Fluid-Infused Elastomers for Geothermal Drilling
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Solution Overview
Problem
Elastomers used in harsh environments such as geothermal drilling and chemical exposure suffer from material degradation, leading to high operational costs due to frequent replacements and downtime.
Innovation Solution
Fluid-infused polymers with chemically inert, thermally stable fluids are developed to create a barrier against degradative conditions, enhancing material performance and reliability by infusing the elastomers with a fluid greater than 0% and up to 50% by volume, and using methods like high temperature and pressure infusion to optimize the elastomer/fluid combination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastomers are used in harsh environments (high temperature, pressure, chemical exposure), then they can perform drilling and geothermal operations, but they suffer from material degradation and loss of performance
Solution Approach 1:
A fluid intermediary substance is introduced between the elastomer and the harsh environment. The fluid infuses into the elastomer matrix (0-50% by volume) and acts as a barrier that prevents direct contact between degradative species (oxygen, chemicals, extreme temperatures) and the elastomer polymer chains, thereby maintaining material stability while enabling operation in harsh environments
Solution Approach 2:
The invention creates a composite material system consisting of the elastomer base material combined with infused fluid (halocarbon, fluorocarbon, or other thermally stable fluids). This composite structure combines the mechanical properties of the elastomer with the protective properties of the fluid, achieving both environmental adaptability and long-term reliability
2Reliability
If elastomeric materials are replaced frequently due to degradation, then material performance is maintained, but operational costs increase significantly (up to $1M/day productivity loss)
Solution Approach 1:
The fluid infusion is performed as a preliminary treatment before the elastomer is deployed to harsh environments. This pre-infusion process saturates the elastomer with protective fluid, creating an internal barrier system that prevents degradation from occurring during service, thereby extending component life and reducing replacement frequency
Solution Approach 2:
The infused fluid acts as a cushioning protective layer within the elastomer structure, absorbing and mitigating the harmful effects of environmental stressors before they can cause damage to the polymer matrix. This beforehand protection prevents the need for frequent replacements
3Quantity of substance
If high temperature and pressure infusion is applied to infuse fluid into elastomer, then fluid infusion depth and concentration are improved, but process complexity and equipment requirements increase
Solution Approach 1:
The infusion process utilizes changes in temperature and pressure parameters to control fluid uptake. By cycling between elevated temperature/pressure (to promote infusion) and reduced pressure (to remove excess fluid), the process achieves controlled fluid saturation (0-50% by volume) without requiring overly complex equipment
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 fluid-infused elastomers exhibit increased reliability, durability, and extended lifespan, with potential for reduced friction and customizable performance in specific environments, demonstrating improved mechanical performance and resistance to degradation.
Implementation Method 1
subjecting the material having a surface and a thickness and comprising an elastomer to a temperature and a pressure while submerged in a halocarbon fluid to infuse an amount of the halocarbon fluid into the material
Implementation Method 2
infuse an amount of the halocarbon fluid into the material to a depth greater than the surface
Data Source
AI summary
The present invention relates to fluid-infused elastomers that outperform their non-infused base elastomer in harsh environmental conditions. These fluid-infused polymers may be used in applications including geothermal technologies where the oil-infused elastomers may be subject to harsh conditions.