Shape Memory Material with Core-Shell Nanoparticles for Thermal Retention

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Solution Overview

Problem

Conformable devices used in wellbores, such as packers and sand screens, face challenges in maintaining their expanded shape after the external heat supply is stopped, as the temperature in the wellbore often falls below the glass transition temperature of shape memory materials, causing them to revert to a compressed state.

Innovation Solution

Incorporating heat transfer nanoparticles with a core and shell structure into shape memory materials, where the core melts below the glass transition temperature of the material, allowing stored thermal energy to be released and maintaining the expanded shape of conformable devices even after the heat supply is stopped.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If shape memory materials are heated by supplied heated fluid, then the conformable device expands to its desired shape, but when the heated fluid supply is stopped, the material temperature falls below glass transition temperature and the expand ceases

Engineering Contradiction:

Improveduration of expanded shape retentionVSAvoidtemperature maintenance above glass transition temperature

Core Design Contradiction:

Duration of action of moving objectVSTemperature

Solution Approach 1:

The patent incorporates heat transfer nanoparticles with melting points below the glass transition temperature of the shape memory material. These nanoparticles are pre-integrated into the material structure and automatically melt when exposed to heated fluid, releasing stored thermal energy to maintain the material temperature above its glass transition temperature even after the external heated fluid supply is stopped. This preliminary preparation of thermal energy storage enables sustained expansion without continuous external heating.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes the phase transition (melting) of heat transfer nanoparticles to store and release thermal energy. The nanoparticles are designed with melting points below the glass transition temperature of the shape memory material. When heated fluid is supplied, the nanoparticles melt and store thermal energy. When the external heat supply is stopped, the nanoparticles solidify and release the stored heat, maintaining the material temperature above its glass transition temperature and ensuring continued expansion.

Inventive Principle:

Principle #36Phase transitions

2Duration of action of moving object

If heat transfer nanoparticles are added to shape memory material, then stored thermal energy is released to maintain expanded shape, but the device complexity increases

Engineering Contradiction:

Improveduration of expanded shape retentionVSAvoidmaterial composition complexity

Core Design Contradiction:

Duration of action of moving objectVSDevice complexity

Solution Approach 1:

The patent creates a composite material system by incorporating heat transfer nanoparticles into the shape memory material matrix. This composite structure integrates the thermal energy storage functionality of the nanoparticles with the shape memory properties of the base material. The nanoparticles serve as embedded thermal energy reservoirs within the material structure, enabling the composite to maintain its expanded shape longer without requiring separate external heating systems or complex control mechanisms.

Inventive Principle:

Principle #40Composite materials

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

Ensures that conformable devices retain their expanded shape for a longer period by utilizing stored thermal energy from the nanoparticles, enhancing deployment efficiency and stability in downhole environments.

Implementation Method 1

heat transfer nanoparticles that store thermal energy when external heat energy is supplied to such materials and transfer such stored heat energy to the shape memory material after the external heat energy supply has been stopped

Methodology Applied

Scientific EffectThermal energy storage: Thermal Energy Storage

Implementation Method 2

heat transfer nanoparticles... transfer such stored heat energy to the shape memory material

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

the core has a melting point below the glass transition temperature of the base shape memory material and the melting point of the shell

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 4

A shape memory material has a glass transition temperature and when such a material is heated to or above such temperature, it expands

Methodology Applied

Scientific EffectShape memory effect: Shape Memory Polymer

Data Source

PatentUS9228420B2Conformable materials containing heat transfer nanoparticles and devices made using same

Publication Date: 2016.01.05 BAKER HUGHES CO

AI summary

In one aspect, a method of forming a shape conforming material is disclosed that in one non-limiting embodiment may include: providing a base shape memory material having a glass transition temperature; and adding a selected amount of heat transfer nanoparticles to the base shape conforming material to provide the shape conforming material. In one aspect, the heat transfer nanoparticles include a core and a shell, wherein the core has a melting point below the glass transition temperature of the base shape memory material and the melting point of the shell.