Large Diameter Ball Sealer Impact Resistance
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Solution Overview
Problem
Conventional ball sealers for hydrocarbon resource recovery lack sufficient impact resistance and dimensional precision, particularly for larger diameters, which can lead to cracking and loss of sealing ability when subjected to high-pressure water streams during hydraulic fracturing.
Innovation Solution
A ball sealer with a diameter of at least 25 mm, composed of a disintegrable aliphatic polyester resin core coated with a resin material having higher impact resistance, utilizing polyglycolic acid resin and reinforced with fillers, and manufactured through an insert injection molding process to ensure high mechanical strength and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ball sealers are made from disintegrable aliphatic polyester resin to enable disposal after use, then the environmental friendliness and ease of disposal are improved, but the impact resistance and mechanical strength deteriorate
Solution Approach 1:
The ball sealer is constructed as a composite structure with a core made from disintegrable aliphatic polyester resin and an outer coating layer made from resin material with higher impact resistance. This composite structure allows the ball to be disposed of after use (core disintegrates) while maintaining sufficient impact resistance during operation (coating layer protects).
2Adaptability or versatility
If the diameter of ball sealers is increased to 25 mm or more for use in frac plugs and frac sleeves, then the sealing capability and applicability in hydraulic fracturing are improved, but the dimensional precision and resistance to cracking deteriorate
Solution Approach 1:
The composite structure with impact-resistant coating layer provides the mechanical strength needed for larger diameter ball sealers (25 mm or more) to maintain dimensional precision and resist cracking during hydraulic fracturing operations, while the disintegrable core maintains sealing capability.
Solution Approach 2:
The invention changes the material parameters by selecting specific disintegrable aliphatic polyester resins and coating materials with appropriate mechanical properties, allowing larger diameter ball sealers to achieve both sealing capability and resistance to cracking through optimized material selection.
3Strength
If ball sealers are made from non-disintegrable materials such as aluminum or nylon to improve sealing ability, then the mechanical strength and sealing capability are improved, but the ease of disposal and environmental friendliness deteriorate
Solution Approach 1:
The ball sealer uses a composite structure where the disintegrable aliphatic polyester resin core provides sealing ability through form-fitting deformation into perforations, while the impact-resistant coating layer maintains mechanical strength. After use, the core disintegrates enabling easy disposal, eliminating the need to retrieve non-disintegrable materials like aluminum or nylon.
Data Source
AI summary
A ball sealer for hydrocarbon resource recovery, characterized by being obtained by coating a spherical core that comprises at least one layer comprising a disintegrable aliphatic polyester resin with a resin material that has higher impact resistance than the aliphatic polyester resin and by having a diameter of not less than approximately 25 mm (1 inch). This ball sealer has a large diameter, retains the property of being disintegrable after fracturing, and has impact resistance which makes the ball withstand high-velocity loading. The sealer is suitable for use in hydraulic fracturing, which is commonly used for recovering hydrocarbon resources including petroleum and gases.This large-diameter ball sealer can be efficiently formed with high dimensional accuracy by a method including at least one insert injection molding step.