Phase-Change Material Thermal Buffer for Downhole Tools

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Solution Overview

Problem

Devices operating in high-temperature environments, such as downhole oil field tools, face reliability issues due to heat exposure.

Innovation Solution

Incorporating a phase-change material within the housing of heat-sensitive devices to absorb and dissipate heat, maintaining the device at a stable temperature by using a heat-conductive substance and designing the material to conform to the device's contours, allowing it to expand and potentially escape excess volume.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If phase-change material is added to protect heat-sensitive devices, then reliability is improved, but device complexity increases

Engineering Contradiction:

ImprovereliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies phase transition by incorporating phase-change material that undergoes phase change at a specific temperature to absorb excess heat. The material transitions from solid to liquid phase, absorbing latent heat and maintaining the device at a stable temperature, thereby improving reliability without requiring complex active cooling systems.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The phase-change material acts as an intermediary between the heat-sensitive device and the external high-temperature environment. It absorbs heat through phase change and prevents direct heat transfer to the device, serving as a thermal buffer that protects the device while maintaining simplicity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If phase-change material is used to absorb heat, then temperature stability is improved, but volume increases due to expansion

Engineering Contradiction:

Improvetemperature stabilityVSAvoidvolume

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

The phase-change material is nested within the housing in an empty volume space. The housing contains the phase-change material, which is contained within a defined space. This nested arrangement allows the material to expand during phase change without increasing the overall device volume, as the expansion is accommodated within the pre-designed housing space.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The housing is designed with flexibility or expansion space to accommodate the phase-change material's volume changes. The housing structure allows for expansion of the material during phase transition while maintaining the external dimensions of the device, effectively managing volume changes without compromising temperature stability.

Inventive Principle:

Principle #30Flexible shells and thin films

3Loss of energy

If heat-conductive substance is applied to conform to device contours, then heat management efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveheat management efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by modifying the physical state of the heat-conductive substance. The material is applied in a malleable or liquid state that allows it to conform to the device contours, and then it is cured or solidified to maintain the conformal shape. This approach achieves excellent thermal contact without requiring complex manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

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

Enhances the reliability of heat-sensitive components by maintaining them at a stable temperature, thereby protecting them from excessive heat, and allowing for efficient heat management within the constrained space of downhole tools.

Implementation Method 1

a phase-change material is enclosed in the housing... upon occurrence of a phase-change event

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

the phase-change material absorbs heat... maintaining the device at a stable temperature

Methodology Applied

Scientific EffectLatent heat absorption: Latent Heat

Implementation Method 3

using a heat-conductive substance... efficient heat management

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10024152B2Improving reliability in a high-temperature environment

Publication Date: 2018.07.17 HALLIBURTON ENERGY SERVICES INC

AI summary

A housing contains an internal volume. A heat-sensitive device is contained by the housing and consumes a device percentage of the internal volume. The device percentage equals the percentage of the internal volume of the housing consumed by the heat-sensitive device. A phase-change material is positioned within the housing to conduct heat from the heat-sensitive device. The phase-change material consumes a percentage of the internal volume equal to 100 percent minus the device percentage minus an expansion percentage. The phase-change material expands in volume by an amount more than 75 percent of the expansion percentage upon occurrence of a phase-change event.