Foamed Conformable Material for Wellbore Isolation
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Solution Overview
Problem
Existing methods for wellbore screen materials struggle with controlling the microcellular structure of foamed conformable materials, leading to unpredictable mechanical and filtration properties, particularly in irregularly shaped boreholes, where gravel packing is inefficient due to shape irregularities and the difficulty in achieving desired conformability and screening filtration.
Innovation Solution
A method involving reaction injection molding to control the microcellular structure of foamed polymer materials by varying the quality of component mixing, using a mixing device such as an impeller or jet impingement mixer to achieve a preselected average cell size, allowing for adaptable conformability and effective screening of production flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gravel packing is used to fill the annular space in irregular boreholes, then wellbore isolation is achieved, but the method is inefficient due to shape irregularities and requires additional materials
Solution Approach 1:
The patent uses shape-memory polymer foam that changes its physical state in response to temperature changes. The foam is deployed in a compressed state and then heated to trigger expansion, transforming from a low-volume state to a high-volume state that conforms to the borehole shape. This parameter change enables the same material to adapt to irregular borehole geometries without requiring gravel packing.
Solution Approach 2:
The patent employs a composite material system consisting of shape-memory polymer foam combined with a heating element. The foam provides the conformable barrier while the heating element (such as an electrical heater or thermal pack) provides the trigger for expansion. This composite approach integrates the barrier function and activation function into a single deployable system.
2Ease of manufacture
If screen expansion technology is used to eliminate annular space, then gravel packing is eliminated, but the method fails in irregularly shaped boreholes
Solution Approach 1:
The shape-memory polymer foam undergoes a phase transition when heated, changing from a compressed low-volume state to an expanded high-volume state. This parameter change allows the foam to adapt to irregular borehole shapes, unlike traditional expansion screens that maintain a fixed geometry. The foam's ability to change volume and conform to the borehole wall makes it reliable in irregular wellbores.
3Adaptability or versatility
If foamed polymer material is used to conform to borehole shape, then adaptability to irregular shapes is improved, but control of microcellular structure becomes difficult
Solution Approach 1:
The patent pre-forms the polymer foam with a controlled closed-cell structure during manufacturing, establishing the desired microcellular architecture before deployment. By controlling the foam formation process (including cell size, distribution, and wall thickness) during fabrication, the patent ensures that when the foam is later deployed and expanded in the borehole, it achieves both conformability and predictable filtration characteristics. The preliminary structuring of the foam matrix allows subsequent expansion without compromising microcellular control.
4Ease of manufacture
If traditional foaming process is used to create microcellular structure, then material production is simple, but controlling cell size and microcellular structure is unpredictable
Solution Approach 1:
The patent employs controlled chemical or physical parameters during the foam formation process to achieve consistent cell sizes. By adjusting factors such as blowing agent concentration, polymer molecular weight, crosslinking density, or temperature profiles during foaming, the patent achieves predictable and repeatable microcellular structures. This parameter control transforms the foaming process from an unpredictable art to a controllable manufacturing process.
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 approach enables the production of foamed conformable materials with controlled cell sizes, enhancing mechanical and filtration properties, allowing for versatile screen assembly designs and improved placement configurations in wellbores, effectively addressing the challenges of irregular borehole shapes and gravel packing inefficiencies.
Implementation Method 1
Self-conforming expandable screens comprising thermosetting open-cell shape-memory polymeric foam have been disclosed. Shape-memory materials are materials that have the ability to return from a deformed state (temporary shape) to their original (permanent) shape induced by an external stimulus or trigger. The shape memory effect of these materials can be triggered, for example, by temperature change
Implementation Method 2
a material is selected that will expand after being contacted with wellbore fluids
Implementation Method 3
One method of providing a microcellular structure is by foaming a polymer
Data Source
AI summary
A process of making a foamed conformable material by reaction injection molding comprises providing a first component from a first feed tank at a first flow rate, via a first conduit, to a mixing device; providing a second component from a second feed tank at a second flow rate, via a second conduit, to the mixing device, the second component reactive with the first component in the presence of a foaming agent; mixing the first component and the second component in the mixing device to form a reaction mixture; introducing the reaction mixture into an injection molding device; molding the reaction mixture to form a foamed conformable material; wherein the mixing of the reaction mixture is adjusted to achieve a desired average cell size of the foamed conformable material. The process can produce wellbore-conforming materials that can function to filter out sand or other undesirable fines from a formation.