Downhole Seal Apparatus with Temperature-Dependent Bonding

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Solution Overview

Problem

Conventional downhole tubular seals face challenges in maintaining effective sealing under varying temperature and pressure conditions, as the bonding agents used to secure the sealing material to the metal inserts can restrict movement and conformability, leading to suboptimal sealing performance in high-temperature environments.

Innovation Solution

A disappearing bond is employed between the sealing element and the metal insert, using a bonding agent that maintains the bond at lower temperatures but breaks down at higher temperatures, allowing the sealing element to operate independently and form a more effective seal by moving into irregularities in the tubular surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a bonding agent is used to secure the sealing element to the metal insert, then the sealing element is retained in position, but the bonding agent restricts movement and conformability of the sealing element under varying temperature conditions

Engineering Contradiction:

Improvesealing performanceVSAvoidconformability to irregular surfaces

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The bonding agent's properties are designed to change with temperature - it maintains bonding strength at lower temperatures to retain the sealing element, but breaks down at higher temperatures to allow movement and conformability. This parameter change resolves the contradiction by providing both retention and adaptability at different operational stages.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The bonding agent transitions from a static bonded state to a dynamic unbonded state in response to temperature changes. This dynamic behavior allows the sealing element to be fixed during installation but free to conform to irregular surfaces during operation, resolving the contradiction between retention and adaptability.

Inventive Principle:

Principle #15Dynamics

2Strength

If the bonding agent maintains a strong bond, then the sealing element remains secured to the insert, but the bond prevents the sealing element from moving into irregularities in tubular surfaces

Engineering Contradiction:

Improvebond strengthVSAvoidmovement freedom

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The bonding agent's strength parameter is made temperature-dependent, being strong at installation temperatures to secure the sealing element, but weakening or breaking down at operational temperatures to enable movement and conformability to irregular surfaces.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If the sealing element is rigidly bonded to the metal insert, then positioning is precise, but conformability to irregular borehole shapes is reduced

Engineering Contradiction:

Improvepositioning accuracyVSAvoidconformability to irregular shapes

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The bonding agent undergoes parameter changes with temperature, transitioning from a rigid bonded state during manufacturing and installation to a flexible or unbonded state during operation, allowing the sealing element to conform to irregular borehole shapes while maintaining precise initial positioning.

Inventive Principle:

Principle #35Parameter changes

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

This approach enhances sealing performance by enabling the sealing element to conform to irregular borehole shapes and maintain a seal under high temperatures and pressures, improving the overall efficiency and longevity of the downhole seal apparatus.

Implementation Method 1

bonding a sealing element to an insert with a bond that bonds at temperatures less than a first temperature and increasingly breaks down at temperatures higher than the first temperature

Methodology Applied

Scientific EffectThermal decomposition: Decomposition (biological)

Data Source

PatentUS9540899B1Downhole seal apparatus and method thereof

Publication Date: 2017.01.10 BAKER HUGHES CO

AI summary

A method of forming a downhole seal between inner and outer tubulars. The method including bonding a sealing element to an insert with a bond that bonds at temperatures less than a first temperature and increasingly breaks down at temperatures higher than the first temperature. Defeating the bond between the sealing element and the insert at a second temperature higher than the first temperature; and, subsequently forming a seal between the inner and outer tubulars with the sealing element. Also included is a downhole sealing apparatus.