Additive Manufacturing of Energetic Materials for Shaped Charges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wellbore perforation technologies face limitations in creating precise and controlled penetration in geologic formations due to the inability to fabricate complex geometries and density gradients in explosive materials using conventional methods, which restricts the effectiveness of perforation tools in enhancing hydrocarbon permeability.
Innovation Solution
The use of additive manufacturing processes, such as three-dimensional printing, to construct energetic components like shaped charges with complex geometries and density gradients, allowing for the creation of voids and distinct material layers within explosive materials to achieve specific penetration effects when detonated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for explosive materials, then manufacturing simplicity is maintained, but manufacturing precision and ability to create complex geometries deteriorate
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional manufacturing methods to additive manufacturing processes, fundamentally changing the manufacturing parameters and capabilities. This enables precise control over explosive material geometry, density gradients, and internal structures that were previously unachievable with traditional methods.
Solution Approach 2:
The patent utilizes composite materials by creating multi-density explosive compositions with distinct material layers within the shaped charge. The additive manufacturing process enables integration of different explosive materials with varying densities and properties to achieve specific penetration effects, combining multiple material functions into a single complex structure.
2Manufacturing precision
If conventional explosive materials are used, then ease of manufacture is maintained, but ability to achieve specific penetration effects deteriorates
Solution Approach 1:
The patent applies local quality by creating regions with different material properties within the explosive composition. The additive manufacturing process enables placement of specific explosive materials with tailored densities and compositions in specific locations to optimize penetration performance for different target conditions, rather than using uniform explosive material throughout.
Solution Approach 2:
The patent introduces a new dimension of control by creating three-dimensional density gradients and internal geometries within the explosive material. The additive manufacturing process enables variation of material properties in all three spatial dimensions, allowing complex internal structures and density transitions that cannot be achieved with conventional two-dimensional layering or casting methods.
3Manufacturing precision
If limited or controlled explosive charge is used, then penetration control is improved, but ability to generate sufficient penetration effect deteriorates
Solution Approach 1:
The patent applies parameter changes by optimizing the density distribution and material composition parameters of the explosive charge. The additive manufacturing process enables precise control over density gradients and material properties to maximize the penetration force per unit of explosive material, achieving higher penetration efficiency with controlled charge sizes.
Solution Approach 2:
The patent uses composite materials with different explosive densities and compositions to optimize the balance between penetration force and charge size. By combining high-density and low-density explosive materials in specific configurations, the shaped charge achieves enhanced penetration capability while maintaining controlled overall charge mass.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the formation of precise and controlled perforations in wellbores, enhancing hydrocarbon permeability and improving the efficiency of wellbore servicing operations by allowing for tailored penetration effects that conventional methods cannot achieve.
Implementation Method 1
The at least one explosive is constructed by an additive manufacturing process
Implementation Method 2
The shaped charge may be detonated in a wellbore
Implementation Method 3
at least one void is defined in a booster explosive
Data Source
AI summary
A shaped charge for use in a well perforating tool includes at least one explosive component fabricated by an additive manufacturing process such as three-dimensional printing. The additive manufacturing process may facilitate the production of complex geometries including voids and/or density gradients in the explosive materials that, when detonated, produce a specific penetration effect in a wellbore. The explosive materials may be deposited individually as a pellet, or may be deposited on one or both of a case and a liner acting as a scaffold during the additive manufacturing process.