Plasticized Polymer Composition for Downhole Tools
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Solution Overview
Problem
The manufacturing of downhole tools with polymer compositions is hindered by high molecular weight polymers that require increased melt-processing temperatures, leading to energy-intensive and costly processes, and the presence of metal assemblies can further complicate the process, while also risking degradation of components.
Innovation Solution
A plasticized polymer composition incorporating a water-soluble plasticizer is used, which allows for depressed melt temperatures or glass transition temperatures, facilitating easier processing and subsequent strengthening in aqueous environments, enabling improved mechanical properties and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high molecular weight polymer is used, then strength and toughness of the final product is improved, but viscosity of polymer melt increases making processing difficult
Solution Approach 1:
The patent changes the chemical composition parameters of the polymer by incorporating specific plasticizers (phthalate esters, adipate esters, citrate esters) and antistatic agents in controlled amounts. This modifies the polymer's melt viscosity and processing characteristics while maintaining the strength and toughness requirements for downhole tool applications.
Solution Approach 2:
The patent creates a composite polymer material by combining base polymer with specific plasticizers and antistatic agents. This composite formulation allows the material to exhibit both the necessary mechanical strength for downhole environments and improved processability through reduced melt viscosity, resolving the contradiction between strength and ease of manufacture.
2Ease of manufacture
If melt-processing temperature is increased to process high viscosity polymer melt, then processing capability is improved, but energy consumption and manufacturing cost increase
Solution Approach 1:
The patent modifies the polymer composition by adding plasticizers and antistatic agents, which changes the melt rheology parameters. This allows the polymer to be processed at lower temperatures with reduced viscosity, thereby decreasing energy consumption while maintaining processing capability.
3Strength
If metal assembly is included in downhole tool, then structural strength is improved, but manufacturing complexity and energy requirements increase
Solution Approach 1:
The patent develops a composite polymer formulation that can achieve the necessary structural strength without requiring metal assemblies. The optimized polymer composition with plasticizers and antistatic agents provides sufficient mechanical properties for downhole applications, eliminating the need for complex metal-reinforced structures and simplifying manufacturing.
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 use of a plasticized polymer composition with a water-soluble plasticizer allows for easier formation and enhanced mechanical properties of downhole tools, reducing manufacturing complexity and time, while maintaining strength in subterranean environments.
Implementation Method 1
allowing the water-soluble plasticizer to leach out of the downhole tool or the component thereof
Data Source
AI summary
A downhole tool or a component thereof may comprise a plasticized polymer composition that comprises a polymer and a water-soluble plasticizer, wherein the plasticized polymer composition has a first deflection test value. The tool may be exposed to an aqueous-based medium where the water-soluble plasticizer may leach out of the tool such that the plasticized polymer composition has a second deflection test value after exposure to the aqueous-based medium that is less than about 10% of the first deflection test value.