Composite Epoxy Sealant for Well Sealing Thermal Management

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Solution Overview

Problem

Epoxy resin sealants used in well sealing applications face challenges due to their exothermic setting reaction, which generates high temperatures, leading to stress and potential failure of the seal due to thermal expansion mismatch with steel casings and slow heat transfer, resulting in inadequate sealing performance, especially in large-volume applications at low temperatures.

Innovation Solution

A composite epoxy sealant is developed by incorporating solid particulate materials that enhance thermal conductivity and heat capacity while reducing the coefficient of thermal expansion, thereby mitigating the exothermic temperature increase and improving bonding performance by optimizing reaction kinetics and strength development.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If epoxy resin sealant is used for well sealing, then the sealant can effectively seal small leaks and cracks, but the exothermic setting reaction generates high temperatures causing stress and potential seal failure

Engineering Contradiction:

Improvesealing effectivenessVSAvoidpeak temperature during setting

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent uses a composite material system consisting of epoxy resin combined with reactive diluents, hardeners, and functional additives. This composite formulation modifies the thermal properties of the base epoxy resin, reducing the exothermic temperature spike while maintaining sealing effectiveness and structural integrity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the chemical parameters of the epoxy system by incorporating reactive diluents and modifying the hardener composition. These parameter changes alter the reaction kinetics and thermal characteristics, lowering the peak temperature during setting while preserving the sealant's ability to bond and seal effectively.

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If epoxy resin is used in large-volume applications, then the sealant can provide adequate coverage, but the low thermal conductivity results in slow heat transfer and prolonged high temperature

Engineering Contradiction:

Improvesealant volumeVSAvoidheat dissipation efficiency

Core Design Contradiction:

Quantity of substanceVSLoss of energy

Solution Approach 1:

The patent modifies the thermal parameters of the epoxy sealant by incorporating materials with improved thermal conductivity. This allows large-volume applications to dissipate heat more efficiently, preventing prolonged high temperature conditions that could compromise seal integrity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces intermediary substances (reactive diluents and functional additives) that act as thermal conduits within the epoxy matrix. These intermediaries facilitate heat transfer throughout the sealant volume, enabling more uniform and efficient heat dissipation in large-volume applications.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If epoxy resin is used in low-temperature applications, then the sealant can be applied in cold environments, but the exothermic reaction creates excessive temperature increase relative to the ambient temperature

Engineering Contradiction:

Improveapplication temperature rangeVSAvoidtemperature increase during setting

Core Design Contradiction:

Adaptability or versatilityVSTemperature

Solution Approach 1:

The patent adjusts the chemical composition parameters of the epoxy system, specifically the ratios of resin to reactive diluent and the type of hardener used. These parameter changes reduce the heat of reaction, allowing the sealant to be applied in low-temperature environments without creating excessive temperature increases that could damage the seal or surrounding structures.

Inventive Principle:

Principle #35Parameter changes

4Productivity

If high hardener concentration is used to achieve desirable setting times, then the setting time is reduced, but the temperature increase during reaction is amplified

Engineering Contradiction:

Improvesetting rateVSAvoidexothermic temperature increase

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent changes the composition parameters by incorporating reactive diluents and selecting specific hardener types that provide a more moderate reaction rate. This allows the sealant to achieve adequate setting times without the extreme temperature increases associated with high hardener concentration formulations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses partial action by incorporating reactive diluents that moderate the reaction intensity. This partial modification of the chemical system allows for controlled setting rates while avoiding the excessive heat generation that would result from using full-strength high-concentration hardener formulations.

Inventive Principle:

Principle #16Partial or excessive action

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

The composite epoxy sealant effectively reduces peak temperatures during setting, minimizes stress from thermal contraction, and ensures a durable, resilient seal by maintaining bonding integrity with steel casings, even in large-volume applications at low temperatures.

Implementation Method 1

incorporating solid particulate materials that enhance thermal conductivity and heat capacity while reducing the coefficient of thermal expansion, thereby mitigating the exothermic temperature increase

Methodology Applied

Scientific EffectThermal conductivity: Conduction (thermal)

Implementation Method 2

Methodology Applied

Scientific EffectHeat capacity: Heat Sink

Implementation Method 3

the setting of epoxy, i.e., the hardening thereof from a liquid to a solid form, is an exothermic chemical reaction, and because the epoxy has low thermal conductivity and low heat capacity, it experiences an increase in temperature after the resin and hardener are intermixed and the exothermic reaction there between initiates and progresses

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Implementation Method 4

Methodology Applied

Scientific EffectCoefficient of thermal expansion: Thermal Expansion

Data Source

PatentUS10378299B2Method of producing resin composite with required thermal and mechanical properties to form a durable well seal in applications

Publication Date: 2019.08.13 WILD WELL CONTROL

AI summary

In one embodiment of this disclosure, method of formulating a sealant to span an opening and form a seal with surfaces across the opening is provided. The method further includes selecting a fluid material capable of contacting and adhering to the surface of the opening and which reacts to form a solid material as a result of a thermal reaction. The method further includes selecting and intermixing one or more solids with the fluid material to form a composite, wherein the composite cures from a fluid to a solid and bond to the surfaces of the opening and the change in volume of the composite as the temperature thereof changes during curing is insufficient to cause it to pull away from the surfaces of the opening or fail internally.