Aggregate Application on Expandable Tubulars via Flexible Sheet Carrier
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for applying aggregates to expandable tubulars are labor-intensive, time-consuming, and require skill, as they involve applying small bits one at a time with specific spacing and adherence requirements, with the risk of sagging or falling off if the tubing is rolled, and the process is slow due to the need for sequential application and long curing times.
Innovation Solution
A method involving attaching aggregates to a flexible sheet with a first adhesive, wrapping the sheet around the tubular with a second adhesive of higher strength applied to ensure secure attachment, allowing the adhesives to cure before removing the sheet, which allows for simultaneous application of aggregates across multiple locations on the tubular.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bits/aggregates are applied one at a time sequentially, then precise spacing and adherence can be achieved, but the application process becomes extremely time-consuming and labor-intensive
Solution Approach 1:
The patent divides the application process into two segments: first, attaching multiple bits/aggregates to a flexible sheet in a controlled environment where precise spacing can be achieved; second, wrapping the pre-assembled sheet around the tubular. This segmentation allows precision work to be done offline and transferred to the tubular as a complete unit, dramatically increasing productivity while maintaining spacing precision.
Solution Approach 2:
The patent applies bits/aggregates to the flexible sheet in advance, before the actual wrapping operation. This preliminary action allows all spacing and positioning to be completed beforehand in a controlled setting, eliminating the need for time-consuming sequential application during the tubular wrapping process.
2Area of stationary object
If the tubing is rolled during application, then coverage can be maintained, but the bits/aggregates will fall off or sag and lose their spacing
Solution Approach 1:
The patent introduces a flexible sheet as an intermediary carrier between the bits/aggregates and the tubular. The bits are first attached to the sheet where they are protected from gravity-induced sagging, then the entire assembly is wrapped around the tubular. The sheet acts as a stable platform that maintains bit positions during both attachment and wrapping operations.
Solution Approach 2:
The patent uses a flexible sheet (thin film) as the base for attaching bits/aggregates. This flexible carrier can be wrapped around the tubular conformally while maintaining the relative positions of the bits. The flexibility allows the sheet to adapt to the tubular's curvature without causing bits to shift or sag.
3Reliability
If multiple sections of tubular are applied sequentially with long curing times, then proper adhesion is achieved, but the total application time becomes excessively long
Solution Approach 1:
The patent merges multiple bit application operations into a single wrapping operation. Instead of applying and curing adhesive for each bit or small section separately, all bits are attached to the sheet first, then the entire sheet is wrapped around the tubular in one operation. This combines multiple sequential steps into a single parallel operation, dramatically reducing total time while maintaining adhesion strength.
Solution Approach 2:
The patent enables continuous application of bits/aggregates around the entire tubular circumference in a single wrapping operation, rather than interrupting for curing periods between sections. The flexible sheet allows continuous placement of multiple bits simultaneously, maintaining continuous useful action throughout the application process.
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 method significantly reduces application time and cost by enabling the simultaneous application of aggregates across the tubular's circumference, ensuring consistent spacing and adherence, and allows for pre-prepared sheets to streamline the process, reducing preparation time and inventory needs.
Implementation Method 1
attaching the at least one aggregate to a flexible sheet
Implementation Method 2
a second adhesive is applied to the outside diameter of the tubular before wrapping the flexible sheet around the tubular, wherein the second adhesive has a higher adhering strength than the first adhesive
Implementation Method 3
the second adhesive is allowed to cure after wrapping the flexible sheet around the tubular
Data Source
AI summary
Herein disclosed is a method of applying at least one aggregate to a tubular, comprising attaching the at least one aggregate to a flexible sheet; wrapping the flexible sheet around the tubular with the at least one aggregate between the sheet and tubular. Herein also disclosed is an assembly comprising a tubular, at least one aggregate, and a flexible sheet wrapped around the tubular with the at least one aggregate between the tubular and the sheet. In an embodiment, the at least one aggregate is adhered to the sheet by a first adhesive and the at least one aggregate is adhered to the tubular by a second adhesive, wherein the second adhesive has a higher adhering strength than the first adhesive. In an embodiment, the flexible sheet is removed and the at least one aggregate remains attached to the tubular. The use of such an assembly is discussed.