Downhole Tool Sealing Element Using Degradable Acrylate Composite
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Solution Overview
Problem
Traditional downhole tools require complex and costly retrieval methods, as their dissolvable components lack the structural integrity and elastic properties necessary for effective sealing, leading to inefficient removal processes.
Innovation Solution
A downhole tool with a body and sealing element composed of a composite material, including rubber and a degradable acrylate-based polymer that degrades upon exposure to aqueous fluids, allowing for fluid sealing and subsequent self-destruction without the need for milling or drilling, facilitating easier removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If dissolvable materials are used for the downhole tool body, then tool removal complexity is reduced, but the sealing element loses structural integrity and elastic properties necessary for effective sealing
Solution Approach 1:
The sealing element is segmented into two distinct material components: a dissolvable acrylate-based polymer matrix and an indissolvable rubber phase. This segmentation allows each material to fulfill its specific function - the polymer provides dissolvability for easy removal while the rubber maintains structural integrity and elastic sealing properties throughout the tool's operational life.
Solution Approach 2:
The sealing element is constructed as a composite material combining dissolvable acrylate-based polymer and indissolvable rubber. This composite structure resolves the contradiction by integrating materials with complementary properties - the polymer matrix enables tool dissolution for simplified removal while the dispersed rubber phase provides the necessary mechanical strength and elastic recovery for effective sealing against the wellbore.
2Strength
If traditional metal materials are used for downhole tools, then structural integrity is maintained, but retrieval operations become complex and costly involving milling or drilling
Solution Approach 1:
The material parameters of the sealing element are changed from traditional permanent metals to a dissolvable acrylate-based polymer composite. This parameter change transforms the end-of-life behavior of the tool - instead of requiring mechanical removal through milling or drilling, the tool can dissolve in the wellbore environment, dramatically simplifying retrieval operations while maintaining adequate structural integrity during operation through the rubber reinforcement.
3Device complexity
If dissolvable materials are used for the sealing element, then tool removal is simplified, but the material cannot exhibit expansive or elastic properties necessary for sealing
Solution Approach 1:
The indissolvable rubber phase acts as an intermediary within the dissolvable polymer matrix. During the sealing phase, the rubber provides the necessary elastic properties and expansive capability to conform to the wellbore surface and create an effective seal. During the removal phase, the rubber maintains the structural framework while the polymer matrix dissolves, allowing the tool to be retrieved without complex operations.
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 degradable acrylate-based polymer composite material enables efficient fluid sealing during operations and subsequent self-destruction, reducing the time and cost associated with tool removal by allowing the tool to drop into a rathole, thus streamlining the retrieval process.
Implementation Method 1
at least a portion of the degradable acrylate-based polymer degrades upon exposure to an aqueous fluid in a wellbore environment
Implementation Method 2
the dissolvable materials that have been proposed for use in forming a downhole tool body are often highly brittle and are physically or chemically incapable of exhibiting expansive or elastic properties necessary for a sealing element
Data Source
AI summary
A downhole tool comprising a body and a sealing element, wherein the sealing element is composed of a composite material comprising a rubber and a degradable acrylate-based polymer, and wherein at least a portion of the degradable acrylate-based polymer degrades when exposed to an aqueous fluid in a wellbore environment.