Dissolvable Wellbore Tool Cellular Nanomatrix Coating
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Solution Overview
Problem
Existing wellbore components and tools require frequent removal and disposal, which is costly and time-consuming due to their limited service life, and current degradable materials lack the mechanical strength and durability needed for wellbore operations.
Innovation Solution
Development of lightweight, high-strength metallic materials with a cellular nanomatrix structure, comprising a particle core coated with a nanoscale metallic layer, allowing for controlled dissolution in wellbore fluids while maintaining mechanical integrity until needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If degradable polymers are used to eliminate milling or drilling operations, then disposal time and cost are reduced, but mechanical strength and fracture toughness are insufficient
Solution Approach 1:
The patent applies composite materials by combining degradable metal alloys with matrix materials to create a composite structure that maintains mechanical strength while enabling controlled dissolution. The composite nature allows the material to exhibit both structural integrity during service and degradability for disposal, resolving the contradiction between strength and disposal time.
Solution Approach 2:
The patent utilizes parameter changes by controlling the dissolution rate of the degradable metal alloy through composition adjustments and environmental conditions (temperature, pH, fluid composition). This allows the material to maintain strength during operation while enabling controlled dissolution when disposal is needed, addressing both mechanical strength requirements and disposal time reduction.
2Strength
If conventional materials are used for wellbore components, then mechanical strength is sufficient, but removal requires time-consuming milling or drilling operations
Solution Approach 1:
The patent changes the chemical parameters of the material by using degradable metal alloys that undergo dissolution when exposed to specific wellbore fluids or environmental conditions. This transformation allows the material to transition from a stable, strong state during service to a dissolvable state for rapid removal, eliminating the need for mechanical milling or drilling operations.
Solution Approach 2:
The patent replaces the mechanical removal system (milling or drilling operations) with a chemical dissolution system. Instead of using mechanical force to remove components, the degradable metal alloy dissolves chemically when exposed to controlled environmental conditions, significantly improving removal efficiency and productivity.
3Ease of manufacture
If degradable metal alloys are formed by conventional melting and solidification, then material can be produced, but alloy structures may not result in optimal mechanical properties or dissolution characteristics
Solution Approach 1:
The patent applies parameter changes by controlling composition, cooling rates, and processing parameters during alloy formation to achieve desired microstructures. By adjusting these parameters, the patent optimizes both the mechanical properties and dissolution characteristics of the degradable metal alloy, ensuring reliable performance while maintaining ease of manufacture.
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 materials provide enhanced mechanical strength and controlled dissolution, enabling efficient removal of wellbore tools and components without the need for milling or drilling, reducing operational costs and time.
Implementation Method 1
a coating layer formed from a plurality of substantially contiguous coated particles forming a substantially-continuous, cellular nanomatrix comprising a nanomatrix material
Data Source
AI summary
A tool configured to dissolve in a selected subsurface environment includes a coating layer disposed about a particle core. The coating layer is formed from a plurality of substantially contiguous coated particles forming a substantially-continuous, cellular nanomatrix comprising a nanomatrix material.