Composite Transducer Teflon Window Borehole Imaging

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Solution Overview

Problem

Acoustic logging tools face significant challenges in imaging borehole sidewalls due to high attenuation of acoustic signals in borehole fluids, particularly in heavily-weighted oil-based muds, which limits the effective path length and resolution, and existing solutions require complex structures like mud excluder assemblies with specific acoustic properties.

Innovation Solution

A rotatable transducer assembly with a composite transducer that uses an acoustically transparent window and a polymer matrix with high-quality factor Piezoelectric (PZT) rods to propagate and receive acoustic signals, reducing attenuation and improving energy transfer through the use of a Teflon window and adjustable spacing to minimize reverberations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If acoustic frequency is increased to improve resolution, then imaging resolution is improved, but acoustic signal attenuation increases

Engineering Contradiction:
Improveimaging resolutionVSAvoidacoustic signal attenuation
Core Design Contradiction:
Measurement precisionVSLoss of energy

Solution Approach 1:

The patent introduces an acoustically transparent window made of solid material (such as Teflon or polymethylacrylate) as an intermediary medium between the transducer and the borehole fluid. This window has lower acoustic attenuation than the drilling fluid, allowing high-frequency acoustic signals to pass through with reduced energy loss while maintaining imaging resolution. The window acts as a mediator that enables high-frequency operation without suffering from the severe attenuation characteristics of oil-based muds.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Length of stationary object

If path length through borehole fluid is increased to image deeper formations, then imaging depth is improved, but signal attenuation increases

Engineering Contradiction:
Improveimaging depthVSAvoidsignal attenuation
Core Design Contradiction:
Length of stationary objectVSLoss of energy

Solution Approach 1:

The acoustically transparent window serves as an intermediary that reduces attenuation for the entire acoustic path. By providing a low-attenuation solid medium interface, it enables acoustic energy to travel longer distances through the borehole fluid to reach deeper formations while maintaining sufficient signal strength for imaging.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Loss of energy

If transducer size is increased to reduce attenuation, then acoustic signal transmission is improved, but device size increases

Engineering Contradiction:
Improveacoustic signal attenuationVSAvoidtransducer size
Core Design Contradiction:
Loss of energyVSVolume of moving object

Solution Approach 1:

The patent changes the physical parameters of the interface between transducer and borehole fluid by introducing a solid window with specific acoustic properties (lower attenuation coefficient). This parameter change allows the use of smaller transducers while maintaining effective acoustic transmission, as the window compensates for the size limitation by providing a low-attenuation path.

Inventive Principle:
Principle #35Parameter changes

4Loss of energy

If mud excluder assembly is used to reduce attenuation, then acoustic signal transmission is improved, but device complexity increases

Engineering Contradiction:
Improveacoustic signal attenuationVSAvoidstructure complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent extracts only the essential function of the mud excluder assembly - providing an acoustically transparent interface - and implements it through a simple window structure rather than a complex assembly. The window can be integrated directly into the transducer housing or tool body, eliminating the need for separate excluder mechanisms while maintaining acoustic performance.

Inventive Principle:
Principle #2Taking out (Extraction)

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 solution enhances the imaging of borehole sidewalls by improving signal transmission and reception in heavily attenuating fluids, extending the operating range and reducing reverberations, thereby providing clearer and more accurate images of the earth formation.

Implementation Method 1

high-quality factor Piezoelectric (PZT) rods to propagate and receive acoustic signals

Methodology Applied
Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

acoustically transparent window and a polymer matrix with high-quality factor Piezoelectric (PZT) rods to propagate and receive acoustic signals

Methodology Applied
Scientific EffectAcoustic transmission: Sound

Implementation Method 3

receive a reflection from a wall of the borehole

Methodology Applied
Scientific EffectAcoustic reflection: Reflection

Data Source

PatentUS10416330B2Composite transducer for downhole ultrasonic imaging and caliper measurement
Publication Date: 2019.09.17 BAKER HUGHES CO
  • US10416330B2 patent drawing
  • US10416330B2 patent drawing
  • US10416330B2 patent drawing

AI summary

A transducer assembly for downhole imaging includes a 1-3 Piezoelectric composite transducer of high Q ceramic rods in a polymer matrix. The assembly also includes a TeflonĀ® window, a fluid-filled cavity adjacent to the window, and impedance matching material between the composite transducer and the fluid. The transducer is positioned to reduce the reverberation time.