Lapped Coating for Degradable Downhole Fracturing Balls

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Solution Overview

Problem

Conventional downhole tools used in hydraulic fracturing are prone to degradation due to exposure to corrosive fluids and humidity, leading to reduced shelf-life and performance issues when used in harsh downhole environments.

Innovation Solution

A lapped tool or component, such as a hydraulic fracturing ball, is created by machining a base body and applying a lapped coating made from materials like aluminum oxide, silica, and diamond paste, which provides a protective layer that reduces surface imperfections and exposure to corrosive fluids, allowing for controlled degradation and extended shelf-life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional downhole tools are used without protective coating, then the tool structure is simple and manufacturing is easier, but the tool degrades quickly due to exposure to corrosive fluids and humidity

Engineering Contradiction:

Improvetool durabilityVSAvoidtool structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining a base tool body with a lapped coating layer made from aluminum oxide, silica, and diamond paste. This composite structure provides both the mechanical integrity of the base material and the corrosion-resistant properties of the lapped coating, resolving the contradiction between durability and structural simplicity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The lapped coating acts as a thin protective film that shields the base tool from corrosive environments. This thin film approach provides protection without significantly increasing structural complexity, addressing the contradiction between reliability improvement and device complexity.

Inventive Principle:

Principle #30Flexible shells and thin films

2Object-affected harmful factors

If a lapped coating is applied to protect the tool, then the tool's resistance to corrosive fluids improves, but the manufacturing process becomes more complex and time-consuming

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidmanufacturing process

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The lapped coating is applied during the manufacturing process as a preliminary protective measure before the tool is deployed. This preliminary action ensures corrosion resistance is built-in from the start, avoiding the need for post-manufacturing treatments and simplifying the overall manufacturing workflow.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The use of composite lapped coating materials (aluminum oxide, silica, diamond paste) provides superior corrosion resistance in a single application layer, reducing the number of manufacturing steps required compared to multiple coating layers, thus improving ease of manufacture while maintaining high corrosion resistance.

Inventive Principle:

Principle #40Composite materials

3Object-generated harmful factors

If the tool is made fully degradable, then environmental impact is reduced, but the tool loses structural integrity before deployment

Engineering Contradiction:

Improveenvironmental impactVSAvoidstructural integrity

Core Design Contradiction:

Object-generated harmful factorsVSStrength

Solution Approach 1:

The lapped coating serves as a protective shell that maintains the tool's structural integrity during storage and deployment by shielding the degradable base material from environmental exposure. Once deployed, the coating degrades along with the base material, ensuring environmental friendliness. This thin film approach provides protection without compromising the degradable nature of the tool.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The lapped coating provides beforehand cushioning protection to the degradable tool body, preventing premature degradation during storage and handling. This protective layer ensures the tool maintains its structural integrity until deployment, after which both the coating and base material degrade together to minimize environmental impact.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 lapped coating slows down initial degradation, protecting the tool from environmental exposure and ensuring it remains intact during deployment, with a two-stage degradation process that allows for timed exposure to production fluids, enhancing the tool's sphericity and durability.

Implementation Method 1

a lapped coating made from materials like aluminum oxide, silica, and diamond paste, which provides a protective layer that reduces surface imperfections and exposure to corrosive fluids

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS10508525B2Degradable downhole tools and\or components thereof, method of hydraulic fracturing using such tools or components, and method of making such tools or components

Publication Date: 2019.12.17 BUBBLETIGHT LLC

AI summary

A downhole tool or component, such as a hydraulic fracturing ball, may have a base body having an outer surface. The outer surface of the base body may have a lapped coating thereon. The downhole tool or component may be made by lapping the outer surface of the base body with a lapping slurry. The downhole tool or component may be used in downhole applications, such as hydraulic fracturing, and may resist degradation upon exposure to fluids, such as production fluids.