Gradient Composite Coating for Disintegrable Downhole Tools
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Solution Overview
Problem
In downhole applications, such as hydraulic fracturing, ball or plug seat assemblies interfere with subsequent operations and are difficult, costly, and time-consuming to remove, necessitating advancements in designs that enable selective removal.
Innovation Solution
A coating with a gradient composite structure comprising a bonding component and an erosion and/or corrosion-resistant component is applied to a disintegrable substrate, allowing for controlled and predictable disposal by configuring the coating to fail or dissolve within a specified timeframe, enhancing erosion and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ball or plug seat assembly is used in downhole applications, then flow control function is achieved, but removal difficulty and operational interference increase
Solution Approach 1:
The patent applies the disposable principle by designing the seat assembly with a biodegradable substrate that naturally degrades over time in the downhole environment. The housing and/or plug member is formed from biodegradable materials that break down after completing their flow control function, eliminating the need for physical removal operations and associated costs.
2Reliability
If a protective coating is applied to enhance erosion and corrosion resistance, then durability is improved, but removal complexity increases
Solution Approach 1:
The patent applies the local quality principle through a gradient composite coating structure where the composition varies through the thickness. The proximal layer contains a greater amount of bonding component for strong substrate attachment, while the distal layer contains more erosion and corrosion resistant material for environmental protection. This spatial variation in material properties optimizes both protection and biodegradability.
Solution Approach 2:
The patent applies composite materials by creating a multi-layer coating system with different material compositions. The coating comprises a bonding component and an erosion and corrosion resistant component in varying proportions through the thickness, forming a composite structure that combines the benefits of strong adhesion with enhanced environmental resistance while maintaining controlled biodegradability.
3Ease of operation
If the substrate is made disintegrable for easy disposal, then removal cost and time are reduced, but erosion and corrosion resistance deteriorates
Solution Approach 1:
The patent applies parameter changes by modifying the coating composition gradient to control the balance between biodegradability and protection. By adjusting the proportion of bonding component to erosion and corrosion resistant material through the coating thickness, the system achieves both adequate environmental resistance during service and controlled disintegration after function completion.
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 solution enables efficient and controlled disposal of the substrate, reducing the complexity and cost of removing ball or plug seat assemblies by ensuring predictable failure or dissolution, thereby facilitating subsequent operations.
Implementation Method 1
an erosion and/or corrosion resistant component
Implementation Method 2
an erosion and/or corrosion resistant component
Implementation Method 3
a bonding component
Data Source
AI summary
A coating having a gradient composite structure, applied to a substrate, which may be a disposable tool. The gradient composite comprises a bonding component and an erosion and/or corrosion resistant component. When applied to a disposable tool, such as a ball and seat assembly in a downhole environment, the coating enhances the performance of disintegrable materials used in such tools. The coating may be configured to expire at the end of a selected duration, allowing the underlying material to disintegrate.