Degradable Polyurethane Composite for Borehole Tools
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Solution Overview
Problem
Existing borehole components and tools in downhole constructions, such as oil and gas wells, have limited service lives and require costly and time-consuming removal methods like milling or drilling, which are inefficient for hydrocarbon production and CO2 sequestration.
Innovation Solution
A degradable polymer composite comprising a polyurethane with ester, carbonate, or ether groups, combined with acidic or basic powders, which can be molded and designed to rapidly disintegrate at lower temperatures, providing high extrusion resistance and controlled degradation in fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional polyurethanes are used for borehole components, then mechanical strength and extrusion resistance are maintained, but degradation time is prolonged and solid residues remain
Solution Approach 1:
The patent uses composite materials by combining polyurethane with acidic or basic powders (such as calcium oxide, calcium hydroxide, or glass powder). This composite structure enables the material to degrade completely into soluble or dispersible products without leaving solid residues, while maintaining the necessary mechanical strength during service life.
Solution Approach 2:
The patent changes the chemical composition parameters of the polyurethane by incorporating ester, carbonate, or ether groups in the backbone and adding acidic or basic powders. This parameter modification allows the material to degrade at lower temperatures (below 200°F) and completely dissolve or disperse in formation fluids, eliminating solid residue problems.
2Productivity
If conventional removal methods (milling or drilling) are used for borehole components, then component removal is achieved, but time and cost are increased
Solution Approach 1:
The patent replaces mechanical removal methods (milling or drilling) with chemical degradation and dissolution processes. The degradable borehole component naturally breaks down and dissolves in formation fluids through chemical reactions, eliminating the need for time-consuming mechanical intervention and significantly improving productivity.
Solution Approach 2:
The borehole component has self-service capability through its inherent degradability. Once its service life is complete, the component automatically degrades and dissolves in the formation fluids without requiring external removal operations, saving both time and operational costs.
3Temperature
If polyurethane with ester groups is used, then degradation at lower temperatures is achieved, but extrusion resistance may be reduced
Solution Approach 1:
The patent creates a composite material system where polyurethane with ester groups (providing low-temperature degradability) is reinforced with acidic or basic powders. This composite structure maintains extrusion resistance and mechanical strength during service while preserving the ability to degrade at lower temperatures below 200°F.
Solution Approach 2:
The patent applies local quality by having different regions or aspects of the material serve different functions: the polyurethane matrix provides extrusion resistance and structural integrity, while the ester groups and acidic/basic powder components provide controlled degradability at specific temperature thresholds.
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 allows for efficient and cost-effective removal of borehole components by degrading at lower temperatures within weeks, maintaining mechanical properties until needed, and avoiding the drawbacks of conventional polyurethanes, such as prolonged degradation and solid residues.
Implementation Method 1
The polyurethane comprises ester groups, carbonate groups, ether groups, or a combination thereof on a backbone of the polyurethane... exposing an article to a fluid at a temperature of about 25° C. to about 300° C.
Implementation Method 2
a degradable polymer composite comprises a polyurethane comprising one or more of the following groups: ester groups; carbonate groups; or ether groups, in a backbone of the polyurethane; and about 1 to about 30 parts by weight of an acidic or basic powder
Data Source
AI summary
A degradable polymer composite comprises a polyurethane comprising one or more of the following groups: ester groups; carbonate groups; or ether groups, in a backbone of the polyurethane; and about 1 to about 30 parts by weight of an acidic or basic powder comprising particles having an average size of about 5 microns to about 1 millimeter per 100 parts of the polyurethane.