Downhole Tool Bonding With Rupturable Solder Particles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for attaching downhole tools to borehole tubulars often result in damage due to overtightening or loosening, leading to misalignment and inefficiencies in hydrocarbon extraction processes.
Innovation Solution
The use of solder particles with a liquid eutectic metal core and a rupturable outer shell, applied as a suspension to the tools and tubulars, which bond upon mechanical stress or chemical etching, allowing for secure attachment at the wellsite without pre-manufacturing bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If straps are used to attach downhole tools to tubulars, then attachment is simple and quick, but the tools may be overtightened causing damage or become loose leading to misalignment
Solution Approach 1:
The patent replaces the mechanical strap attachment system with a metallurgical bonding system using solder particles. Instead of relying on mechanical fastening that can be overtightened or loosen, the invention uses a phase-change material (liquid eutectic metal) that bonds the tool to the tubular through controlled solidification, eliminating the harmful mechanical stresses while providing secure attachment.
Solution Approach 2:
The invention changes the physical state parameter of the bonding material from solid (traditional solder) to liquid (eutectic metal at operating temperature), allowing it to flow into intimate contact with both surfaces and then solidify upon cooling to create a strong metallurgical bond. This parameter change enables reliable bonding without mechanical stress.
2Loss of time
If downhole tools are attached at the wellsite rather than pre-manufactured, then manufacturing time and costs are reduced, but bonding reliability may be compromised
Solution Approach 1:
The patent applies the solder particles to the tool or tubular surface before wellsite installation, allowing the bonding material to be pre-positioned. At the wellsite, only the simple act of bringing the components together is needed to activate the bond, combining the reliability of pre-applied bonding material with the speed of wellsite assembly.
Solution Approach 2:
The solder particles are designed to self-activate upon contact between the tool and tubular. The mechanical stress of assembly or chemical etching automatically ruptures the protective shell and releases the liquid metal, which then self-bonds the components without requiring additional equipment, expertise, or time at the wellsite.
3Strength
If traditional soldering methods are used, then bonding strength is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The invention utilizes the phase transition of the eutectic metal from liquid to solid state to achieve bonding. The material is applied in a stable, non-tacky state that allows easy handling and positioning, then transitions to a bonded state through simple cooling or activation, providing strong bonding without complex processing equipment or procedures.
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 method reduces manufacturing time and costs by ensuring secure, reliable bonding of downhole tools to borehole tubulars, minimizing damage and maintaining alignment, thereby enhancing the efficiency of hydrocarbon extraction processes.
Implementation Method 1
each particle having an outer shell and a core of liquid metal that solidifies upon rupture of the outer shell
Data Source
AI summary
The present disclosure provides methods for bonding a first downhole tool to a borehole tubular, which include applying solder particles, each particle having an outer shell and a core of liquid metal, to at least one of a surface of the first downhole tool or a surface of the borehole tubular. The methods may also include rupturing the shells of the solder particles to release the liquid metal cores. The methods may further include bonding the first downhole tool to the borehole tubular by allowing the released liquid metal core to solidify.