Crosslinked Polyarylene Elastomer with Mesoporous Silicate
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Solution Overview
Problem
Elastomers used in downhole drilling applications face challenges in achieving a balance between mechanical strength, elasticity, and chemical resistance at high temperatures, as additives often degrade one property while improving another, and high filler loading levels can be detrimental, especially when binders are used.
Innovation Solution
A composition comprising a crosslinked product of polyarylene or polyphenylene sulfide and polyphenylsulfone combined with mesoporous silicate, which provides enhanced mechanical strength and chemical resistance without the need for binders, using a smaller amount of filler and maintaining elasticity at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fillers such as carbon black and nonporous silica are used in significant amounts to improve mechanical strength, then mechanical strength is improved, but the elastomeric properties deteriorate at high temperatures
Solution Approach 1:
The patent employs mesoporous silica particles with controlled pore sizes (2-50 nm) as fillers in the elastomeric composition. The porous structure provides high surface area for polymer-filler interaction while maintaining flexibility and preventing excessive stiffening at high temperatures. The pores can also accommodate thermal expansion and maintain the elastomeric network integrity under thermal stress.
Solution Approach 2:
The patent creates a composite elastomeric system by combining the elastomer matrix with mesoporous silica fillers and specific binder systems. This composite approach allows optimization of both mechanical strength (through filler reinforcement) and high-temperature elastomeric properties (through appropriate binder selection and crosslinking), resolving the contradiction between strength improvement and property deterioration.
2Quantity of substance
If binders are used to bond filler to elastomer to reduce filler loading level, then filler loading is reduced, but the bond dissociates at high temperatures compromising mechanical strength
Solution Approach 1:
The patent changes the chemical parameters of the binder system by selecting specific high-temperature stable compounds such as polyphenylene sulfide, polyether block amide, or polyamide binders. These binders maintain their bonding integrity at elevated temperatures (up to 150°C or higher) where conventional binders would dissociate, thus preserving mechanical strength while allowing reduced filler loading.
Solution Approach 2:
The patent uses crosslinking agents that form permanent, irreversible bonds between filler particles and the elastomer matrix. This creates a durable network that does not require continuous binder adhesion, effectively replacing temporary binder bonds with permanent crosslinked structures that withstand high temperatures without dissociation.
3Quantity of substance
If binders are used to bond filler to elastomer, then filler loading is reduced, but binders function as plasticizer leading to deterioration of tensile properties
Solution Approach 1:
The patent changes the molecular weight and chemical structure parameters of the binder materials to reduce their plasticizing effect. By selecting high molecular weight polymers such as polyether block amides or polyamides with rigid backbone structures, the binders provide reinforcement rather than plasticization, maintaining tensile properties while enabling reduced filler loading levels.
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 achieves balanced mechanical strength, elasticity, and chemical resistance at high temperatures, comparable to perfluoroelastomers, with improved fluid compatibility and reduced filler loading, making it suitable for downhole applications.
Implementation Method 1
a crosslinked product of a polyarylene... and a mesoporous silicate... wherein the mesoporous silicate provides reinforcement and bonding to the polymer matrix
Implementation Method 2
a polymer component comprising a crosslinked product of a polyarylene... a crosslinked product of a polyphenylene sulfide and a polyphenylsulfone
Implementation Method 3
a mesoporous silicate having an average pore size of about 5 nanometers to about 50 nanometers
Data Source
AI summary
A composition contains a polymer component comprising a crosslinked product of a polyarylene, a crosslinked product of a substituted polyphenylene, a crosslinked product of a polyphenylene sulfide and a polyphenylsulfone, or a combination comprising at least one of the foregoing; and a mesoporous silicate having an average pore size of about 5 nanometers to about 50 nanometers. The composition has high-temperature elastomeric properties and excellent mechanical strength. The compositions are useful in oil and gas downhole applications. Methods for the manufacture of the composition and articles comprising the composition are also disclosed.