger than the inner diameter of the cavity within the fragile structure 310, such as about 0.02 inches (0.508 mm) to about 0.060 inches (1.524 mm) larger than the inner diameter of the cavity of the fragile structure 310. In some embodiments, the fragile structure 310 and / or the connecting member 100A can include ridges or other textured surfaces to improve retention or alignment between the fragile structure 310 and the connecting member 100A.

[0058] In embodiments where the connection member 100A comprises a shape memory alloy, the connection member 100A may be cooled to a temperature below the martensite finish temperature (Mt) of the shape memory alloy.f ) temperature, so that the connection member 100A changes its state (eg phase) from austenite ( Figure 3-Figure 5 ) changes to martensite ( Figure 6 and Figure 7 , connecting member 100B). In embodiments where connecting member 100A comprises a shape memory polymer, connecting member 100A may be cooled to a temperature below the glass transition temperature (T g ) temperature, so that the connection member 100A changes its state from a soft solid state ( Figure 3-Figure 5 ) changes to a hard solid state ( Figure 6 and Figure 7 , connecting member 100B).

[0059] Figure 6 and Figure 7 is a simplified perspective view of a connection member 100A in a second, different state (100B) and a "permanent" or unaltered configuration (eg, martensite, but not limited thereto) according to an embodiment of the present disclosure ( Figure 6 ) and simplified cross-section views ( Figure 7 ). Figure 7 yes Figure 6 FIG. 1 is a simplified cross-sectional view of the connecting member 100B taken along the CC plane.

[0060] The connection member 100B may be at a temperature lower than the martensite finish temperature (M f ) temperature, so that the connection member 100B is in a different second state (e.g., martensite phase), and is also in a "permanent" or unchanged configuration. The connection member 100B can be cooled to about -40°C, and the martensite finish temperature (M f ) may be approximately -40°C. In the martensite phase, the connection member 100B may exhibit substantially the same dimensions as the connection member 100A in the austenite phase. In the martensite phase, the dimensions (e.g., inner diameter (D)) of the connection member 100B may be changed by applying stress to the connection member 100B to plastically deform (change the dimensions) the martensite material. IB ), outer diameter (D OB ) and / or length (L B For example, the inner diameter (D IB ), outer diameter (D OB ) and / or length (L B) can be increased by, for example, forcing a formed body made of a hardened material through the opening 106 of the connecting member 100B. For example, the hardness of the hardened material of the formed body can be higher than the hardness of the connecting member 100B (e.g., higher than the hardness of the inner surface 114 located within the opening 106 of the connecting member 100B). As a non-limiting example, the hardness of the hardened material of the formed body can be greater than about 50 Rockwell C hardness (HRC). In addition, the hardened material has an inner diameter (D) greater than the inner diameter (D) of the connecting member 100B. IB ) a larger outer diameter, so that the inner diameter (D IB ) expands as the formed body passes through the opening 106. The expansion of the opening 106 of the connecting member 100B can change the position of the shape memory material and can correspondingly increase the outer diameter (D OB ) and / or length (L B ).

[0061] In embodiments where the connection member 100B comprises a shape memory polymer, the connection member 100B may be at a temperature below the glass transition temperature (T g ) temperature, so that the polymer is in a hard solid state. Connecting member 100B can exhibit substantially the same dimensions as connecting member 100A in a soft solid state. In the hard solid state, the dimensions (e.g., inner diameter (D)) of connecting member 100B can be changed by applying stress to connecting member 100B to plastically deform the hard solid state polymer material in substantially the same manner as discussed with respect to connecting member 100B comprising a shape memory alloy. IB ), outer diameter (D OB ) and / or length (L B )). For example, a formed body made of a hardened material may be passed through (eg, forced through) the opening 106 of the connecting member 100B so that the inner diameter (D IB ) expand and / or change the outer diameter (D) of the connecting member OB ) and / or length (L B In some embodiments, the shaped body may be forced through the opening 106 along the central longitudinal axis 111 of the body 102 so that the inner diameter (D IB )expansion.

[0062] The inner diameter (D IB ) Expansion can be accomplished in a single pass or multiple passes using multiple shaped bodies of different sizes, the size of the shaped body depending on the inner diameter (D) of the connecting member 100B. IB ) of the desired final size. For example, the desired final inner diameter (D IB ) can be larger than the current inner diameter (DIB ) (without changing the configuration) is about 1.5 mm larger. Made of hardened material, the diameter is larger than the inner diameter (D IB ) A first formed body (eg, a first hardened steel ball) approximately 0.5 mm in size may be forced through the opening 106 such that the inner diameter (D IB ) is expanded by about 0.5 mm. Next, a portion of the inner diameter (D IB ) is approximately 0.5 mm larger. A second shaped body (e.g., a second hardened steel ball) and the first hardened steel ball can be forced through the partially expanded opening 106, causing the partially expanded inner diameter to expand by another approximately 0.5 mm, for a total expansion of approximately 1 mm. Additionally, a third shaped body (e.g., a third hardened steel ball) made of a hardened material is larger than the partially expanded inner diameter (D IB ) is about 0.5 mm larger, and a second hardened steel ball can be forced through the partially expanded opening 106 so that the partially expanded inner diameter (D IB ) and then expand by about 0.5 mm to the expanded diameter (D IB ), the total expansion is about 1.5mm. The inner diameter (D IB ) can also increase the outer diameter (D OB ) and / or length (L B ),like Figure 8 and Figure 9 shown.

[0063] Figure 8 and Figure 9 is a simplified perspective view of the connecting member 100B in a second state, in a modified configuration 100C relative to the connecting member 100B, according to an embodiment of the present disclosure ( Figure 8 ) and simplified cross-section views ( Figure 9 ). Figure 9 yes Figure 8 A simplified cross-sectional view of the connecting member taken along the DD plane.

[0064] exist Figure 8 and Figure 9 In the embodiment, the connection member 100C may be maintained below the transformation temperature (eg, below the martensite finish temperature (M ) for shape memory alloys). f ), or for shape memory polymers, below the glass transition temperature (T g )) so that the connection member 100C is maintained in the second state (eg, martensite phase or hard solid state). The size of the connection member 100C (eg, the inner diameter (D) of the opening 106) IC ), the length of the main body 102 (L C ) and optionally the outer diameter of the body 102 (D OC)) can be different (eg, larger, smaller, or substantially the same size) than the corresponding size of the connection member 100B. For example, the inner diameter (D IC ) can be compared with the inner diameter (D IB ) is larger, length (L C ) can be compared to the length (L B ) is larger, and / or the outer diameter (D OC ) can be larger than the outer diameter (D OB ) is larger.

[0065] In the second state (eg, martensite phase or hard solid state) and the expanded configuration, the connection member 100C may exhibit one or more dimensions (eg, inner diameter (D IC ) or outer diameter (D OC )), the one or more dimensions enabling the connection member 100C to be relatively close to the fragile structure 210 ( Figure 10 ) is easily moved, so the connecting member 100C can be positioned on or within the corresponding portion of the fragile structure 210.

[0066] For example, in an embodiment where the fragile structure 210 comprises a shaft having an outer diameter, the inner diameter (D IC ) can be larger than the outer diameter of the fragile structure 210 to facilitate sliding on the shaft. For example, the inner diameter (D IC ) may be about 0.005% to about 5% greater than the outer diameter of the corresponding portion of the fragile structure 210, such as about 0.1% to about 2% greater than the outer diameter of the corresponding portion of the fragile structure 210. As a non-limiting example of a value, the inner diameter (D IC ) can be approximately 0.001 inches (0.0254 mm) to approximately 0.1 inches (2.54 mm) larger than the outer diameter of the corresponding portion of the brittle structure 210, such as approximately 0.01 inches (0.254 mm) to approximately 0.05 inches (1.27 mm) smaller than the outer diameter of the corresponding portion of the brittle structure 210.

[0067] In embodiments where the fragile structure 310 comprises a housing or shaft having a cavity with an inner diameter, the outer diameter (D OC ) can be smaller than the inner diameter of the cavity of the fragile structure 310 so as to facilitate sliding in the cavity. For example, the outer diameter (D OC ) may be about 0.005% to about 5% smaller than the inner diameter of the cavity within the fragile structure 310, such as about 0.1% to about 2% smaller than the inner diameter of the cavity within the fragile structure 310. As a non-limiting example of a value, the outer diameter (D OC) can be approximately 0.001 inches (0.0254 mm) to approximately 0.1 inches (2.54 mm) smaller than the inner diameter of the cavity within the brittle structure 310, such as approximately 0.01 inches (0.254 mm) to approximately 0.05 inches (1.27 mm) smaller than the inner diameter of the cavity within the brittle structure 310.

[0068] Figure 10 is a perspective view of a brittle structure 210 and two connecting members 100C in a second state (e.g., a martensitic or hard solid state) and an altered configuration (e.g., an expanded configuration) according to an embodiment of the present disclosure. The brittle structure 210 can be, for example, a shaft of brittle material (e.g., ceramic, hard metal, glass, graphite, etc.) that can form part of a downhole tool. The brittle structure 210 includes a first end portion 212 and an opposing second end portion 214 that are each configured (e.g., sized, shaped, oriented, and / or arranged) to receive one of the connecting members 100C. As Figure 10 As shown, the central portion 216 of the brittle structure 210 can exhibit a larger diameter than the first end portion 212 and the second end portion 214 of the brittle structure 210. The first diameter of the first end portion 212 can be substantially the same as the second diameter of the second end portion 214. In addition, the first diameter and the second diameter can each be smaller than the inner diameter (D) of the opening 106 in the connecting member 100C. IC ) to facilitate placement of the connecting member 100C within the corresponding first and second end portions 212, 214 of the frangible structure 210. The first and second end portions 212, 214 of the frangible structure 210 are shown as having a substantially constant diameter along the length (L1) of the frangible structure 210 (e.g., in a direction parallel to the longitudinal axis 218 of the frangible structure 210), the length being defined by the distance from the first end 212a of the first end portion 212 to the opposite end of the second end 212b of the first end portion 212. However, in other embodiments, the first and second end portions 212, 214 can taper to have a radially wider portion proximal to the ends of the frangible structure. In other embodiments, each of the first and second end portions 212, 214 can include a stepped feature proximal to the corresponding second end (212b) of the frangible structure, the stepped feature flaring radially outward relative to the remainder of the corresponding first and second end portions 212, 214. The tapered step or wide end of the wide step located proximal to the end of the fragile structure 210 can further mechanically fix the connection member 100C in place for a secure connection. The connection member 100C can be positioned on the first end portion 212 and the second end portion 214 of the fragile structure 210, as shown in FIG. Figure 11 shown.

[0069] Figure 11 yes Figure 10 A simplified side cross-sectional view of one of the connecting members 100C positioned on the first end portion 212 of the brittle structure 210. The connecting member 100C is in a second state (e.g., a martensitic or hard solid state) and a changed configuration. Because the inner diameter (D IC ) is greater than the outer diameter (D B1 ), so there is a gap 220 between the interior surface 114 of the connecting member 100C and the outer surface 221 of the first end portion 212. The gap 220 is sufficient to allow the connecting member 100C to move relative to the first end portion 212 and the brittle structure 210. In the second state, the connecting member 100C can be positioned to be engaged to the first end portion 212 or can be removed from the first end portion 212. In order to remove the gap 220 and secure the connecting member 100C to the first and second end portions 212, 214 of the brittle structure, the assembly of the brittle structure 210 and the connecting member 100C (e.g., a portion of a downhole tool) can be exposed to a temperature above the transformation temperature of the shape memory material (e.g., the austenite finish temperature (ATT)). f ) or glass transition temperature (T g )) temperature, so that the connection member 100C is transformed back to the first state (eg, austenite phase or soft solid state, unaltered state).

[0070] Figure 12 FIG. 3 is a perspective view of a downhole tool component 302 according to an embodiment of the present disclosure, the downhole tool component including a brittle structure 210 and two connecting members 100A placed on a first end portion 212 and a second end portion 214 of the brittle structure 210. Figure 12 , but in other embodiments, the downhole tool component 302 may include a single connecting member 100A located on one of the end portions (e.g., the first end portion 212). The connecting member 100A is in a first state (e.g., an austenite phase or a soft solid state) and a "permanent" or unchanged configuration. Figure 11 The connection member 100C may be subjected to heating, such as by placing the brittle structure 210 including one or more connection members 100C at a temperature above the transformation temperature (eg, above the austenite finish temperature (A f ) or above the glass transition temperature (T g For example, the assembly including the brittle structure 210 and the connecting member 100C can be placed in an oven at a temperature of about 200° C. for about 5 minutes or more. f), the shape memory material of the connecting member 100C returns to the first state (eg, austenite phase, soft solid state) and a "permanent" or unchanged configuration. When the connecting member 100C returns to the first state, the connecting member 100C ( Figure 8 and Figure 9 ) is restored to the size / configuration of the connecting member 100A ( Figure 3-Figure 5 ) to secure the connecting member 100A to the fragile structure 210.

[0071] Figure 13 yes Figure 12 FIG. 1 is a simplified side cross-sectional view of a downhole tool component 302 including a brittle structure 210 and one of the connecting members 100A positioned on a first end portion 212 of the brittle structure 210. The connecting member 100A is in a first state (e.g., an austenitic or soft solid state) and an unchanged configuration. By applying heat, the inner diameter (D IC ) is reduced to match the outer diameter (D B1 ). Therefore, the gap 220 ( Figure 11 ) is eliminated due to the expansion of the material of the connecting member 100C. In some embodiments, the length (L1) of the first end portion 212 of the brittle structure 210 can be the same as the length L of the connecting member 100A. A In another embodiment, the length (L1) of the first end portion 212 of the fragile structure 210 may be substantially the same as the length L1 of the connecting member 100A. A different.

[0072] Additionally, because the connection member 100A in a "permanent" or unmodified configuration tends to exhibit an outer diameter (D B1 ) Smaller inner diameter (D IA), so a contact force 222 (retention force) is applied between the outer surface 221 of the first end portion 212 and the inner surface 114 of the connection member 100A (e.g., but not limited to, a press fit). The contact force 222 or contact pressure between the connection member 100A and the brittle structure 210 can be sufficient to substantially inhibit (e.g., prevent) any axial movement of the connection member 100A relative to the first end portion 212 of the brittle structure 210. For example, the contact force 222 between the connection member 100A and the first end portion 212 of the brittle structure 210 can be in a range from about 500 Newtons (N) to about 10,000 N (10 kilonewtons (kN)), such as from about 1 kN to about 9 kN, from about 3 kN to about 8 kN, or from about 4 kN to about 7 kN (e.g., about 5 kN, about 5.5 kN, or about 6 kN).

[0073] The contact force 222 may be determined by applying an axial force using a tensile testing machine capable of applying at least 10 kN of tensile force. A suitable tensile testing machine is available from 825 University Ave., Norwood, MA, 02062-2643, United States. As a specific non-limiting example, when the connection member 100A includes a shape memory alloy and the connection member 100A is at a temperature lower than the austenite finish temperature (A f ), the contact force 222 may be approximately 5.57 kN (i.e., a tensile force of at least 5.57 kN is required to axially separate the connection member 100A from the brittle structure 210). As another specific, non-limiting example, when the connection member 100A comprises a shape memory alloy and the connection member 100A is at a temperature lower than the austenite finish temperature (A f ) at a temperature above about 150° C., the contact force 222 may be greater than 10 kN (ie, a tensile force of at least 10 kN is required to axially separate the connection member 100A from the brittle structure 210 ).

[0074] Once the connection member 100A is secured to the first end portion 212 and the second end portion 214 of the fragile structure 210, the connection member 100A may undergo one or more material removal processes to form the connection feature 224, such as Figure 14 shown and described.

[0075] Figure 14is a side view of a downhole tool component 302 according to an embodiment of the present disclosure, which includes a connection member 100A having a connection feature 224. As will be described in further detail below, in various embodiments, the body 102 includes a connection feature 224 formed in one or more sidewalls 104, such as at a location such as Figure 14 The outer surface of one or more side walls 104 shown in FIG (eg, external threads, but not limited thereto) or located as shown in FIG. Figure 17 100A is a member 100A that is secured to the first and second end portions 212, 214 of the brittle structure 210. The member 100A may be provided with an inner surface of one or more sidewalls 104 (e.g., internal threads, but not limited thereto). In some embodiments, once the connecting member 100A is secured to the first and second end portions 212, 214 of the brittle structure 210, the connecting member 100A may undergo one or more material removal processes (e.g., machining) to form the connecting features 224 on the exposed surfaces (e.g., the exterior surface 112) of the body 102 of the connecting member 100A. Forming the connecting features 224 may reduce (e.g., eliminate) misalignment issues between the connecting member 100A and the brittle structure 210 once the connecting member 100A is secured to the first and second end portions 212, 214 of the brittle structure 210. However, in other embodiments, the connecting features 224 may be formed on the connecting member 100A in a first state (e.g., an austenitic or soft solid state) and in an unaltered or "permanent" configuration prior to securing the connecting member 100A to the brittle structure 210.

[0076] Non-limiting examples of processes for forming the connection features 224 include drilling, milling, turning, using a die, tapping, etc. The connection features 224 may include ridges and / or grooves, threads, etc. Each connection feature 224 may be configured (e.g., sized, shaped, oriented, and / or arranged) to couple the brittle structure 210 to a corresponding portion of another structure (e.g., another component of the downhole tool component 302).

[0077] The connection feature 224 (e.g., a thread) can be located on at least a portion of the body 102 of the connecting member 100A. In some embodiments, the body 102 of the connecting member 100A includes a connection feature 224 (e.g., a thread) located only on a portion of the exterior surface 112. For example, the body 102 may only include threads located on one-quarter (e.g., in the Z direction), one-half, or three-quarters of the connecting member 100A. In other embodiments, one or more peripheral segments (e.g., circumferential segments) of the connecting member 100A may include the connection feature 224, and the connection feature 224 may not be present in the peripheral segments in between. For example, there may be alternating threaded and non-threaded segments arranged around the circumference of the body 102 of the connecting member 100A. In some embodiments that include the connection feature 224 only on a portion of the peripheral segments of the connecting member 100A, the body 102 of the connecting member 100A may be threaded or non-threaded over the entire length (L) of the connecting member 100A. A ) includes a connection feature 224 (e.g., a thread).

[0078] In some embodiments, the body 102 of the connecting member 100A includes a connecting feature 224 (eg, a thread) located on the entire exterior surface 112 of the body 102. For example, the connecting feature 224 may extend the entire length (L) of the exterior surface 112 of the body 102. A ), and also continuously extends around the entire periphery (eg, circumference) of the main body 102 of the connecting member 100A. Figure 10-14 The inner surface 114 ( Figure 13 ) is shown and described as being fixed to the fragile structure 210, and the connection feature 224 is located on the outer surface 112 of the connection member 100A, but the present disclosure is not limited thereto. Figure 15-17 In the embodiment shown and described, the outer surface 112 of the connecting member 100A may be fixed to the fragile structure 310 ( Figure 15 ) in a cavity thereof, and the connection feature 224 can be located on the interior surface 114 of the connection member 100A.

[0079] Figure 15 FIG2 is a simplified cross-sectional view of two connecting members 100C positioned within a brittle structure 310 in a second state and a modified configuration according to an additional embodiment of the present disclosure. The connecting member 100C is in a second state (e.g., a martensitic or hard solid state) and a modified configuration. Because the outer diameter (D OC ) is smaller than the inner diameter (D B2) is smaller, so there is a gap 320 between the outer surface 112 of the connecting member 100C and the inner surface 312 of the cavity 314. In order to eliminate the gap 320 and fix the connecting member 100C in the first end portion 316 and the second end portion 318 of the brittle structure, the connecting structure 100C or the assembly of the brittle structure 310 and the connecting member 100C (for example, a part of a downhole tool) can be subjected to a temperature higher than the transformation temperature of the shape memory material (for example, the austenite finish temperature (A f ) or glass transition temperature (T g )) temperature, so that the connection member 100C is transformed back to the first state (for example, the austenite phase or the soft solid state).

[0080] Figure 16 According to an additional embodiment of the present disclosure Figure 15 1 is a simplified cross-sectional view of a downhole tool component 402 including a brittle structure 310 and two connecting members 100A in a first state, unchanged in configuration, and fixed within the brittle structure 310. The downhole tool component 402 includes the brittle structure 310 and two connecting members 100A disposed within cavities 314 of first and second end portions 316 and 318 of the brittle structure 310. Figure 16 , but in other embodiments, the downhole tool component 302 may include a single connecting member 100A located on one of the end portions, e.g., the first end portion 316. The connecting member 100A is in a first state (e.g., an austenite phase or a soft solid state) and a "permanent" or unaltered configuration. Figure 15 The connection member 100C may be subjected to heating, such as by placing the brittle structure 310 including one or more connection members 100C at a temperature above the transformation temperature (eg, above the austenite finish temperature (A f ) or above the glass transition temperature (T g )) in an oven, or by applying heat only to the connection member 100C. For example, the assembly of the brittle structure 310 and the connection member 100C may be placed in an oven at a temperature of about 200°C for about 5 minutes or more. f ), the shape memory material of the connection member 100C returns to the first state (e.g., austenite phase, soft solid state) and a "permanent" or unchanged configuration.

[0081] The outer diameter (D OC ) has been increased to match the inner diameter (D B2). Therefore, the gap 220 ( Figure 15 ) is eliminated due to the material expansion of the connecting member 100A. In addition, because the connecting member 100A in the "permanent" or unchanged configuration tends to exhibit an inner diameter (D) greater than that of the cavity 314 located within the first end portion 316 and the second end portion 318 of the fragile structure 310, B2 ) Larger outer diameter (D OA ), so a contact force 322 (retention force) is applied between the inner surface 312 of the cavity 314 and the outer surface 112 of the connection member 100A. The contact force 322, or contact pressure, between the connection member 100A and the brittle structure 310 can be sufficient to substantially inhibit (e.g., prevent) any axial movement of the connection member 100A relative to the first end portion 316 and the second end portion 318 of the brittle structure 310. For example, the contact force 322 between the connection member 100A and the first end portion 316 and the second end portion 318 of the brittle structure 310 can be in a range from about 500 Newtons (N) to about 10,000 N (10 kilonewtons (kN)), such as from about 1 kN to about 9 kN, from about 3 kN to about 8 kN, or from about 4 kN to about 7 kN (e.g., about 5 kN, about 5.5 kN, or about 6 kN). Once the connection member 100A is secured to the first end portion 316 and the second end portion 318 of the fragile structure 310, the connection member 100A may undergo one or more material removal processes to form connection features, such as Figure 17 The outer diameter (D OA ) defines a surface (the surface corresponding to the outer diameter). In the first state and unmodified configuration of the connection member 100A, this surface is fixed to the inner surface 312 of the fragile structure 310.

[0082] Figure 17 According to an embodiment of the present disclosure Figure 15 and Figure 163. A simplified cross-sectional view of a downhole tool component 402 of FIG. 4 includes a connecting member 100A having a connection feature 324. In some embodiments, once the connecting member 100A is secured to the first and second end portions 316, 318 of the brittle structure 310, the connecting member 100A can undergo one or more material removal processes (e.g., machining) to form the connection feature 324 on an exposed surface (e.g., interior surface 114) of the body 102 of the connecting member 100A. Forming the connection feature 324 can reduce (e.g., eliminate) misalignment issues between the connecting member 100A and the brittle structure 310 once the connecting member 100A is secured to the first and second end portions 316, 318 of the brittle structure 310. However, in other embodiments, the connection feature 324 can be formed on the connecting member 100A in a first state (e.g., an austenitic or soft solid state) and an unaltered or "permanent" configuration prior to securing the connecting member 100A to the brittle structure 310.

[0083] Non-limiting examples of processes for forming the connecting features 324 include drilling, milling, turning, tapping, etc. The connecting features 324 may include ridges and / or grooves, threads, etc. Each connecting feature 324 may be configured (e.g., sized, shaped, oriented, and / or arranged) to connect the brittle structure 310 to a corresponding portion of another structure (e.g., another component of the downhole tool component 402).

[0084] The connection feature 324 (e.g., a thread) can be located on at least a portion of the body 102 of the connecting member 100A. In some embodiments, the body 102 of the connecting member 100A includes a connection feature 324 (e.g., a thread) located on only a portion of the interior surface 114. For example, the body 102 may only include threads located on one-quarter (e.g., in the Z direction), one-half, or three-quarters of the connecting member 100A. In other embodiments, one or more internal sections (e.g., circumferential sections) of the interior surface 114 of the connecting member 100A may include the connection feature 324, and the connection feature 324 may not be present in the intervening internal sections. For example, there may be alternating threaded and non-threaded sections arranged around the inner surface 312 of the body 102 of the connecting member 100A. In some embodiments that include a connection feature 324 on only a portion of the interior section of the connecting member 100A, the body 102 of the connecting member 100A may be threaded along the entire length (L12) of the connecting member 100A. A ) includes a connection feature 324 (e.g., a thread).

[0085] In some embodiments, the body 102 of the connection member 100A includes a connection feature 324 (e.g., a thread) located on the entire interior surface 114 of the body 102 of the connection member 100A. For example, the connection feature 224 can extend the entire length (L) of the interior surface 114 of the body 102. A ), and also extends continuously around the entire interior surface 114 (eg, circumference) of the opening 106 within the body 102 of the connecting member 100A.

[0086] In some embodiments, the body 102 of the connection member 100A includes a connection feature 224 ( Figure 14 ), and also includes a connection feature 324 located on the interior surface 114 within the opening 106.

[0087] Downhole tool component 302( Figure 10-14 ) of the connection feature 224 and the connection feature 324 ( Figure 15-17 ) can be configured (e.g., sized, shaped, oriented and / or arranged) to connect to a corresponding portion (e.g., a complementary connection feature) of another structure, such as another component of a corresponding downhole tool (not shown).

[0088] Figure 18 is a perspective view of a downhole tool 500 according to an embodiment of the present disclosure, the downhole tool including a downhole tool component 502 (e.g., 302 ( Figure 10-14 ) or downhole tool component 402 ( Figure 15-17 )) of the downhole tool. The downhole tool 500 may be a downhole mud pulse tool used as part of a downhole telemetry system to provide real-time data to the equipment surface (surface unit, located outside the borehole), as described below with reference to Figure 19As explained. The downhole tool 500 includes a downhole tool component 502 (e.g., downhole tool component 302, 402) connected to an end cap 504 at a first end 512 of the downhole tool component 502, and an actuator 506 connected to an opposite second end 514 of the downhole tool component 502. For example, the end cap 504 may include complementary connection features (e.g., ridges and / or grooves, threads, etc.) connected to connection features 524 (e.g., 224, 324) at the first end 512 of the downhole tool component 502. Additionally, the actuator 506 may include complementary connection features (e.g., ridges and / or grooves, threads, etc.) connected to connection features 524 (e.g., 224, 324) at the opposite second end 514 of the downhole tool component 502. The end cap 504 and the actuator 506 may be made of any suitable material, such as a brittle material, a metal (e.g., steel, Inconel), a polymer (e.g., PEEK), etc. In some embodiments, the end cap 504 may include a valve head 510 and may be made of and / or include a brittle material to improve corrosion resistance and wear resistance to drilling fluids. Additionally, the actuator 506 may include a ductile material, such as a metal (e.g., steel, Inconel, but not limited thereto), to facilitate actuation while suppressing fatigue effects.

[0089] The downhole tool 500 may include one or more additional components 508, such as a battery, a control unit (eg, a processor and memory), a motor, and one or more sensors (eg, a gamma sensor, a gyrometer, an accelerometer, a magnetometer, etc.).

[0090] The downhole tool 500 can be a generally elongated structure arranged along a central longitudinal axis 518 and having a controlled outer diameter, such that the downhole tool 500 can fit within a central opening of a drill string component (e.g., a drill collar). The actuator 506 of the downhole tool 500 can be configured (e.g., sized, shaped, oriented, and / or arranged) to selectively extend and retract the tool component 502 and the end cap 504 relative to the drill collar or the remainder of the downhole tool 500 in a direction parallel to the central longitudinal axis 518 of the downhole tool 500 (e.g., in an axial direction). The actuator 506 can be any suitable linear actuator, such as a linkage mechanism (e.g., a slider-crank, a crank and piston, a cam and follower, etc.), an electric motor, etc.

[0091] Additionally, the end cap 504 may be positioned to include the nozzle 520 ( Figure 6 ) of a housing 516 (eg, a casing, but not limited thereto) ( Figure 6). When the downhole tool 500 is assembled and in operation, the end cap 504 can be configured (e.g., sized, shaped, oriented, and / or arranged) to extend toward and retract from the nozzle 520 to restrict and expand the flow path of the drilling fluid, which generates pressure waves in the drilling fluid within the drill string. Depending on drilling conditions, such as the expected drilling fluid pressure in the wellbore, drilling fluid properties, the type of drilling fluid pump, etc., the end cap 504 can be replaced with another end cap that is more suitable for the specific drilling conditions (e.g., an end cap having a valve head made of a harder material, but not limited thereto). Therefore, the connection features 524 (e.g., 224, 324) on the downhole tool component 502 as described herein can facilitate quick and easy assembly and disassembly, as well as the ability to reuse the end cap 504 and other end caps. It will be appreciated that in a similar manner to the way that connection feature 524 was applied to downhole component 502 through the use of shape memory material, complementary connection features at end cap 504 or complementary connection features at actuator 506 may be applied to the end cap or actuator.

[0092] Figure 19 An earth-boring system 600 is shown that includes a drilling rig 602 suspended from a drill string 604. Figure 19 Included is a partial cross-sectional view of an enlarged portion of drill string 604.

[0093] The drill string 604 has multiple sections of drill pipe 606 connected to each other and a bottom hole assembly 608 (BHA) connected to the drill string of drill pipe 606. The bottom hole assembly 608 may include one or more drill collars 610, a downhole motor 611, and an earth-boring tool 612 located at the downhole end of the drill string 604, which rotates to drill a wellbore 614 in a formation 616. Within the drill collars 610, the BHA 608 may include one or more downhole tools 500, which may be used to collect data about the formation (e.g., gamma signatures) and data about the drilling process (e.g., inclination, azimuth, depth, etc.), which may then be transmitted in real time to a facility surface.

[0094] During the drilling process, drilling fluid 618 (commonly referred to as "drilling mud") circulates from a drilling fluid tank 620, down the center (inner bore) of the drill string 604, out nozzles in the earth-boring tool 612, and back up through the annulus of the wellbore and along one or more sidewalls of the wellbore 614 to the drilling fluid tank 620. For example, a pump 622 may pump drilling fluid from the drilling fluid tank 620 down the drill string 604, and at least some of the drilling fluid 618 may return to the drilling fluid tank 620. The presence of a continuous column of fluid within the center of the drill string 604 and the incompressibility of the fluid enable pressure waves generated via the "mud pulse" downhole tool to be detected via a pressure transducer 624 on the drilling equipment 602. The detected pressure wave signal (e.g., a binary signal pressure wave) can then be decoded via surface computer equipment 628 (e.g., included in a surface unit, but not limited to such) to determine data about the formation (e.g., gamma characteristics) and data about the drilling process (e.g., inclination, azimuth, depth, etc.) that have been collected by the downhole tool 500.

[0095] To generate pressure waves, the end cap 504 can be extended toward and retracted from a nozzle 520 (e.g., an orifice or restrictor) within the downhole tool 500 to produce a pressure wave that travels upward along the fluid column within the drill string 604 and is detected by the pressure transducer 624 and decoded by the surface computer equipment 628.

[0096] A mud pulse downhole tool or any other downhole valve used to manipulate the flow of downhole fluids including abrasive materials in high temperature environments such as those found in a typical borehole having temperatures greater than 150°C would benefit from connections made according to embodiments of the present disclosure. Figure 19 ) can utilize a connection including a connecting member (such as any embodiment of the connecting member disclosed herein).

[0097] Figure 20is a simplified side cross-sectional view of the plunger system 701. The plunger system includes a valve head 710 and downhole components, such as a shaft or rod 702. The rod 702 can be made of steel or any other suitable material and can be surrounded by a guide feature 730. The rod 702 can be moved by an actuator (not shown) to move the valve head 710 in a reciprocating motion relative to a flow restrictor 720 (e.g., a valve seat or nozzle). The valve head 710 includes an end portion 712 and can be made of a brittle material (ceramic, hard metal, glass, graphite, etc.) to make the valve head resistant to wear when exposed to downhole fluid 726 that strikes the valve head and flows along the valve head. The end portion 712 of the valve head 710 can have a cylindrical shape and a circular cross-section in a plane perpendicular to the longitudinal axis 718 of the end portion. The connecting member 800 (shown in a first state) includes a body 802 and one or more sidewalls that define an opening. The connecting member 800 is connected to the end portion 712 of the valve head 710. The connecting member 800 may be made of a shape memory alloy or a shape memory polymer. Figure 20 The connecting member 800 in FIG is shown in a first state (eg, an austenite phase or a soft solid state) and a "permanent" or unchanged configuration. Figure 6-Figure 9 In the process described in the embodiment of the present invention, the connecting member 800 is in the second state (e.g., martensite or hard solid state) of the shape memory alloy ( Figure 8 ) undergoes an expansion process to increase the inner diameter of the connecting member 800 to achieve a second state of changed configuration ( Figure 9 ). The connecting member 800 includes an outer diameter D greater than that of the end portion 712 of the valve head 710 when in the second state and in the modified configuration. C1 Larger inner diameter (see Figures 8-11), allowing the connecting member 800 in the second state and changed configuration to be moved relative to the end portion 712 and positioning the connecting member 800 on or at the end portion 712. After heating the connecting member 800 to above the austenite finish temperature, the connecting member transforms to the austenite phase and unchanged configuration, resulting in an interference fit (contact force) with the outer surface 721 of the end portion 712 of the valve head 710. The interference fit secures the connecting member 800 to the end portion 712 of the valve head 710. A connecting feature 824 (e.g., a thread, a groove, a ridge) is formed on the interior surface 814 of the body 802. The connecting feature 824 can be configured (e.g., sized, shaped, oriented and / or arranged) to couple the valve head 710 to a corresponding portion of the stem 702. The corresponding portion of the rod 702 can be the end portion 704 of the rod and can include a complementary connection feature 724 (e.g., threads, grooves, ridges) that is configured to connect with the connection feature 824 on the connecting member 800, providing a connection between the valve head 710 and the rod 702 so that the valve head moves with the rod when the rod is moved by the actuator. The plunger system 701 can be located in a pulse generator housing (not shown) that is similar to the pulse generator housing. Figure 19 The fluid flows through the pulse generator housing and the flow restrictor 720. By using the rod 702 driven by the actuator to move the valve head 710 toward the flow restrictor 720, the flow through the pulse generator housing and the inner bore of the drill string or BHA ( Figure 19 ) downhole fluid 726. The pressure pulse allows information to be transmitted from a location inside the borehole to a surface location (surface unit) outside the surface borehole. In alternative embodiments, the connection between a valve head made of a brittle material and another downhole component is not limited to mud pulse tools, but can be used in other types of downhole valves, such as flow control valves or diverter valves. In some embodiments, a gap exists between the stem 702 and the valve head 710. In other embodiments, the stem 702 abuts the valve head 710.

[0098] Figure 21 According to an embodiment of the present disclosure Figure 19 A simplified side cross-sectional view of another embodiment of a portion of a BHA. As downhole fluid 1026 flows through the flow restrictor at a high flow rate, the mud pulse tool ( Figure 19) is exposed to wear. It may be beneficial to manufacture the flow restrictor from a material that can withstand degradation by abrasive downhole fluids, such as a ceramic material or a hard metal, glass, or graphite. These materials are brittle, which can prevent the formation of connection features (e.g., threads, grooves, ridges) in their brittle materials to achieve direct connection of the flow restrictor to other components of the mud pulse generator, such as the housing. Using shape memory alloys or shape memory polymers to place the threads formed on the connecting member 1100 on the flow restrictor solves this problem. The flow restrictor 1020 may include a cylindrical shape and a circular cross-section perpendicular to the longitudinal axis 1018 of the flow restrictor. In various embodiments, the connecting member 1100 includes a body 1102, an outer surface 1114, and one or more sidewalls defining an opening 1106. The connecting member 1100 is connected to the flow restrictor 1020. The connecting member 1100 may be made of a shape memory material. In various embodiments, the shape memory material is selected from shape memory alloys and shape memory polymers.

[0099] According to an embodiment of the present disclosure, Figure 21 The connection member 1100 in FIG is shown in a first state (eg, an austenite phase or soft solid state) and a "permanent" or unchanged configuration. Figure 6-Figure 9 In the process described in the embodiment of the present invention, the connecting member 1100 is in the second state (e.g., martensite or hard solid state) of the shape memory alloy ( Figure 8 ) undergoes an expansion process to increase the inner diameter of the connecting member 1100 to achieve a second state of changed configuration ( Figure 9 ). The connecting member 1100 in the second state and modified configuration includes an outer diameter D greater than that of the flow restrictor 1020. D1 Larger inner diameter (see Figures 8-111020 ) allows the connecting member 1100 to be moved relative to the flow restrictor 1020 and positioned on or at the flow restrictor. After the connecting member is heated above the austenite finish temperature, the connecting member transforms into the austenite phase and unchanged configuration, resulting in an interference fit (contact force) with the outer surface 1021 of the flow restrictor 1020. The interference fit secures the connecting member 1100 to the flow restrictor 1020. Connecting features 1124 (e.g., threads, grooves, ridges) are formed on the outer surface 1114 of the body 1102 of the connecting member 1100. The connecting features 1124 can be configured (e.g., sized, shaped, oriented and / or arranged) to couple the flow restrictor 1020 to a corresponding portion of the housing 1002. The corresponding portion of the housing 1002 may include a complementary connection feature 1024 (e.g., a thread, a groove, a ridge) that is configured to connect with the connection feature 1124 on the connecting member 1100, resulting in the flow restrictor 1020 being connected to the housing 1002 such that the flow restrictor is fixedly connected to the housing via the connection features 1024 and 1124. The housing 1002 may be similar to Figure 19 The housing shown in FIG. 1002 may be a different housing within the BHA. In one embodiment, the housing 1002 may be a drill collar. By moving the valve head 1010, which is driven by an actuator (not shown), toward the flow restrictor 1020, the flow through the flow restrictor 1020 and the inner bore of the drill pipe and / or the BHA ( Figure 19 ) generates pressure pulses in the downhole fluid 1026, allowing information to be transmitted from a location inside the borehole to a surface location outside the borehole (surface unit) on the surface.

[0100] Figure 22 yes Figure 20 Simplified side cross-sectional view of another embodiment of the plunger system 701. In various embodiments, as Figure 22 As shown, the inner surface of the connecting member 800 includes a first corresponding surface 815 and a second corresponding surface 817. The first corresponding surface 815 connects the connecting member 800 to the end portion 713 of the rod 702 via an interference fit with the outer surface 723 thereof, and the second corresponding surface 817 connects the connecting member 800 to the end portion 712 of the valve head 710 via an interference fit with the outer surface 721 thereof. The inner diameters of the first corresponding surface 815 and the second corresponding surface 817 may be substantially the same (e.g., Figure 22 as shown) or may be different, which correspond to the outer surfaces of end portion 713 and end portion 712 respectively.

[0101] In various embodiments, the connection between the connecting member 800 and the end portion 713 of the rod 702 is provided by the same method used to connect the connecting member 800 to the end portion 712 of the valve head 710. Specifically, the connecting member 800 is positioned on the end portion 713 of the rod 702 while in the second state (e.g., the martensite phase, but not limited thereto) and in an altered configuration. After applying a stimulus to the connecting member 800 (e.g., heating the connecting member 800 to above the austenite finish temperature), the connecting member 800 transforms to the first state (e.g., the austenite phase, but not limited thereto) and in an unchanged configuration, resulting in an interference fit (external interference fit) with the outer surface 723 of the end portion 713 of the rod 702. An interference fit between the connecting member 800 and the end portion 713 of the stem 702 may be formed via a first corresponding surface 815 on the connecting member 800 , and an interference fit between the connecting member 800 and the end portion 712 of the valve head 710 may be formed via a second corresponding surface 817 on the connecting member 800 .

[0102] In yet another embodiment, the connection member 800 may be formed by transitioning from a second state (e.g., martensite phase, but not limited thereto) and an altered configuration to a first state (e.g., austenite phase, but not limited thereto) and an unaltered configuration (as described above with respect to Figure 15 and Figure 16 ) while increasing its outer diameter to connect the valve head 710 and the rod 702. In this embodiment, the end portion 712 of the valve head 710 and the end portion 713 of the rod 702 each include an inner diameter ( Figure 15 D in B2 ) cavity (reference Figure 15 and Figure 16 In the second state (eg, martensite phase, but not limited thereto) and the modified configuration, the outer diameter ( Figure 15 D in OC) is smaller than the inner diameter of the cavity located in the valve head 710 and the rod 702, allowing the connection member 800 to be positioned in each corresponding cavity. After applying a stimulus to the connection member 800 (e.g., heating the connection member 800 to above the austenite finish temperature, but not limited thereto), the connection member 800 transforms into a first state (e.g., an austenite phase, but not limited thereto) and an unchanged configuration, resulting in an interference fit (internal interference fit) with the inner surface of each corresponding cavity of the rod 702 and the valve head 710. As can be appreciated, the connection between the valve head 710 and the rod 702 can be formed with the connection member 800 using any combination of the various internal interference fits disclosed herein. For example, the connection member 800 is connected to one of the valve head 710 and the rod 702 via an external interference fit, and the connection member 800 is connected to the other of the valve head 710 and the rod 702 via an internal interference fit. In some embodiments, a gap exists between the rod 702 and the valve head 710. In other embodiments, the rod 702 abuts the valve head 710.

[0103] In alternative embodiments, the connection between the flow restrictor 1020 made of a brittle material and another downhole component (e.g., a housing) is not limited to mud pulse tools, but can be used in other types of downhole valves, such as flow check valves or diverter valves. It is expected that the shape memory material connecting member of the above-described embodiments will facilitate the connection between brittle materials (e.g., glass, ceramics, hard metals, graphite, etc.) and tough, ductile materials (e.g., metals) or any other material (including other brittle materials). Thus, brittle materials, which are generally durable in terms of high hardness, resistant to erosion, corrosion, and wear, and lightweight due to their relatively low density, can still take advantage of their advantageous material properties while allowing for easy connection to other downhole components. Furthermore, due to their ability to expand and contract in response to stimuli (such as temperature or stress), the use of shape memory materials can facilitate less precise sizing of brittle structures. Additionally, mechanical connections (such as tapered shafts with wide outer ends or stepped features) can be used to further secure the connecting member due to the high expansion caused by the change in state.

[0104] Additionally, the ability to machine the shape memory material connecting member to form connecting features (such as threads) once the shape memory connecting member is secured to or within the fragile structure can reduce (e.g., eliminate) misalignment issues caused by combining separable components.

[0105] While shape memory connecting members of the type described herein provide advantages to downhole tools used in drilling operations, shape memory connecting members may be used in any situation where securing a connecting member to another downhole component may be advantageous.

[0106] Therefore, it is desirable to have a connecting member, a downhole tool including the connecting member, and a method of forming and using the connecting member and the downhole tool, when compared to conventional downhole tools and conventional methods of forming and using conventional connecting members and conventional downhole tools, to facilitate assembly and mismatches between materials due to material properties.

[0107] Although embodiments of the present disclosure have been described and illustrated herein with respect to particular connection components, downhole tools, and methods, those skilled in the art will recognize and understand that features and elements from different embodiments may be combined to achieve further, additional connection components, downhole tools, and methods as contemplated by the inventors.

[0108] Embodiments of the present disclosure may be further characterized, but not limited thereto, as set forth below.

[0109] Embodiment 1: A downhole valve system for use in drilling, the downhole valve system comprising: a first downhole component, the first downhole component being made of a brittle material and comprising a longitudinal axis; a second downhole component, the second downhole component comprising a first connecting feature; and a connecting member, the connecting member being formed of a shape memory material and comprising: an outer surface having an outer diameter; an inner surface having an inner diameter, one of the outer diameter and the inner diameter being capable of being changed by applying a stimulus to the shape memory material; and a second connecting feature, the second connecting feature being complementary to the first connecting feature, formed on one of the outer surface and the inner surface, the connecting member being fixed to the first downhole component at a corresponding surface of one of the inner diameter and the outer diameter, and being fixed to the second downhole component via the first connecting feature and the second connecting feature to connect the second downhole component to the first downhole component.

[0110] Embodiment 2: The downhole valve system according to embodiment 1, wherein the first downhole component comprises a pressure lower than 20 MPa·m 1 / 2 Fracture toughness K 1C .

[0111] Embodiment 3: The downhole valve system of any one of embodiments 1 and 2, wherein the first downhole component comprises a valve head positioned within the downhole valve system to be exposed to downhole fluid during operation of the downhole valve system.

[0112] Embodiment 4: The downhole valve system of any one of embodiments 1 to 3, wherein the first downhole component comprises a flow restrictor positioned within the downhole valve system to be exposed to downhole fluid during operation of the downhole valve system.

[0113] Embodiment 5: The downhole valve system according to any one of embodiments 1 to 4, wherein the downhole valve system is selected from a downhole mud pulse generator, a diverter valve, and a downhole stop valve.

[0114] Example 6: A downhole valve system according to any one of Examples 1 to 5, wherein the shape memory material is capable of changing between a first state and a second state by applying the stimulus, and the connecting member includes an inner diameter that is smaller when in the first state than the inner diameter when in the second state.

[0115] Embodiment 7: The downhole valve system of any one of Embodiments 1 to 6, wherein the shape memory material comprises nickel-titanium-niobium alloy (NiTiNb).

[0116] Embodiment 8: The downhole valve system of any one of Embodiments 1 to 7, wherein the connection member is secured to the first downhole component at a corresponding surface of one of the inner diameter and the outer diameter via an interference fit.

[0117] Embodiment 9: The downhole valve system of any one of embodiments 1 to 8, wherein the first connection feature comprises threads.

[0118] Embodiment 10: The downhole valve system according to any one of embodiments 1 to 9, wherein the brittle material is selected from ceramics and hard metals.

[0119] Example 11: A downhole valve system for use in drilling, the downhole valve system comprising: a first downhole component, the first downhole component being made of a brittle material and comprising a longitudinal axis; a second downhole component; and a connecting member, the connecting member being formed of a shape memory material and comprising: an outer surface having an outer diameter; and an inner surface having an inner diameter, one of the outer diameter and the inner diameter being capable of being changed by applying a stimulus to the shape memory material; the connecting member being fixed to the first downhole component at a first corresponding surface of one of the inner diameter and the outer diameter, and the connecting member being fixed to the second downhole component at a second corresponding surface of one of the inner diameter and the outer diameter to connect the second downhole component to the first downhole component.

[0120] Embodiment 12: The downhole valve system of embodiment 11, wherein the first downhole component is selected from a valve head and a flow restrictor, the valve head and the flow restrictor being positioned within the downhole valve system to be exposed to downhole fluid during operation of the downhole valve system.

[0121] Embodiment 13: A method for forming a downhole tool, the method comprising: providing a first downhole component and a second downhole component, the first downhole component being made of a brittle material and comprising a longitudinal axis, the second downhole component comprising a first connection feature; and connecting the second downhole component to the first downhole component using a connection member, the connection member being formed of a shape memory material and comprising: an outer surface having an outer diameter; an inner surface having an inner diameter, one of the inner diameter and the outer diameter being capable of being changed by applying a stimulus to the shape memory material; and a second connection feature, the second connection feature being complementary to the first connection feature, formed on one of the outer surface and the inner surface, the connection being formed by fixing the connection member to the first downhole component at a corresponding surface of one of the inner diameter and the outer diameter and connecting the connection member to the second downhole component via the first connection feature and the second connection feature to connect the second downhole component to the first downhole component.

[0122] Embodiment 14: The method according to embodiment 13, wherein the first downhole component comprises a pressure lower than 20 MPa·m 1 / 2 Fracture toughness K 1C .

[0123] Embodiment 15: The method of any one of Embodiments 13 and 14, wherein the first downhole component comprises a valve head positioned within a downhole valve system to be exposed to downhole fluid during operation of the downhole valve system.

[0124] Embodiment 16: The method of any one of Embodiments 13 to 15, wherein the first downhole component comprises a flow restrictor positioned within a downhole valve system to be exposed to downhole fluid during operation of the downhole valve system.

[0125] Example 17: A method according to any one of Examples 13 to 16, wherein the shape memory material is capable of changing between a first state and a second state by applying the stimulus, and connecting the second downhole component to the first downhole component using a connecting member includes: arranging the connecting member relative to the first downhole component when in the second state; applying the stimulus to the shape memory material to change the shape memory material from the second state to the first state, and fixing the connecting member to the first downhole component.

[0126] Embodiment 18: The method of any one of Embodiments 13 to 17, wherein the shape memory material comprises a nickel-titanium-niobium alloy (NiTiNb).

[0127] Embodiment 19: The method of any one of Embodiments 13 to 18, wherein securing the connection member to the first downhole component comprises forming an interference fit.

[0128] Embodiment 20: The method of any one of embodiments 13 to 19, wherein the first connection feature and the second connection feature each comprise a thread, and the connection between the connection member and the second downhole component is formed by threading the first connection feature to the second connection feature.

Claims

1. A downhole valve system for use in a borehole, the downhole valve system comprising: a first downhole component made of a brittle material and comprising a longitudinal axis; a second downhole component, the second downhole component comprising a first connection feature; and A connecting member, the connecting member is formed of a shape memory material and includes: an outer surface with an outer diameter; an inner surface with an inner diameter, one of the outer diameter and the inner diameter can be changed by applying a stimulus to the shape memory material; and a second connecting feature, the second connecting feature is complementary to the first connecting feature and is formed on one of the outer surface and the inner surface, the connecting member is fixed to the first downhole component at a corresponding surface of one of the inner diameter and the outer diameter, and is fixed to the second downhole component via the first connecting feature and the second connecting feature to connect the second downhole component to the first downhole component.

2. The downhole valve system according to claim 1, wherein: The first downhole component comprises a material lower than 20 MPa·m 1 / 2 Fracture toughness K 1C .

3. The downhole valve system according to claim 1, wherein: The first downhole component includes a valve head positioned within the downhole valve system to be exposed to a downhole fluid during operation of the downhole valve system.

4. The downhole valve system according to claim 1, wherein: The first downhole component includes a flow restrictor positioned within the downhole valve system to be exposed to downhole fluid during operation of the downhole valve system.

5. The downhole valve system according to claim 1, wherein: The downhole valve system is selected from a downhole mud pulse generator, a diverter valve and a downhole stop valve.

6. The downhole valve system according to claim 1, wherein: By applying the stimulus, the shape memory material is capable of changing between a first state and a second state, the connecting member comprising an inner diameter when in the first state that is smaller than the inner diameter when in the second state.

7. The downhole valve system according to claim 6, wherein: The shape memory material includes nickel-titanium-niobium alloy (NiTiNb).

8. The downhole valve system according to claim 6, wherein: The connecting member is secured to the first downhole component at the corresponding surface of one of the inner diameter and the outer diameter via an interference fit.

9. The downhole valve system according to claim 1, wherein: The first connection feature includes threads.

10. The downhole valve system according to claim 1, wherein: The brittle material is selected from ceramics and hard metals.

11. A downhole valve system for use in a borehole, the downhole valve system comprising: a first downhole component made of a brittle material and comprising a longitudinal axis; a second downhole component; and A connecting member formed of a shape memory material and comprising: an outer surface having an outer diameter; and an inner surface having an inner diameter, one of the outer diameter and the inner diameter being capable of being changed by applying a stimulus to the shape memory material; the connecting member being fixed to the first downhole component at a first corresponding surface of one of the inner diameter and the outer diameter, and the connecting member being fixed to the second downhole component at a second corresponding surface of one of the inner diameter and the outer diameter to connect the second downhole component to the first downhole component.

12. The downhole valve system according to claim 11, wherein: The first downhole component is selected from a valve head and a flow restrictor, the valve head and the flow restrictor being positioned within the downhole valve system to be exposed to downhole fluid during operation of the downhole valve system.

13. A method of forming a downhole tool, the method comprising: providing a first downhole component and a second downhole component, the first downhole component being made of a brittle material and comprising a longitudinal axis, the second downhole component comprising a first connection feature; as well as The second downhole component is connected to the first downhole component using a connecting member, the connecting member is formed of a shape memory material and includes: an outer surface with an outer diameter; an inner surface with an inner diameter, one of the inner diameter and the outer diameter can be changed by applying a stimulus to the shape memory material; and a second connecting feature, the second connecting feature is complementary to the first connecting feature, and is formed on one of the outer surface and the inner surface, the connection is formed by fixing the connecting member to the first downhole component at a corresponding surface of one of the inner diameter and the outer diameter and connecting the connecting member to the second downhole component via the first connecting feature and the second connecting feature to connect the second downhole component to the first downhole component.

14. The method according to claim 13, wherein: The first downhole component comprises a material lower than 20 MPa·m 1 / 2 Fracture toughness K 1C .

15. The method according to claim 13, wherein: The first downhole component includes a valve head positioned within a downhole valve system to be exposed to a downhole fluid during operation of the downhole valve system.

16. The method according to claim 13, wherein: The first downhole component includes a flow restrictor positioned within a downhole valve system to be exposed to a downhole fluid during operation of the downhole valve system.

17. The method according to claim 13, wherein: By applying the stimulus, the shape memory material can be changed between a first state and a second state, and connecting the second downhole component to the first downhole component using a connecting member includes: arranging the connecting member relative to the first downhole component when in the second state; applying the stimulus to the shape memory material to change the shape memory material from the second state to the first state, and fixing the connecting member to the first downhole component.

18. The method according to claim 17, wherein: The shape memory material includes nickel-titanium-niobium alloy (NiTiNb).

19. The method according to claim 17, wherein: Securing the connection member to the first downhole component includes forming an interference fit.

20. The method according to claim 13, wherein: The first connection feature and the second connection feature each include threads, and the connection between the connection member and the second downhole component is formed by threading the first connection feature to the second connection feature.

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