Fluoroplastic Sleeve Liner Hangers for Geothermal Well Sealing

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Solution Overview

Problem

Traditional liner hangers used in subsurface wells face challenges in geothermal and corrosive environments due to the degradation of elastomeric seals under extreme temperature and chemical exposure, leading to potential failure and loss of mechanical integrity.

Innovation Solution

The use of fluoroplastic sealing elements and sleeves, such as PTFE, PFA, ETFE, and PVDF, which provide enhanced chemical and thermal resistance, combined with manufacturing methods like sleeve insertion, welding, shrink fitting, layer wrapping, and 3D printing, to create a durable and reliable expandable liner hanger system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If elastomeric elements are used in traditional liner hangers, then mechanical support and sealing are provided, but degradation occurs under extreme temperature and chemical exposure

Engineering Contradiction:

Improvesealing capabilityVSAvoidextreme temperature resistance

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent changes the material parameter from traditional elastomers to fluoroplastic materials (PTFE, PFA, ETFE, PVDF) which have fundamentally different thermal and chemical resistance properties, enabling operation in extreme temperature and corrosive environments where traditional elastomers degrade

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite construction combining metallic body components with fluoroplastic sealing elements and sleeves, creating a hybrid system that leverages the mechanical strength of metals and the chemical/thermal resistance of fluoroplastics to achieve reliability in geothermal environments

Inventive Principle:

Principle #40Composite materials

2Reliability

If elastomeric elements are used in traditional liner hangers, then sealing is achieved, but chemical corrosion resistance deteriorates

Engineering Contradiction:

Improvesealing capabilityVSAvoidchemical corrosion resistance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material composition from elastomeric compounds to fluoroplastic materials which possess inherently superior chemical inertness and corrosion resistance, preventing degradation from exposure to downhole chemicals while maintaining effective sealing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional elastomeric seals with fluoroplastic sealing elements that have extended service life in corrosive environments, effectively eliminating the need for premature replacement due to chemical degradation

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If fluoroplastic materials are used, then chemical and thermal resistance is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal and chemical resistanceVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent divides the liner hanger into distinct segments: metallic body components and fluoroplastic sealing elements/sleeves, allowing each to be manufactured separately using optimized processes and then assembled, thereby managing the complexity of working with fluoroplastic materials

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces fluoroplastic sleeves as intermediary components that can be inserted over or onto metallic components, providing a simplified assembly approach where the sleeves act as protective and sealing layers that accommodate the unique manufacturing requirements of fluoroplastic materials

Inventive Principle:

Principle #24Intermediary (Mediator)

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 fluoroplastic materials and innovative manufacturing processes result in a liner hanger system that maintains mechanical integrity and sealing capabilities in high-temperature, high-pressure environments, resisting corrosion from downhole chemicals and ensuring long-term performance in geothermal applications.

Implementation Method 1

heating the fluoroplastic sleeve... causes the fluoroplastic sleeve to shrink and bond with the body

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Implementation Method 2

heating the plurality of fluoroplastic layers forms the plurality of fluoroplastic layers into a unitary material

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250320793A1Fluoroplastic based liner hangers for geothermal and corrosive environments

Publication Date: 2025.10.16 HALLIBURTON ENERGY SERVICES INC

AI summary

Some implementations include a method comprising positioning a fluoroplastic sleeve on a body of a liner hanger configured for insertion in a borehole. The method also may include heating the fluoroplastic sleeve.