Crosslinked PPS-Polyphenylsulfone Elastomer for Downhole Seals
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Solution Overview
Problem
Current elastomers used in downhole drilling and completion applications face degradation due to high temperatures and harsh chemical environments, leading to reduced mechanical properties and reliability, especially when exposed to corrosive fluids.
Innovation Solution
A crosslinked product of polyphenylene sulfide and polyphenylsulfone is developed, which is manufactured by heating the polymers in the presence of a crosslinking agent at elevated temperatures to create a high-temperature elastomer with improved chemical resistance and elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluoropolymers are used to achieve chemical resistance under wet conditions at high temperature, then chemical resistance is improved, but the material becomes soft and develops cracks over time
Solution Approach 1:
The patent creates a composite elastomer by blending polyphenylene sulfide (PPS) with fluoropolymer particles. This composite structure combines the chemical resistance of fluoropolymers with the mechanical strength and elasticity of PPS, resolving the contradiction where fluoropolymers alone become soft and crack at high temperatures while maintaining chemical resistance.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the elastomer through controlled crosslinking of PPS chains. This crosslinking process changes the molecular structure to improve both mechanical strength and chemical resistance simultaneously, allowing the material to maintain its properties under high temperature and wet conditions without becoming soft or cracking.
2Temperature
If polyetheretherketone is used to withstand high heat and caustic chemicals, then thermal stability is improved, but elasticity is lost and the material becomes brittle
Solution Approach 1:
The patent changes the physical state and molecular structure of polyphenylene sulfide through crosslinking at elevated temperatures. This process creates a network structure that provides thermal stability while maintaining elasticity, resolving the contradiction where PEEK becomes brittle and loses elasticity at high temperatures.
Solution Approach 2:
The patent forms a composite elastomer combining PPS with fluoropolymer particles, where the PPS matrix provides elasticity and the fluoropolymer particles enhance thermal stability and chemical resistance. This composite structure allows the material to withstand high temperatures while maintaining the elasticity needed for sealing applications.
3Reliability
If elastomers are used in downhole applications to maintain mechanical properties under wet conditions, then chemical resistance is improved, but the material degrades over time at high temperature
Solution Approach 1:
The patent applies crosslinking to change the molecular structure of polyphenylene sulfide, creating a network that resists degradation at high temperatures. This structural modification extends service life by preventing the elastomer from becoming soft and losing mechanical properties over time in harsh downhole environments.
Solution Approach 2:
The patent creates a composite elastomer system where PPS provides the base matrix with crosslinked structure for thermal stability, and fluoropolymer particles provide enhanced chemical resistance. This composite structure extends service life in downhole applications by maintaining mechanical properties under wet conditions at high temperatures.
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 resulting elastomer maintains excellent mechanical properties, including elasticity and chemical resistance, even under wet conditions at high temperatures, making it suitable for continuous use in harsh downhole environments.
Implementation Method 1
heating the polyphenylene sulfide and the polyphenylsulfone in presence of a crosslinking agent at a temperature and for a time effective to form the crosslinked product of polyphenylene sulfide and polyphenylsulfone
Implementation Method 2
heating the polyphenylene sulfide and the polyphenylsulfone in presence of a crosslinking agent at a temperature and for a time effective to form the crosslinked product
Data Source
AI summary
A composition includes a crosslinked product of a polyphenylene sulfide and a polyphenylsulfone. A method for the manufacture of the crosslinked product of a polyphenylene sulfide and a polyphenylsulfone includes heating the polyphenylene sulfide and the polyphenylsulfone in presence of a crosslinking agent at a temperature and for a time effective to form the crosslinked product of polyphenylene sulfide and polyphenylsulfone.