Permeable Material Compacting Method Using Helical Winding and Thermal Control
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Solution Overview
Problem
Existing methods for compacting permeable materials for gravel packing in the downhole industry require compaction or compression prior to deployment, which can be inefficient and may not fully utilize the materials' potential for volume reduction and recovery.
Innovation Solution
A compacting method and apparatus using a mandrel and skewed rollers to compact permeable materials in a helical fashion, with integrated heating and cooling mechanisms to optimize temperature adjustments and volume reduction, allowing for multiple layers and precise alignment, enabling efficient compaction and subsequent unwinding of the materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If permeable material is compacted using conventional compression methods, then volume reduction is achieved, but the material cannot be fully recovered to its original state
Solution Approach 1:
The patent applies temperature parameter changes by heating the permeable material during compaction and then cooling it during recovery. This thermal parameter change enables the material to be compacted to a fraction of its original volume while maintaining the ability to recover, as the heat treatment modifies the material's structural properties temporarily without permanent damage
2Volume of moving object
If permeable material is compacted to maximum density, then space efficiency is improved, but the material loses its ability to expand and conform to the annulus
Solution Approach 1:
The patent employs periodic action through sequential heating and cooling cycles. The material is heated during compaction to achieve maximum density, then cooled to enable expansion. This periodic thermal action allows the material to alternate between compacted and expanded states, maintaining both space efficiency and adaptability
3Device complexity
If conventional compaction methods are used, then the process is simple, but temperature control and layer alignment are insufficient
Solution Approach 1:
The patent merges multiple functions into the compaction apparatus: heating elements are integrated into the compaction rollers, cooling systems are built into the housing, and alignment guides are incorporated into the feed mechanism. This combination of functions achieves precise temperature control and layer alignment while maintaining relative process simplicity
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 compaction and volume reduction of permeable materials, allowing for improved deployment in gravel packing applications, with enhanced temperature control and layer alignment, thereby improving the materials' performance and recovery characteristics.
Implementation Method 1
at least one set of rollers having surfaces defining a minimum dimension therebetween configured to compact permeable material rolled therebetween to a thickness of the minimum dimension
Implementation Method 2
with integrated heating and cooling mechanisms to optimize temperature adjustments and volume reduction
Implementation Method 3
with integrated heating and cooling mechanisms to optimize temperature adjustments and volume reduction
Data Source
AI summary
A permeable material compacting method includes, feeding permeable material between at least one set of rollers, decreasing a thickness of the permeable material, and wrapping the permeable material around a mandrel in a helical fashion.