Downhole Setting Tool Impact Dampening with Polyurethane Foam
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current setting tools for subterranean wells require lengthy assemblies and use hydraulic fluids to dampen shock forces, which complicates operations in harsh environments and increases tool length, making them difficult to deploy in deviated or horizontal wells.
Innovation Solution
The introduction of a setting tool with impact-resistant materials, such as polyurethane energy-absorbing materials and dilatant non-Newtonian fluids, which absorb energy without hydraulic fluids, reducing tool length and improving assembly efficiency by compressing at a constant rate to dissipate shock loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic fluids are used to dampen shock forces in setting tools, then shock dampening effectiveness is improved, but tool length increases and assembly complexity increases
Solution Approach 1:
The patent removes the hydraulic fluid damping system from the setting tool, extracting the problematic component that caused length and complexity issues. Instead, it uses solid impact-resistant materials (polyurethane and dilatant non-Newtonian fluid in a semi-solid state) that provide shock dampening without requiring hydraulic reservoirs, pumps, or complex fluid management systems, thereby reducing tool length while maintaining reliability
Solution Approach 2:
The patent changes the physical state parameter of the damping medium from liquid (hydraulic fluid) to semi-solid (dilatant non-Newtonian fluid and polyurethane material). This parameter change allows the material to provide effective shock dampening in a compact form factor, reducing tool length while maintaining or improving dampening effectiveness through the shear-thickening properties of the dilatant material
2Reliability
If hydraulic fluids are used to dampen shock forces, then shock dampening is improved, but device complexity increases
Solution Approach 1:
The patent extracts the complex hydraulic system components (reservoirs, pumps, valves, fluid passages) and replaces them with simple solid or semi-solid impact-resistant materials. This dramatically reduces assembly complexity while maintaining shock dampening effectiveness, as the solid materials require no assembly beyond placement into the tool structure
Solution Approach 2:
The patent uses simple, easily replaceable solid impact-resistant materials (polyurethane and dilatant non-Newtonian fluid) that can be easily installed and replaced without complex assembly procedures. These materials are simpler and more straightforward than hydraulic systems, reducing both assembly complexity and maintenance requirements
3Ease of manufacture
If standard steel pipe setting tools are used, then manufacturing simplicity is improved, but shock force dampening capability deteriorates
Solution Approach 1:
The patent uses composite materials (polyurethane and dilatant non-Newtonian fluid) that combine the shock-absorbing properties of polyurethane with the shear-thickening characteristics of dilatant materials. These composite materials provide superior shock force dampening capability compared to standard steel pipe, while still being manufacturable through standard industrial processes for forming and assembling the tool components
4Length of moving object
If tool length is reduced for deviated well deployment, then deployability in challenging geometries is improved, but shock dampening capability may deteriorate
Solution Approach 1:
The patent changes the physical state and density parameters of the damping medium to achieve high shock dampening effectiveness in a compact volume. The dilatant non-Newtonian fluid and polyurethane composite provide high energy absorption per unit volume, enabling effective shock dampening in a shorter tool length that can be deployed in deviated and horizontal wells
Solution Approach 2:
The use of composite materials with high energy-absorption characteristics allows the patent to achieve effective shock dampening in a compact form factor. The combination of polyurethane and dilatant non-Newtonian fluid provides superior energy absorption per unit length, enabling reduced tool length while maintaining or improving shock dampening capability
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
This solution reduces tool length, enhances operational reliability, and simplifies field assembly by effectively dampening shock forces without hydraulic fluids, allowing for more efficient deployment in challenging well geometries.
Implementation Method 1
dilatant non-Newtonian fluids, which absorb energy without hydraulic fluids
Implementation Method 2
dilatant non-Newtonian fluids, which absorb energy without hydraulic fluids
Implementation Method 3
polyurethane energy-absorbing materials, which absorb energy without hydraulic fluids, reducing tool length and improving assembly efficiency by compressing at a constant rate to dissipate shock loads
Data Source
AI summary
A method and apparatus for using a plurality of impact dampening discs composed of a closed cell polyurethane foam composite with polyborodimethylsiloxane as a dilatant non-Newtonian fluid dispersed through a foam matrix in a downhole setting tool to absorb the energy released during setting operations.