Degradable Composite Materials Accelerated Breakdown
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Solution Overview
Problem
Current degradable materials used in oil and gas production, pharmaceuticals, and consumer products do not adequately degrade quickly enough under downhole conditions, particularly at low temperatures, necessitating the development of materials that can accelerate degradation in water at temperatures below 60°C.
Innovation Solution
The development of degradable composite materials comprising a degradable polymer mixed with discrete filler particles that accelerate degradation, including water-soluble, meltable, and reactive fillers, which can degrade in 60°C water in less than 30 days, and even faster at lower temperatures, with the option of protective coatings to control or fine-tune the degradation rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional degradable materials are used, then they maintain structural integrity over time, but they do not degrade quickly enough under downhole conditions, particularly at low temperatures
Solution Approach 1:
The material is segmented into a composite structure consisting of a degradable polymer matrix and discrete filler particles. The filler particles are distributed throughout the polymer matrix, creating a segmented architecture where each component performs a specific function: the polymer provides structural integrity while the filler particles accelerate degradation through catalytic activity, hydrolysis, or melting mechanisms.
Solution Approach 2:
The invention employs composite materials by combining a degradable polymer with discrete filler particles that have specific degradation-promoting properties. The composite structure allows the polymer matrix to maintain structural integrity while the filler particles (such as metal oxides, hydroxides, carbonates, salts, or waxes) accelerate degradation through chemical catalysis, hydrolysis enhancement, or phase transformation at low temperatures.
2Productivity
If filler particles are added to accelerate degradation, then degradation rate increases, but the material may degrade too quickly during manufacturing processes
Solution Approach 1:
The invention utilizes parameter changes by selecting filler particles with specific properties (melting points, catalytic activities, solubility characteristics) that allow them to remain stable during manufacturing processes such as extrusion and molding, then trigger degradation under downhole conditions. The filler particles are chosen to withstand processing temperatures while accelerating degradation at lower downhole temperatures through catalytic or hydrolytic mechanisms.
Solution Approach 2:
The filler particles act as intermediaries that mediate between the polymer matrix and the degradation environment. They provide a controlled interface where degradation is initiated and accelerated through catalytic activity, hydrolysis promotion, or phase transformation, allowing the material to maintain stability during processing while enabling rapid degradation under service conditions.
3Productivity
If smaller filler particles are used, then degradation acceleration is enhanced, but manufacturing and handling becomes more difficult
Solution Approach 1:
The invention applies local quality by using discrete filler particles of controlled size distribution (10 nm to 5 microns) that provide localized degradation acceleration at particle-polymer interfaces. The particles are distributed non-uniformly throughout the matrix, with higher degradation activity concentrated at the particle surfaces where catalytic or hydrolytic reactions occur, while the bulk polymer maintains its structural properties.
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
These composite materials achieve accelerated degradation, with some formulations reaching 100% weight loss within a week at temperatures as low as 40°C, enhancing their suitability for various industrial, medical, and consumer applications by ensuring efficient breakdown and reduced retrieval needs in oilfield services and other uses.
Implementation Method 1
degradable composite composition comprises a degradable polymer mixed with discrete particles of a filler that acts to accelerate the degradation of the degradable polymer
Implementation Method 2
The discrete particles can be water soluble materials
Implementation Method 3
include hygroscopic or hydrophilic materials
Implementation Method 4
a meltable material, such as wax
Implementation Method 5
a reactive filler that can catalyze degradation, such as a material that provides an acid, base or metal ion
Data Source
AI summary
In general, the current application relates to degradable composite and blend materials that have accelerated degradation in water in low temperature conditions, and their various industrial, medical and consumer product uses. In some embodiments, the degradable composite composition comprises a degradable polymer mixed with discrete particles of a filler that acts to accelerate the degradation of the degradable polymer. Such materials degrade in 60 C water in less than 30 days, <14 days, and even <7 days. Various materials are provided that can degrade equally fast at lower temperatures, such as 50 C, or even 40 C.