Techniques for property evolution of porous thermoset

Abstract

A structural thermoset media, processes, and compositions are described herein. A method includes providing one or more monomers and one or more catalysts to form a thermoset composition. The method also includes generating an elastomeric material using the one or more monomers and the one or more catalysts. Further, the method includes generating an elastomeric material based on a reaction between the one or more catalysts and the one or more monomer units. The elastomeric material has a first crosslink density between about 40% and 80%. The first crosslink density of the elastomeric material is configured to increase to a second crosslink density when subjected to downhole conditions to generate a structural thermoset material. The second crosslink density is greater than or equal to about 95%.

Description

TECHNIQUES FOR PROPERTY EVOLUTION OF POROUS THERMOSETCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to US Provisional Patent Application havingSerial No. 63 / 579,604, which was filed on August 30, 2023, US Provisional Patent Application having Serial No. 63 / 591,938, which was filed on October 20, 2023, US Provisional Patent Application having Serial No. 63 / 637,543, which was filed on April 23, 2024, US Provisional Patent Application having Serial No. 63 / 637,217, which was filed April 22, 2024, US Provisional Patent Application having Serial No. 63 / 550,716, which was filed on February 7, 2024, and US Provisional Patent Application having Serial No. 63 / 674,643, which was filed on July 23, 2024, each of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present disclosure generally relates to a porous thermoset composition with evolving properties, such as glass transition temperature, modulus, crosslink density, or a combination thereof.

[0003] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it may be understood that these statements are to be read in this light, and not as admissions of prior art.

[0004] In many hydrocarbon wells, inflowing fluid passes through a sand screen which filters out particulates from the inflowing oil or gas. The sand screen prevents sand from entering the wellbore and reduces damage that may occur by erosion. Conventionally, sand screens are made with a metallic mesh material. Once the sand screen is placed into the wellbore, gravel packs are pumped to fill the annulus between the screen and the formation.

[0005] In other instances, some metallic sand screens are expandable and are expanded downhole after placement in the wellbore. The result is a reduction in the annulus between the screen and the formation. The expandable screens in many instances have a limited expansion ratio, and the ability of the expandable screen to conform to borehole irregularities may not be satisfactory. Further, the ability of the expandable sand screen to resist borehole collapse may be reduced. Conventional sand screens are rated to resist greater external pressure than expandable sand screens. Expandable sand screens resist less external pressure because of plastic deformation experienced by their metallic components.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0007] FIG. l is a sectional view of a sand screen positioned in a wellbore, in accordance with an embodiment of the present disclosure;

[0008] FIG. 2 is an embodiment of a method of generating the porous structural thermoset material of FIG. 1, in accordance with an embodiment of the present disclosure; and

[0009] FIG. 3 is a flow diagram of a method for generating a structural thermoset material that may be used in the method of FIG. 2, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION

[0010] Certain embodiments commensurate in scope with the present disclosure are summarized below. These embodiments are not intended to limit the scope of the disclosure, but rather these embodiments are intended only to provide a brief summary of certaindisclosed embodiments. Indeed, the present disclosure may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

[0011] All numerical values within the detailed description herein are modified by “about” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art. For example, “about” or “approximately” may refer to ±0.5%, ±1%, ±2, ±5%, ±10%, or ±15%.

[0012] As used herein, the term “coupled” or “coupled to” may indicate establishing either a direct or indirect connection (e.g., where the connection may not include or include intermediate or intervening components between those coupled), and is not limited to either unless expressly referenced as such. The term “set” may refer to one or more items. Wherever possible, like or identical reference numerals are used in the figures to identify common or the same elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale for purposes of clarification.

[0013] As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.”

[0014] Furthermore, when introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment,” “an embodiment,” or “some embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate therecited features. Furthermore, the phrase A “based on” B is intended to mean that A is at least partially based on B. Moreover, unless expressly stated otherwise, the term “or” is intended to be inclusive (e.g., logical OR) and not exclusive (e.g., logical XOR). In other words, the phrase A “or” B is intended to mean A, B, or both A and B.

[0015] Present embodiments described herein generally relate to making and using a porous structural thermoset material. In some embodiments, this porous structural thermoset material can be used in sand control applications, among other applications. For example, one or more embodiments of the present disclosure relate to a porous structural thermoset material that is able to expand once deployed downhole to conform to an irregularly shaped wellbore for sand control operations. As further described below, the porous structural thermoset material according to one or more embodiments of the present disclosure exhibits permeability, robustness, and an expansion ratio that are favorable for sand control operations by allowing for support of the formation during the production of oil.

[0016] Embodiments herein of present techniques and generated porous structural thermoset material have advantages to techniques of mixing of dissolvable particles into resin, in which it is very difficult to create and network the resultant product and these techniques tend to lead to increases in the viscosity and reductions in the processability of the materials involved. Present techniques described herein include a true injection or resin infusion process around the scaffold of the dissolvable network whereas mixing in dissolvable particles will tend to limit porosity and coat the dissolvable particles (making it difficult to remove after curing).

[0017] The present techniques can be performed on the surface (e.g., not downhole), as this maximizes consistency, increases porosity, and allows for more clearance during any running in hole (RIH) operation. With increased porosity, the porous structural thermoset material can be compressed uphole to a smaller diameter for RIH operations. This is in contrast to other techniques, which can involve attempts to dissolve components of a sand screen downhole, which utilizers more physical space and is more difficult to control relative to the present techniques and the porous structural thermoset material.

[0018] The present techniques are additionally different from “foam” or “foaming” methods. The fundamental difference between the porous structural thermoset material generated via present embodiments and foaming methods is that the present techniques are controllable in contrast to the unpredictable nature of foaming (e.g., triggered by volatilization of various components to create porosity). Additionally, present techniques provide increased repeatability, since with foams and foaming methods, it is difficult to both create repeatable sizes of pores and throats as well as to interconnect them (i.e., making an open cell vs. closed cell foam). The present techniques do not have these limitations of foam and foaming methods.

[0019] Aspects of the present disclosure are directed to a thermoset composition that is capable of transforming into multiple materials via a crosslinking reaction. In general, the thermoset composition is a mixture (e.g., a liquid mixture) that includes one or more monomer units, at least one catalyst, and optionally, certain additives and reagents as described in more detail herein. The thermoset composition is capable of a transforming into an elastomeric material (e g., a thermoset elastomeric material) via polymerization and partial curing (e.g., crosslinking) of the polymer. Further, the elastomeric material is capable of transforming into a structural thermoset material via additional curing. As discussed in more detail herein, elastomeric material has a relatively low modulus (e.g., less than about 100 MPa), a relatively low glass transition temperature (Tg) (e.g., less than or equal to about 50°C), and a first crosslink density (e.g., between about 40% to 80%). The elastomeric material is relatively soft, and thus, may conform to irregular surfaces, shapes, or other features within a borehole or other downhole environment where it may be deployed. Certain additives and / or catalysts that are added to the thermoset composition (e.g., and thus are present in the elastomeric material) may be capable of causing additional crosslinking when the elastomeric material is subjected to downhole conditions (e.g., heat) within the downhole environment. For example, a catalyst or other reagent may have increased activity when subject to downhole conditions. Accordingly, the elastomeric material may undergo additional crosslinking, thereby transforming into the structural thermoset material. As compared to the elastomeric material, the structural thermoset material has a relatively high modulus (e.g., greater than about 0.5 GPa), a relatively high glass transition temperature (e.g.,110°C or otherwise greater than the temperature of the downhole conditions), and a second crosslink density (e.g., greater than or equal to about 95%). Accordingly, the previously soft and easy to deploy elastomeric material transforms into a rigid, structural thermoset material that is capable of withstanding mechanical erosion and other relatively harsh downhole conditions.

[0020] With the foregoing in mind, FIG. l is a sectional view of a sand screen positioned in a wellbore according to one or more embodiments of the present disclosure is shown. Specifically, the wellbore 100 includes an open bore hole 102, a production tubing string 104, which may be a base pipe according to one or more embodiments, and a sand screen 106. While wellbore 100 is illustrated as being a substantially vertical, uncased well, it should be recognized that the subject disclosure is equally applicable for use in cased wellbores as well as in horizontal and / or inclined wellbores. The sand screen 106 includes a filter member 108 and a polymeric material, such as the porous elastomeric material 110 according to one or more embodiments of the present disclosure. The sand screen 106 is shown positioned in the wellbore 100 adjacent a producing formation 114. In some embodiments, the sand screen 106 (and / or the porous elastomeric material 110) can be, for example, an annular shaped member that can be disposed about the production tubing string 104. In addition, according to one or more embodiments of the present disclosure, the porous elastomeric material 110 may be the only filtration agent without the use of any filter member 108. In one or more embodiments of the present disclosure, the filter member 108 can be configured for additional structural support of the porous elastomeric material 110.

[0021] Still referring to FIG. 1, in a well completion method according to one or more embodiments of the present disclosure, at least one base pipe (e.g., production tubing string 104) may be covered with the porous elastomeric material HOaccording to one or more embodiments of the present disclosure. The porous elastomeric material 110 covering the base pipe as the production tubing string 104 may be covered with a retainer before running the base pipe as the production tubing string 104 to a location in the wellbore 100. Upon exposure to a condition in the wellbore 100, the retainer may degrade and expose the porous elastomeric material 110 to the wellbore fluids. In one or more embodiments, variousmethods are employed to trigger expansion of the elastomeric material 110. As the porous elastomeric material 110 expands into and fdls the annulus, the porous elastomeric material 110 conforms to a wall of the wellbore 100. Because the porous elastomeric material 110 is able to conform to the wellbore 100 wall in this way and has a permeability that is about equivalent to or greater than the permeability of the surrounding formation, the porous elastomeric material 110 is able to allow formation fluids into the base pipe as the production tubing string 104 while filter debris including sand from fluids from the producing formation 114. After the downhole operation is complete, the porous elastomeric material 110 may be detached from the base pipe as the production tubing string 104, and the base pipe as the production tubing string 104 may be lifted out of the wellbore 100.

[0022] In this manner, the porous elastomeric material 110 can have many beneficial applications for downhole tools in the oilfield, in particular for a conformable sand screen as sand screen 106 used in oil and / or in gas operations. The porous elastomeric material 110 can also be applied to / relevant to downhole tools involving a porous medium, such as for filtering or sealing applications. The porous elastomeric material 110 can be porous, allowing downhole fluids to be produced through it. Simultaneously, the pores can be small enough that erosive sand particles can be captured before they enter the completions equipment. Once in the proper location downhole (e.g., in the wellbore 100 adjacent a producing formation 114), the porous elastomeric material 110 can expand and conform to the wellbore 100. The high strength of the porous elastomeric material 110 can also allow it to support the wellbore 100. This support can be especially important, for example, during drawdown, as suction created by pumps drawing fluids from the producing formation 114 can destabilize the producing formation 114. The structural strength of the porous elastomeric material can allow it, for example, to inhibit collapse during drawdown, ensuring sustained production from the well.

[0023] In this manner, the high mechanical strength of the porous elastomeric material is a desirable property for use in oilfield operations, allowing porous elastomeric material to withstand large loads. In addition to the porous elastomeric material having high strength, it can also have desirable chemical compatibility. In some embodiments, the porouselastomeric material, which is formed by irreversible chemical reactions to generate a crosslinked structure that does not melt (also called thermosetting polymers, thermoset resins, or thermosetting resins) can include (but are not limited to) the following chemistries and variants: polyesters, cyanate esters, epoxies, phenolics, methacrylates, melamines, vinyl esters, bismaleimides, thermoset cyclic polyolefins, polyimides, and benzoxazines. Furthermore, the compounds used in the generation of the porous elastomeric material can be thermally stable to high temperatures and can be resistant to chemical attack.

[0024] The present “structural thermoset” material can be mechanically as a rigid thermosetting polymer where the non-porous, bulk material (when cured to form a densely crosslinked network) has a modulus (compressive, flexural, tensile, or elastic) of at least, for example, approximately 0.5 GPa below the glass transition temperature (Tg). In other embodiments, structural thermosets typically have a Tgabove ambient (e.g., about 25°C). Additionally, some embodiments, the structural thermoset can be reinforced with fillers, such as ceramic or metallic particles of various types and / or geometries, to enhance the mechanical properties of the cured porous elastomeric material 110 (e.g., the structural thermal set material as described in more detail in FIG. 3). This can include spherical, non- spherical, or high aspect ratio silica (both crystalline and amorphous), boron nitride, aluminosilicate, alumina, aluminum nitride, and zirconium tungstate. Metallic reinforcements can include a variety of ferrous and non-ferrous, with preference to corrosion resistant materials (i.e. nickel alloys, stainless steels, etc.). In this manner, in some embodiments, the mechanical strength, thermal stability, and thermal conductivity of the porous structural thermoset material can be modified and improved through the addition of additional materials.

[0025] The elastomeric material can be made to be porous. The porous structure can have a variety of purposes, including: to allow fluid to pass through the material, to filter solid particles, and / or to create an interpenetrating composite network. In some embodiments, the interpenetrating thermoset composite network can have two or more materials with vastly different thermal, viscous, mechanical, electrical, or magnetic properties.

[0026] FIG. 2 illustrates a first embodiment of a method of generating the porous elastomeric material 110. As will be described in greater detail, the method illustrated in FIG. 2 illustrates creation of the porous elastomeric material 110 via encapsulating a removable material with a structural thermoset material, such as, but not limited to, a structural thermoset polymer. For example, in block 115, particles of a removable material 118 can be loaded into a mold 120. While the mold 120 is shown as an open mold, a closed mold can be used to facilitate resin injection (vs. potting in open mold). In some embodiments, mold 120 can be shaped and sized to fit within a desired sand screen 106 or the mold 120 can form a bulk porous elastomeric material 110 shape, from which the sand screen form 106 is fabricated (machining, cutting, etc.). Moreover, while generation of the porous elastomeric material 110 into a sand screen 106 is described, it should be noted that other devices and / or configurations are envisioned. For example, the porous elastomeric material 110 can be shaped into forms for separation operations (e.g., as a separator used in separating oil and water), filtration operations (e.g., as a filter on a pump used in oil and gas operations, as an actuator or actuator device (e.g., to move to open and close a valve), or in similar operations.

[0027] The material selected as the removable material 118 can be chosen based on various properties, for example, its compressibility, the size of its particles, the manner in which it can be removed from the mold 120, and / or other characteristics. In some embodiments, the removable material 118 can be a dissolvable material. For example, salt, sugar, polyvinyl alcohol (PVA), or another liquid soluble material can be used as the removable material 118. The salt selected can include Sodium Chloride, however, additionally and / or alternatively other salts can be utilized, for example, Magnesium Chloride, Calcium Chloride, Potassium Chloride, or other suitable salts. Likewise, numerous types of sugars can be utilized as the removable material 118. The removable material 118 can be chosen to be dissolvable in the presence of water or a different liquid (e.g., a solvent). In still other embodiments, removable material 118 can be a material that melts instead of one that dissolves in the presence of a liquid. For example, removable material 118 can be, for example, paraffin wax, carnauba wax, or another material that can be removable upon exposure to heat (e.g., temperatures up to or over approximately 85° C). In furtherembodiments, the removable material 118 can be a solid material that sublimes upon exposure to heat (e.g., temperatures up to or over approximately 85° C). For example, naphthalene can be utilized as the removable material 118, since it sublimes at temperatures at or around 85° C. In some embodiment, the removable material 118 can be a mixture of two or more types of removable materials.

[0028] In conjunction with block 116, compression of the removable material 118 can be undertaken in some embodiments. This can assist in generating a desired network of removable particles, which can define a pore and pore throat network in the resulting porous structural thermoset material that is generated. In one or more embodiments, in conjunction with block 116, the removable material 118 can be compressed in the mold 120 (e.g., into a network or a layer or another structure of compressed removable material 118) prior to the porous structural thermoset material being applied to the mold 120. This can be accomplished via use of a press 121 or another suitable device. This compression process can increase the loading of removable material 118 in the mold 120. The compression can also, for example, improve the porosity of the final part, as the particles of the removable material 118 are forced to have more contact with each other, ensuring that when the removable material 118 is removed, the pores generated in the porous elastomeric material 110 from the removal of the removable material 118 are connected.

[0029] This compression process can also alter the shape of the removable material 118, which can impact the shape of the pores generated in the porous elastomeric material 110. That is, the pore size and / or shape in the resultant porous elastomeric material 110 can be dictated by this compression process (e.g., the amount of compression applied, by applying different compressions to different portions of the removable material 118, etc.). For example, the compression process can be applied in different directions, for example, to provide anisotropic properties. Thus, in the case of manufacturing a sand screen 106 that is annular (i.e., has an annular shape), compression could be applied axially or radially, and the direction of compression applied would affect the pore morphology.

[0030] In some embodiments, sintering (e.g., binding) of the particles of the removable material 118 can also be undertaken. Likewise, liquid (e.g., water or a liquid solvent) can beapplied to the removal material 118 (or removable materials 118 if two or more materials are utilized as the removable material 118), which can be dried thereafter to form a desired network (e.g., layout of pores) in the porous structural thermoset material that is generated. The network that is created can be generated layer by layer or in bulk. Image 122 provides an example of the removable material 118 that can be loaded in to the mold 120 in conjunction with block 115 and / or compressed in conjunction with block 116 when compression is undertaken.

[0031] In block 124, thermoset composition 126 (e g., structural thermal mixture, structural thermoset formulation, structural thermoset precursor) can be added to the mold 120.

[0032] The thermoset composition can be added in an amount to wholly or partially cover the removable material 118. For example, the thermoset composition can encapsulate and fill the interstices of the particles of the removable material 118. The thermoset composition is an uncured version of the porous elastomeric material. That is, in conjunction with block 124, the thermoset composition may be in an uncured form of the porous elastomeric material when placed or otherwise added to the mold 120. Once added to the mold 120, the thermoset composition in its uncured state (e.g., viscous liquid) may be cured (i.e., hardened). This curing can be accomplished by exposing the thermoset composition to heat, radiation (e.g., ultraviolet light), pressure, a curing agent, and / or a catalyst. The curing of the thermoset composition can result in an infusible and insoluble resultant porous elastomeric material. Image 128 illustrates an example of the porous elastomeric material having been cured with the removable material 118 present therein (e.g., the removable material 118 encapsulated with the porous elastomeric material). As described in more detail herein, it may be advantageous to partially cure (e.g., as compared to fully curing) the thermoset composition such that it is capable of conforming to irregularities in surfaces, shapes, and other features in a borehole.

[0033] Block 130 of FIG. 2 includes removal of the removable material 118. This removal can be effected by the application of a liquid (e.g., to dissolve the removable material 118), heat (e.g., to melt the removable material 118 or to sublime the removable material118), and / or a catalyst to the removable material 118 and the porous elastomeric material 110 in the mold 120. The removal process can be selected to match the material used as the removable material. In this manner, the removal process can include external stimulation that supports the removal of the particles of the removable material 118. Such external stimulation can include, for example, exposure to a solvent, a temperature change, a pressure change, agitation, and / or or ultrasonic waves. Upon removal of the removable material 118, pores 132 remain in the porous elastomeric material 110. Image 134 illustrates an example of the porous elastomeric material 110 having the removable material 118 removed.

[0034] As illustrated in block 130, the pores 132 of the porous elastomeric material 110 can be interconnected (e.g., as a network), allowing fluid to move between pores 132 through connecting pore throats 131 and ultimately through the entire material. This can assist in generating a network, which can define a pore 132 and pore throat 131 network in the resulting porous elastomeric material 110 that is generated. In some embodiments, the pores 132 can be, for example, approximately between approximately 1 micron and 1000 microns in diameter. The pore throats 131 range in size from approximate 0.1 microns to 100 microns. The pores 132 can be non-spherical and non-ellipsoidal, with each pore 132 potentially having multiple branches and / or nodes. The pores 132 could also be anisotropic. For example, in the case of the porous elastomeric material 110 used in a sand screen 106 (or as sand screen 106), the length scale of the pore 132 could be larger in a radial direction relative to the length scale in the angular and axial directions. These differing length scales could facilitate high permeability in the radial direction while also supporting good sand retention properties. The dissolvable particle sizes and morphology are chosen in such a way to design the sizes of the pores 132 and pore throats 131. In some embodiments, a sand screen made from the porous thermoset can be designed specifically for the size distribution of sands in the formation.

[0035] The pore 132 sizes can also have a non-uniform distribution. For example, a portion of the pores 132 in the porous elastomeric material 110 can have relatively smaller sizes, for example, to capturing sand more efficiently, while another portion of the pores 132 in the porous elastomeric material 110 can have larger sizes relative to the smaller sized pores.These larger sized pores 132 would allow the porous elastomeric material 110 to be more permeable relative to a porous elastomeric material 110 made with only smaller sized pores 132. In some embodiments, different removable materials 118 (i.e., having different particle sizes) can be used, for example, in conjunction with one another to generate the porous elastomeric material 110 having differently sized pores 132. In other embodiments, the removable material 118 can be selected as having a characteristic of different particle sizes therein, thus leading to different pore 132 sizes in the porous elastomeric material 110 when the removable material 118 is removed.

[0036] In the case of a sand screen 106, for example, smaller sized pores 132 could be located close to the formation 114 (e.g., along an outer portion of the porous elastomeric material 110 that would be disposed most closely to and / or in direct contact with the formation 114) to inhibit sand ingress, while larger sized pores 132 can be disposed in an inner region of the porous elastomeric material 110 (e.g., in an inner portion of the porous elastomeric material 110 that would be disposed most closely to and / or in direct contact with the production tubing string 104) to facilitate higher permeability. The distribution of pore sizes could be bimodal (a mixture of small and large pores), trimodal, or simply monomodal with a large standard deviation.

[0037] It is presently recognized that the desired material properties for the polymeric screen 106 during compression & deployment process differ significantly from the desired properties during well production. For example, during compression, the thermoset composition 126 would ideally have a low modulus, allowing the screen to easily deform. Once downhole, it may be desirable for the porous elastomeric material 110 to be compliant and continue to have a relatively low modulus (e.g., less than or equal to about 100 MPa), which may prevent the screen from exerting a significant force on the formation and potentially damage it. However, during operation, it is desirable for the thermoset composition to be rigid and have a relatively high modulus (e.g., about 0.5 GPa or greater), resisting the drawdown pressure and potential wellbore collapse. To meet these desirable properties, it is presently recognized that it may be advantageous for the elastomeric material 11 Oto have a low modulus, high elongation and sub-ambient glass transition temperatureduring installation (e.g., less than or equal to about 50°C), which may provide a elastomeric material 110 that is compliant and compressed before deployment to provide a smaller profile for a RIH operation. Once in position, the elastomeric material may harden in situ to form the structural thermoset resin, which has a greater modulus, crosslink density, and Tgas described herein. This strength is essential for the screen to support the formation during production. To harden the elastomeric material 110 to form the structural thermoset resin, this process generally involves a chemical change to the polymer matrix resulting from a chemical reaction.

[0038] This chemical change, caused by a chemical reaction, may evolve (e.g., increase) the glass transition temperature of the elastomeric material 110, transitioning the material from the elastic to the glassy domain, thereby forming a rigid, structural material (i.e., the structural thermoset resin). Without wishing to be bound by theory, it is believed that as the material becomes glassier, the modulus of the material increases. The improved stiffness improves the ability of the screen to support the formation downhole. The higher modulus may also improve erosion resistance of the structural thermoset material (e.g., as described with respect to FIG. 3), thereby improving its lifetime downhole. It some instances, the sand screen 106 would be exposed to erosive sand particles, and in many cases the smallest sand particles are allowed to be produced. In these scenarios, the greater erosion resistance could extend the life of the sand screen. Accordingly, it may be advantageous to form the thermoset composition such that is chemically activatable to form a rigid structural material having an intrinsic glass transition temperature (Tg) such that it exceeds a threshold Tg.

[0039] Accordingly, certain aspects of the present disclosure are directed to methods for forming and utilizing a thermoset composition that is capable of chemically activating by multiple reactions to form the elastomeric material 110 and the structural thermoset material. The elastomeric material is relatively easy to deploy in the manner generally described. - For example, the resulting porous elastomeric material may have Tgand modulus that are relatively low such that the elastomeric material 110 may conform suitably to irregular structures, surfaces, or shapes in the borehole.

[0040] FIG. 3 shows an example method 200 for generating a rigid structural material using the thermoset composition. As shown, the method 200, at block 210, include forming the thermoset composition. In general, forming the thermoset composition may include providing one or more monomers 212, one or more catalysts 214, one or more additives 216, one or more polymer structure modifiers 218, one or more structural thermoset reagents 220, or a combination thereof.

[0041] In some embodiments, the monomers 212 may include one or more cyclic olefins, such as such as dicyclopentadiene (DCPD), tricyclopentadiene (TCPD), ethylidene- norbomene (ENB), norbornene (NB), or other cyclic olefins capable of being polymerized through in a ring-opening metathesis (ROMP) reaction.

[0042] In some embodiments, the one or more monomers 212 may include a combination of two cyclic olefins. In general, the combination may include x wt% of a first cyclic olefin and 100-x wt% of a second cyclic olefin. As one non-limiting example, the combination of cyclic olefins may include 10 weight percent (10%) or less of DCPD and 90 wt% or more TCPD, 20 wt% or less of DCPD and 80 wt% or more of TCPD, 30 wt% or less of DCPD and 70 wt% or more TCPD, 40 wt% or less of DCPD and 60 wt% or more of DCPD, about 50 wt% of DCPD and 50 wt% of TCPD, 60 wt% more of DCPD and 40 wt% or less TCPD, 70 wt% more of DCPD and 30 wt% or less TCPD, 80 wt% more of DCPD and 20 wt% or less TCPD, or 90 wt% more of DCPD and 10 wt% or less TCPD. It should be noted that the previously mentioned weight percentages may also apply to a combination that includes DCPD and ENB, DCPD and PB, TCPD and ENB, or other combinations of cyclic olefins known to one of ordinary skill in the art.

[0043] In some embodiments, the one or more monomers 212 may include a combination of more than two cyclic olefins. In general, the combination may include x wt% of a first cyclic olefin, wt% of a second cyclic olefin, and 100 - (x + y) wt% of a third cyclic olefin. As one non-limiting example, the combination of cyclic olefins may include between 10 to 30 wt% of DCPD, 10 to 30 wt% of ENB, and 80 to 40 wt% of TCPD. It should be noted that the previously mentioned weight percentages may also apply to a combination that includesany three of TCPD, DCPD, ENB, NB, or other cyclic olefins known to one of ordinary skill in the art.

[0044] The catalyst 214 may include a homogeneous catalyst or a heterogeneous catalyst. For example, the catalyst 214 may include a transition metal-based catalyst that includes molybdenum-based catalysts, rhenium-based catalysts, ruthenium-based catalysts, titanium- based catalysts, or a combination thereof, and other catalysts that may be used for ROMP. For example, the transition metal-based catalyst may include a tetrahedral, trigonal bipyramidal, or octahedral-coordinated transition metal. In some embodiments, the catalyst 214 may include a first catalyst that causes substantial cross-linking at a first temperature (e.g., at ambient conditions) and a second catalyst that causes substantial cross-linking at a second temperature higher than the first temperature.

[0045] The additives 216 may include inhibitors that prevent the thermoset composition from fully curing before it reaches a target location. In some embodiments, the additives 216 may include ceramics that increase the mechanical properties of the elastomeric material 110 and, ultimately, the structural thermoset material. At least in some instances, the additives 216 may include plasticizers.

[0046] The polymer structure modifiers 218 may include chemicals compositions other than polymers that are capable of reacting with the monomers 212. For example, the polymer structure modifiers 218 may include relatively long chain hydrocarbons (e.g., having 8 more, 9 or more, 10 or more, 12 or more, 14 or more, 16 or more) carbons on a main chain. The polymer structure modifiers 218 may include modified vegetable oils or linseed oils, such as DILULIN, or other long chain hydrocarbons modified with cyclic olefins or otherwise included one or more carbon-carbon double bonds, carbonyls, functional groups capable of participating in a ROMP reaction, or a combination thereof. As compared to the monomers 212, the polymer structure modifiers 218 do not polymerize but may covalently link to the polymer formed using the monomer 212. At least in some instances, the polymer structure modifiers 218 may include plasticizers.

[0047] The structural thermoset reagents 220 generally include chemicals that initiate, and are consumed, one or more of the reactions described below that impart a crosslink density to form the elastomeric material 110 and / or the structural thermoset material. For example, the structural thermoset reagents may include oxidizing agents such as peroxides, oxygen, ozone, hypochlorites, chlorate, perchlorates, permanganates, persulfates, sulfates, or a combination there of.

[0048] At block 222, the process 200 includes generating an elastomeric material 110 (e.g., the porous elastomeric material that is the partially cured thermoset composition). In general, generating the elastomeric material includes initiating a reaction to partially cure the thermoset composition. As described herein, partial curing may impart a crosslink density to the elastomeric material between about 40% to about 80%. In some embodiments, the reaction may be initiated by at least one of the catalysts 214. Accordingly, the reaction causes the liquid mixture to cure, thereby forming an elastic solid with a relatively low modulus (e.g., less than or equal to about 100 MPa as described herein) and low Tg(e.g., about 50°C or less). In some embodiments, the process 200 may include removing the dissolved particles (e.g., 118) to impart a porous structure to the elastomeric material that is soft and elastic. In general, this optional step may be performed after partially curing the thermoset composition to form the elastomeric material. At this point curing temperatures and times are much lower than those described below with respect to forming the rigid structural material 202.

[0049] At block 224, the process 200 includes providing structural elastomeric material to a downhole environment. In some embodiments, the elastomeric material may be coating, wrapped, or otherwise contained in a containment fdm or material that facilitates providing the elastomeric material downhole and preventing the elastomeric material from curing before the elastomeric material reaches a target location. For example, the containment film or material may be capable of degrading, dissolving, or otherwise being removed based on the downhole conditions.

[0050] At block 226, the process 200 includes forming the structural thermoset material 228 (e.g., porous structural thermoset material). In general, forming the structural thermoset material 228 includes initiating a reaction to cause additional crosslinking of the elastomericmaterial 110. For example, the curing to form the structural thermoset material 228 may impart a crosslink density greater than about 95%, 96%, 97%, 98%, or 99%. In some embodiments, forming the structural thermoset material 228 may include curing and / or oxidation via the structural thermoset reagents 228. In some embodiments, forming the structural thermoset material 228 may include curing by way of a catalyst 214. Furthermore, the oxidizing agent may also advantageously release heat, thereby facilitating the curing of the thermoset composition while the thermoset composition is downhole. It is presently recognized that the oxidizing, curing, and the heat providing by the oxidizing agent may adjust (e.g., evolve) the Tgand hardness of the material to a sufficient amount such that the cured thermoset composition (e.g., the porous elastomeric material) is suitable for load bearing.

[0051] Accordingly, the thermoset composition 126 is generally a precursor for forming the elastomeric material 110 and, ultimately, a structural thermoset material 228 (e.g., a rigid structural material). As referred to herein, the “elastomeric thermoset material” or “elastomeric material” 110 generally includes a modulus that between about 1 to 2 orders of magnitude less than the modulus of the “structural thermoset material” 228. For example, the elastomeric material 110 may have a modulus between that is less than or equal to about 100 MPa, 90 MPa, 80 MPa, 70 MPa, 50 MPa, 25 MPa, 10 MPa, or 5 MPa. In some embodiments, the elastomeric material 110 may have a modulus with a lower bound of about 5 MPa, 10 MPa, 25 MPa, or 50 MPa, and an upper bound of 50 MPa, 70 MPa, 80 MPa, 90 MPa, or 100 MPa. As another non-limiting example, the elastomeric material 110 may have a modulus that is at least 1 order of magnitude less than the modulus of the structural thermoset material 228. As such, the structural thermoset material 228 may have a modulus that is greater than or equal to about 500 MPa, 700 MPa, 1000 MPa, 2000 MPa, 4000 MPa, 5000 MPa, 6000 MPa, 7000 MPa, or 8000 MPa.

[0052] As described herein, the elastomeric material 1 10 has a Tgthat is less than ambient temperature or the ambient bottom hole temperature. For example, the elastomeric material 110 may have a Tgthat is less than or equal to about 50°C, 45°C, 40°C, 35°C, 30°C, 20°C, or 10°C. For example, the elastomeric material 110 may have a Tgthat is about 10°C, 9°C, 8°C, 7 °C, 6 °C, or 5°C. The structural thermoset material 228 may have a Tgthat is greater than ambient temperature or the ambient bottom hole temperature. For example, the structural thermoset material 228 may have a Tgthat is greater than or equal to about 110°C, 120°C, 130°C, 150°C, or 200°C

[0053] Further, the elastomeric material 110 may have a lower crosslink density than the structural thermoset material 228. In some embodiments, the elastomeric material 110 may have a crosslink density of between about 40% and 80%. For example, the elastomeric material 110 may have a crosslink density with a lower bound of about 40%, 45%, 50%, or 55%, and an upper bound of about 50%, 55%, 60%, 65%, 70%, 75%, or 80%. The structural thermoset material 228 may have a crosslink density that is greater than or equal to about 95%, 96% or greater, 97% or greater, 98% or greater, or 99% or greater.

[0054] As mentioned above it may be advantageous to control the Tgsuch that it exceeds a threshold Tg. Techniques for controlling the Tginclude curing by heat, curing by catalyst, adjustment the amount or activation of inhibitors, and secondary reactions, each of which are discussed below. It should be noted that the techniques below may be used to perform block 222, block 226, or both.Cure by Heat

[0055] The addition of heat to the thermoset may cause the polymer of the elastomeric material 110 to undergo a curing process downhole, thereby forming the structural thermoset material 228. As the elastomeric material 110 is exposed to high temperatures downhole, the polymer of the elastomeric material may react, forming additional crosslinks. Heat is commonly utilized for polymerization, and in some cases, it can induce crosslinking without catalysts or chemical crosslinking agents. If the polymer is only partially cured on the surface (e g., as the elastomeric material), heat from the well may cause the polymer to continue curing, as the bottom hole temperature (BHT) can often be much higher than the surface temperature.

[0056] Heat may also be added artificially downhole to promote crosslinking. In some cases, the BHT may be insufficiently high to cure the polymer of the elastomeric material 110. Alternatively, the rate of heat transfer or crosslinking at the BHT may be too slow, which may delay production from the well. In those instances, additional heat may be artificially added. For example, once the sand screen 106 is positioned and expanded, electrical power may be sent downhole to heater coils, which may reside on the inside diameter (ID) of the base pipe. The heat from these coils would pass through the base pipe to the polymeric sand screen, promoting crosslinking. Alternatively, an exothermic reaction may be induced downhole to provide additional heat. For example, calcium oxide, magnesium, and aluminum react with water to generate large amounts of heat, which is commonly utilized for self-heating food packaging. The reactants may be embedded in the degradable film, the sand screen’s pores, or even contained within the base pipe. The reactants may be designed for release only after deployment, such as by encapsulation in a degradable material.Cure by Catalyst

[0057] In some structural thermoset chemistries, catalysts can induce crosslinking of the elastomeric material 110 to form the structural thermoset material 228. Catalysts are often used in the initial polymerization process during manufacturing, but additional catalysis downhole may increase the crosslink density in the compound. The additional cure provided by catalysis would evolve the Tg and increase the modulus of the polymeric screen.

[0058] One example method to promote additional catalyst exposure downhole is to inject the catalyst downhole once the screen is positioned and expanded. Catalysts can often be suspended in other fluids, and the catalyst can be pumped downhole through the base pipe, allowing the chemical to permeate the screen. After sufficient time has elapsed for additional crosslinking, the catalyst may be flushed out of the well and potentially reused. To ensure the catalyst does not plug the screen, the catalyst may be designed to be much smaller than the pore size of the screen. Additionally, if the catalyst is pumped from the base pipe outward through the screen, produced hydrocarbons would flow in the opposite direction during production, helping clear any plugged pores.

[0059] As a simplification of the first example method above, a second example method includes utilizing the injected fluid as a catalyst as compared to suspending the catalyst in a fluid. If so, the lack of solid particles may reduce the plugging concerns as well as any particle settling concerns as the fluid travels to the screen.

[0060] A third example method includes placing the additional catalyst 214 within capsules which are embedded within the screen. The capsules may be designed such that, after enough time has passed for the degradable film to dissolve, the capsules would rupture, causing catalyst 214 to encounter the sand screen 106 formed using the thermoset composition. The capsules may degrade in the presence of downhole fluids, or the degradation may be triggered from the surface. For the latter case, a fluid may be injected downhole that chemically degrades the capsule or that changes the pH to corrode the capsule.

[0061] Similar to the previous concept, in a fourth example method, the catalyst 214 may be embedded within the degradable film or the containment filler. Once the film or containment filler are degraded or removed, the sand screen 106 expands, conforming to the wellbore. At that point, the sand screen 106 may begin hardening. If the catalyst is embedded in those materials, the catalyst release would be automatically triggered.

[0062] A fifth example method involves reactivating the catalyst 214 in the polymer (e.g., the elastomeric material 110). As mentioned previously, catalysts 214 may be utilized in the polymer manufacturing process. In some cases, the catalyst 214 becomes degraded or inefficient with time, and this deactivated catalyst 214 resides in the final produced polymeric parts. For the sand screen 106, the catalyst may be reactivated downhole, facilitating additional crosslinking. Catalyst reactivation may occur through exposure to an injected chemical.

[0063] A catalyst 214 may be activated downhole by the expansion of the sand screen 106. The sand screen 106 would expand downhole due to the degradation of the restraint. As the sand screen 106 expands, its internal stress decreases. The change in stress or strain may activate catalyst embedded in the polymer matrix of the elastomeric material. Forexample, the sand screen 106 expansion may cause scission of ligands attached to the catalyst.The removal of the ligands may activate the catalyst and initiate the downhole cure.

[0064] Lastly, a change in acidity may initialize the additional crosslinking of the thermoset composition. It is presently recognized that some chemical reactions only occur in the proper acidity (e.g., threshold range of pH). Rather than directly exposing the polymer to the chemical, which induces curing, the downhole acidity may be changed. Alternatively, the catalyst may be activated by the acid. In this case, one catalyst may provide an initial cure during manufacturing, and a secondary catalyst would initialize a second reaction downhole after exposure to acid. Both catalysts would be present during the manufacturing process.Inhibitor Adjustment

[0065] Some polymeric systems crosslink so readily that inhibitors are added to the polymer to slow down the reaction. These inhibitors may extend the pot life, facilitating processing and preventing premature crosslinking during manufacturing. The curing step in the manufacturing process may be initiated by heating the material high enough to overcome these inhibitors.

[0066] If the inhibitors may be removed once the sand screen 106 is positioned, additional crosslinking may occur. The thermoset composition, ultimately used for the structural thermoset material of the sand screen 106, may be designed to undergo a partial cure during manufacturing, such as at elevated temperature, combined with a high quantity of inhibitor (e.g., additives 216). Once downhole, the inhibitor may migrate out of the polymer matrix of the structural thermoset material into the fluids downhole. Alternatively, the inhibitor may exit the polymer matrix after exposure to an injected fluid specifically chosen to facilitate the extraction of inhibitor. The absence of inhibitor in the polymer would cause additional crosslinking of the sand screen 106 to occur, due to the presence of the uninhibited catalyst.

[0067] Rather than eliminating the inhibitor by diffusion out of the polymer matrix, the inhibitor may be rendered ineffective. Instead of relying on mass transfer to migrate the inhibitor out of the polymer, the inhibitor may be degraded, causing it to ineffectively block the crosslinking reaction. In some instances, downhole conditions (e.g., downhole fluids, heat, injected fluids, or a combination thereof) may reduce the ability of the inhibitor to prevent the catalyst from initiating further crosslinking to generate the structural thermoset material 228.Secondary Reaction Mechanism for Downhole Curing

[0068] Based on the base polymer chemistry, various types of chemical bonds can exist in the fully cured part. Some molecules have multiple sites available to be crosslinked. For many elastomers, the base polymer is formed between monomers (e.g., monomer units), but crosslinks between individual polymer chains are subsequently formed during manufacturing of the final part. These secondary bonds can have an entirely separate chemical mechanism from the original polymerization process and can often utilize previously disconnected chemical species.

[0069] Similarly, the polymeric sand screen may be designed to undergo two separate reactions at different stages of its life cycle. The first reaction mechanism (e.g., to form the elastomeric material 110) may occur on the surface during manufacturing, providing enough crosslinks to make the material elastomeric and retain its shape. A secondary reaction (e.g., to form the structural thermoset material 228) may occur downhole based on exposure to downhole fluids or injected catalyst, among other concepts. Differentiating this concept, the chemical reaction mechanisms may be entirely separate between the manufacturing process and downhole. For example, the starting chemistry can have multiple functionalities. In one form, the same oligomer or monomer can have multiple functionalities. In another form, two or more separate monomers or oligomers with different functionalities can be deployed. In either case, the reactions can form networks that react at different rates and yield unique properties.

[0070] An additional approach is to form an interpenetrating polymer network. For example, the manufacturing process would consume one type of molecule. The secondary molecule type, while not chemically bonded with the base polymer of the elastomeric material, may be dissolved or blended in the polymer matrix. The downhole reaction would link the second molecule groups together. The final material would be composed of two separate but interlaced polymer networks.

[0071] A liquid may be dissolved in the polymer matrix on the surface that may crosslink into the matrix downhole. This liquid may have a similar chemistry to the base polymer but may be composed of low molecular weight chains (compared to most of the polymer matrix). During compression and deployment, the liquid may act as a plasticizer, with the benefits previously mentioned (e.g., modulus suppressant and / or reduces the Tg, and thus the overall crosslinking). In general, the plasticizer (e.g., an additive 216) may be added to form the thermoset composition 126, keeping the elastomeric material 110 relatively soft and compliant as compared to the structural thermoset material 228. The plasticizer may leach out of the polymer matrix downhole to make the porous media hard. The examples of plasticizers are Polybutadiene rubber, ethyl vinyl acetate, LDPE, Di octyl phthalate, glycerol, polyurethane rubber etc. The liquid may form bonds with the polymer matrix downhole, increasing the crosslink density in the material and increasing the sand screen 106’s modulus.

[0072] Similar to the capsulated catalyst concept, a liquid polymerizable material may be contained in capsules that rupture downhole. Many polymerizable materials exist in liquid form, especially at elevated BHT temperatures. These polymerizable materials can also form structural thermosets after curing. The liquid material may be put into capsules and embedded in the polymer screen. Once the sand screen 106 expands, the capsules may rupture, using similar triggers to those listed with the capsulated catalyst concept. The liquid would flow into the polymer screen and polymerize, possibly due to interaction between the liquid and catalyst embedded in the polymer screen. The added polymer might constrict or plug pores downhole, but the sand screen 106 may be designed to have a high porosity during manufacturing, ensuring sufficient porosity during well production.

[0073] In general, various methods can be used to deploy the peroxides, which can be either within the compound during manufacturing process or after deploying the porous media downhole, and various mixtures can be employed. To expose the porous media to the reagents, it is presently recognized that the concentration of peroxides H2O2 to H2O will be key to drive the proper reaction kinetics. Furthermore, the downhole chemistry and carrier fluid or gas will be very important. One advantage of using the reagent after the porous media is downhole is that the same chemical (or variation of it) can be used to dissolve the degradable film covering the porous media during deployment. It could also be used to dissolve / remove the filter cake on the formation.

[0074] Accordingly, the process 200 may be used to form the thermoset composition (e.g., partially cured) and / or the that has a suitable amount unsaturation and cyclic olefins that may be activated downhole for a further reaction using heat and / or free radicals that will substantially eliminate the unsaturation via oxidation or crosslinking.

[0075] The technical effect of the disclosed embodiments include a forming a chemically activatable thermoset composition. In general, the thermoset composition may undergo a first reaction to form the elastomeric material. Once downhole, the elastomeric material may undergo an additional reaction to form the structural thermoset material or media having a relatively high glass transition temperature (e.g., greater than about 1 0 °C, between about 150 °C to about 300 °C, between about 150 °C to about 250 °C). Further, the disclosed structural thermoset material or media may have a relatively low viscosity (e.g., about 100 cP or less, about 90 cP or less, about 80 cP or less) in an uncured state and a relatively low thermal expansion coefficient after curing.

[0076] The subject matter described in detail above may be defined by one or more clauses, as set forth below.

[0077] A method, comprising providing one or more monomer units; providing one or more catalysts; forming a structural thermoset composition based on the one or more monomer units and the one or more catalysts; and generating an elastomeric material based on a reaction between the one or more catalysts and the one or more monomer units, whereinthe elastomeric material has a first crosslink density between about 40% and 80%, wherein the first crosslink density of the elastomeric material is configured to increase to a second crosslink density when subjected to downhole conditions to generate a structural thermoset material, and wherein the second crosslink density is greater than or equal to about 95%.

[0078] The method of any preceding clause, further comprising providing the elastomeric material into a borehole; and generating a structural thermoset material having the second crosslink density based on the downhole conditions with the borehole.

[0079] The method of any preceding clause, wherein the elastomeric material comprises a first modulus that is less than or equal to about 100 MPa or less, and wherein the structural thermoset material has a second modulus that is greater than or equal to about 500 MPa.

[0080] The method of any preceding clause, wherein the elastomeric material comprises a first glass transition temperature (Tg) that is less than or equal to about 50°C, and wherein the structural thermoset material has a second glass transition temperature that is greater than or equal to about 120°C.

[0081] The method of any preceding clause, comprising providing one or more polymer structure modifiers configured to covalently link to the polymer formed by the monomer units, wherein the method comprises forming the structural thermoset composition based on the one or more monomer units, the one or more catalysts, and the one or more polymer structure modifiers.

[0082] The method of any preceding clause, wherein the one or more monomer units comprise cyclic olefins.

[0083] The method of any preceding clause, wherein the one or more catalysts comprise a first catalyst and a second catalyst, wherein the method comprises generating the elastomeric material based on the reaction between the first catalyst and the one or more monomer units, and wherein the second catalyst is configured to increase the first crosslink density to the second crosslink density when subjected to the downhole conditions.

[0084] The method of any preceding clause, comprising providing one or more oxidizers, wherein the method comprises forming the structural thermoset composition based on the one or more monomer units, the one or more catalysts, and the one or more oxidizers.

[0085] An elastomeric composition includes a polymer comprising a first crosslink density between about 40% and 80%, wherein the elastomeric composition comprises a first glass transition temperature (Tg) that is less than or equal to about 50°C; and one or more reagents configured to increase the first crosslink density to a second crosslink density based on the elastomeric composition being subject to downhole conditions.

[0086] The elastomeric composition of any preceding clause, wherein the one or more reagents comprise a catalyst configured to activate based on the downhole conditions.

[0087] The elastomeric composition of any preceding clause, wherein the one or more reagents comprise an oxidizing agent configured to activate based on the downhole conditions.

[0088] The elastomeric composition of any preceding clause, wherein the polymer comprises a modulus that is less than or equal to about 100 MPa.

[0089] The elastomeric composition of any preceding clause, comprising one or more long chain hydrocarbons modified with cyclic olefins.

[0090] The elastomeric composition of any preceding clause, comprising one or more inhibitors configured to prevent the one or more reagents from increasing the first crosslink density at ambient conditions.

[0091] The elastomeric composition of any preceding clause, comprising a containment film that encapsulates the polymer and the one or more reagents.

[0092] The elastomeric composition of any preceding clause, wherein the second crosslink density is greater than or equal to about 95%.

[0093] The elastomeric composition of any preceding clause, comprising one or more plasticizers.

[0094] An elastomeric composition includes a polymer comprising a first crosslink density between about 40% and 80%, wherein the elastomeric composition comprises a first modulus that is less than or equal to about 100 MPa; and one or more reagents configured to increase the first crosslink density to a second crosslink density and increase the first modulus to a second modulus based on the elastomeric composition being subject to downhole conditions.

[0095] The elastomeric composition of any preceding clause, wherein the one or more reagents are configured to increase the Tgof the polymer to greater than or equal to about 120°C based on the elastomeric composition being subject to downhole conditions.

[0096] The elastomeric composition of any preceding clause, wherein the second modulus is greater than or equal to about 0.5 GPa.

[0097] The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. Moreover, the order in which the elements of the methods described herein are illustrated and described may be re-arranged, and / or two or more elements may occur simultaneously. The embodiments were chosen and described in order to best explain the principals of the disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the disclosure and various embodiments with various modifications as are suited to the particular use contemplated.

[0098] Finally, the techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elementsdesignated as “means for [perform]ing [a function]...” or “step for [performing [a function], . it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Claims

CLAIMS1. A method, comprising: providing one or more monomer units; providing one or more catalysts; forming a structural thermoset composition based on the one or more monomer units and the one or more catalysts; and generating an elastomeric material based on a reaction between the one or more catalysts and the one or more monomer units, wherein the elastomeric material has a first crosslink density between about 40% and 80%, wherein the first crosslink density of the elastomeric material is configured to increase to a second crosslink density when subjected to downhole conditions to generate a structural thermoset material, and wherein the second crosslink density is greater than or equal to about 95%.

2. The method of claim 1, further comprising: providing the elastomeric material into a borehole; and generating a structural thermoset material having the second crosslink density based on the downhole conditions with the borehole.

3. The method of claim 1, wherein the elastomeric material comprises a first modulus that is less than or equal to about 100 MPa or less, and wherein the structural thermoset material has a second modulus that is greater than or equal to about 500 MPa.

4. The method of claim 1, wherein the elastomeric material comprises a first glass transition temperature (Tg) that is less than or equal to about 50°C, and wherein the structural thermoset material has a second glass transition temperature that is greater than or equal to about 120°C.

5. The method of claim 1, comprising providing one or more polymer structure modifiers configured to covalently link to the polymer formed by the monomer units, whereinthe method comprises forming the structural thermoset composition based on the one or more monomer units, the one or more catalysts, and the one or more polymer structure modifiers.

6. The method of claim 1, wherein the one or more monomer units comprise cyclic olefins.

7. The method of claim 1, wherein the one or more catalysts comprise a first catalyst and a second catalyst, wherein the method comprises generating the elastomeric material based on the reaction between the first catalyst and the one or more monomer units, and wherein the second catalyst is configured to increase the first crosslink density to the second crosslink density when subjected to the downhole conditions.

8. The method of claim 1, comprising providing one or more oxidizers, wherein the method comprises forming the structural thermoset composition based on the one or more monomer units, the one or more catalysts, and the one or more oxidizers.

9. An elastomeric composition comprising: a polymer comprising a first crosslink density between about 40% and 80%, wherein the elastomeric composition comprises a first glass transition temperature (Tg) that is less than or equal to about 50°C; and one or more reagents configured to increase the first crosslink density to a second crosslink density based on the elastomeric composition being subj ect to downhole conditions.

10. The elastomeric composition of claim 9, wherein the one or more reagents comprise a catalyst configured to activate based on the downhole conditions.

11. The elastomeric composition of claim 9, wherein the one or more reagents comprise an oxidizing agent configured to activate based on the downhole conditions.

12. The elastomeric composition of claim 9, wherein the polymer comprises a modulus that is less than or equal to about 100 MPa.

13. The elastomeric composition of claim 9, comprising one or more long chain hydrocarbons modified with cyclic olefins.

14. The elastomeric composition of claim 9, comprising one or more inhibitors configured to prevent the one or more reagents from increasing the first crosslink density at ambient conditions.

15. The elastomeric composition of claim 9, comprising a containment film that encapsulates the polymer and the one or more reagents.

16. The elastomeric composition of claim 9, wherein the second crosslink density is greater than or equal to about 95%.

17. The elastomeric composition of claim 9, comprising one or more plasticizers.

18. An elastomeric composition, comprising a polymer comprising a first crosslink density between about 40% and 80%, wherein the elastomeric composition comprises a first modulus that is less than or equal to about 100 MPa; and one or more reagents configured to increase the first crosslink density to a second crosslink density and increase the first modulus to a second modulus based on the elastomeric composition being subject to downhole conditions.

19. The elastomeric composition of claim 18, wherein the one or more reagents are configured to increase the Tgof the polymer to greater than or equal to about 120°C based on the elastomeric composition being subject to downhole conditions.

20. The elastomeric composition of claim 18, wherein the second modulus is greater than or equal to about 0.5 GPa.

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