Ductile Cementing Materials for Downhole Frac Plugs
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Solution Overview
Problem
Current frac plugs and downhole tools face challenges in achieving high compressive strength and cost-effectiveness while withstanding high pressures and forces during setting and fracturing operations.
Innovation Solution
The use of cementitious materials combined with ductility modifying agents such as ionomers, functionalized fillers, metallic fibers, and polymeric fibers to create components with improved strength and ductility, which are then used in frac plugs and bridge plugs to control fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If filament winding or filler orientation techniques are used to increase compressive strength of plug components, then the compressive strength is improved, but the cost increases due to machining procedures and materials used
Solution Approach 1:
The patent applies composite materials by combining cementitious materials with aggregates and ductility modifying agents (metallic fibers, polymeric fibers, ionomers, functionalized fillers) to create a composite cement composition that achieves high compressive strength without requiring expensive filament winding or machining procedures. The composite structure allows the materials to work together synergistically to provide both strength and cost-effectiveness.
Solution Approach 2:
The patent changes the chemical and physical parameters of the cementitious material by incorporating specific ductility modifying agents and adjusting the composition ratios of cement, aggregate, and additives. This allows the material to achieve desired mechanical properties through compositional modification rather than through expensive post-processing techniques like filament winding.
2Ease of manufacture
If conventional cementitious materials are used in downhole tools, then the manufacturing cost is reduced, but the compressive strength and ductility are insufficient to withstand high pressures and forces
Solution Approach 1:
The patent transforms conventional cementitious materials into a high-performance composite by adding ductility modifying agents including metallic fibers, polymeric fibers, ionomers, and functionalized fillers. This composite approach maintains cost-effectiveness while dramatically improving compressive strength and ductility to levels suitable for withstanding high downhole pressures and forces.
Solution Approach 2:
The patent enhances specific local properties of the cementitious material by strategically incorporating different ductility modifying agents that provide localized reinforcement and ductility enhancement. The functionalized fillers and fibers are distributed throughout the matrix to provide targeted improvement in stress-bearing regions while maintaining overall cost-effectiveness.
Data Source
AI summary
A downhole tool for controlling the flow of a fluid in a wellbore includes a component that comprises: a cementitious material; an aggregate; and a ductility modifying agent comprising one or more of the following: an ionomer; a functionalized filler; the functionalized filler comprising one or more of the following: functionalized carbon; functionalized clay; functionalized silica; functionalized alumina; functionalized zirconia; functionalized titanium dioxide; functionalized silsesquioxane; functionalized halloysite; or functionalized boron nitride; a metallic fiber; or a polymeric fiber.