Graphite Silicate Mold for Complex Downhole Tool Geometry

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Solution Overview

Problem

Conventional mold technologies struggle to form downhole tools with complex geometries, such as rotary drill bits, without damaging the tools during removal, and fail to accommodate features like flow channels and sensitive components effectively.

Innovation Solution

A mold composed of a graphite/sodium silicate/sand mixture, optionally with thermoplastic inserts, is formed by reacting with carbon dioxide to solidify, allowing for complex geometries and subsequent removal of the tool without damage, using a method that includes 3D printing for inserts and controlled heating to burn out thermoplastics, ensuring even heat distribution and mechanical integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional mold technologies are used to form downhole tools with complex geometries, then the tools can be formed, but the tools are damaged during removal from the mold

Engineering Contradiction:

Improvegeometry complexityVSAvoidtool integrity during removal

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The mold is divided into multiple segments or sections that can move independently relative to each other. This segmentation allows the mold to open and release the formed tool without requiring complete disassembly, enabling tools with complex geometries to be formed and removed intact by progressively opening the segmented mold sections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mold incorporates movable and adjustable components that can dynamically change configuration during the forming and removal processes. The mold sections can shift positions and angles to accommodate complex tool geometries during formation, then reconfigure to enable tool extraction without damage.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If displacements are inserted in the mold to accommodate complex geometries, then the geometries can be formed, but the displacements must be removed after forming

Engineering Contradiction:

Improvegeometry complexityVSAvoidmold structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The mold is pre-configured with adjustable sections and movable components in specific positions to accommodate complex tool geometries during the forming process. These preliminary configurations are built into the mold design, eliminating the need to insert temporary displacements and subsequent removal operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #15Dynamics

3Strength

If the mold material provides mechanical strength for complex geometries, then the tool can be formed, but thermal conductivity may be insufficient for even heat distribution

Engineering Contradiction:

Improvemold mechanical strengthVSAvoidheat distribution uniformity

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The mold is constructed from composite materials that combine the mechanical strength properties of materials like steel or cast iron with thermal conductivity enhancements through embedded graphite elements, copper layers, or other thermally conductive additives. This composite structure provides both the structural integrity needed for complex geometries and the thermal pathways required for uniform heat distribution during the forming process.

Inventive Principle:

Principle #40Composite materials

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

Enables the formation of downhole tools with complex geometries and sensitive components, facilitating their removal without damage, while providing mechanical strength and thermal conductivity through the use of graphite and sodium silicate reaction products.

Implementation Method 1

A mold composed of a graphite/sodium silicate/sand mixture, optionally with thermoplastic inserts, is formed by reacting with carbon dioxide to solidify

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

providing mechanical strength and thermal conductivity through the use of graphite and sodium silicate reaction products

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

using a method that includes 3D printing for inserts and controlled heating to burn out thermoplastics

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS12036610B2Mold for downhole tool or component thereof

Publication Date: 2024.07.16 HALLIBURTON ENERGY SERVICES INC

AI summary

The disclosure provides a mold for a downhole tool or component thereof. The mold includes a grain material, a sodium silicate and carbon dioxide reaction product, and between 0.1% and 10% graphite by weight, inclusive, graphite. The disclosure further provides a method of forming a mold for a downhole tool or component thereof by filling a mold housing with graphite/sodium silicate/grain material mixture including between 0.1% and 10% graphite by weight, inclusive and shaping the mixture into a pre-mold having the same shape as the mold to be formed, and subjecting the pre-mold to an atmosphere having elevated amounts of carbon dioxide as compared to ambient air for a time sufficient to allow the sodium silicate to react with the carbon dioxide to form sufficient reaction products to bind the other pre-mold components and solidify a mold.