Filament Wound Composite Tools Interlaminar Strength
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Solution Overview
Problem
Composite frac and bridge plugs used in oil and gas well completion face interlaminar shear failures at elevated temperatures and pressures, limiting their effectiveness in high-temperature and high-pressure applications, and current manufacturing methods are costly.
Innovation Solution
Incorporating blown fiber roving strands with standard roving strands during the filament winding process to create strand loops that interlock between layers, enhancing interlaminar shear strength in composite mandrels and sleeves for frac and bridge plugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If filament winding process is used to manufacture composite frac and bridge plugs, then manufacturing cost is reduced, but interlaminar shear strength at elevated temperatures and pressures is insufficient
Solution Approach 1:
The patent applies composite materials by combining standard roving strands with blown fiber roving strands in the filament winding process. The blown fiber strands create loops that interlock between layers, while standard rovings provide structural integrity. This composite fiber approach maintains the cost-effectiveness of filament winding while significantly improving interlaminar shear strength for high-temperature and high-pressure applications.
2Adaptability or versatility
If higher pressures and operating temperatures are used in well completion operations, then application capability is improved, but interlaminar shear failures increase
Solution Approach 1:
The patent implements beforehand cushioning by pre-forming loops in the blown fiber strands before the winding process. These pre-formed loops are designed to interlock with adjacent layers during winding, creating a proactive interlocking mechanism that prevents interlaminar shear failures before they occur under high pressure and temperature conditions.
3Ease of manufacture
If standard roving strands are used in filament winding, then manufacturing simplicity is maintained, but interlaminar shear strength is insufficient
Solution Approach 1:
The patent applies local quality by using standard roving strands in regions requiring structural integrity and blown fiber roving strands in regions requiring interlaminar bonding. The blown fiber strands with loops are strategically positioned at layer interfaces to provide localized interlocking, while standard rovings maintain overall structural strength. This differentiated fiber approach improves interlaminar shear strength without significantly complicating the manufacturing process.
Data Source
AI summary
Composite products and related methods are disclosed. In some examples, methods of filament winding composite components and products, such as a sleeve and/or a mandrel for use in down-hole applications, are disclosed. The winding of components can involve using a percentage of fiber roving strands that are blown during manufacture such that they have fiber loops that when wound as layers forms bridges across the discrete layers to enhance the inter-laminar strength of the composite product.