Shape-Memory Polymer Foam Deployment Control
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Solution Overview
Problem
Existing wellbore devices face challenges in precise installation and deployment of shape-memory polymer foam-based conformable sand screens and other downhole tools, requiring effective prevention of premature deployment and reliable control of deployment rate and extent.
Innovation Solution
Incorporating a deployment fluid that lowers the glass transition temperature (Tg) and rigidity of polymeric shape-memory materials, allowing for controlled geometric alteration and recovery to the original shape upon temperature change, with optional removal of the fluid to restore original properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If shape-memory polymer foam is used for wellbore devices, then the device can return to its original geometric shape when exposed to temperature change, but premature deployment during installation and run-in becomes a risk
Solution Approach 1:
A deployment fluid is introduced as an intermediary substance between the shape-memory polymer foam and the environment. This fluid modifies the polymer's glass transition temperature (Tg) and rigidity, allowing the device to remain in its altered geometric state during installation and run-in, and only deploy when the fluid is removed or its concentration is reduced below a threshold level.
Solution Approach 2:
The deployment fluid changes the physical parameters of the shape-memory polymer foam by lowering its glass transition temperature and rigidity. This parameter modification enables precise control over when and how the device deploys, resolving the contradiction between shape recovery capability and deployment control reliability.
2Reliability
If the polymeric shape-memory material is contacted by deployment fluid to lower Tg and rigidity, then deployment control is improved, but the device complexity increases
Solution Approach 1:
The wellbore device utilizes the natural temperature and fluid conditions of the wellbore environment to trigger deployment. The deployment fluid is already present in the wellbore, and the device automatically responds to changes in fluid concentration or temperature, eliminating the need for complex external control systems or additional deployment mechanisms.
3Loss of time
If deployment fluid is used to enable geometric alteration, then the deployment timing can be controlled, but the loss of substance occurs when fluid is removed from contact
Solution Approach 1:
The deployment fluid is discarded into the wellbore environment after serving its purpose of controlling device deployment. The fluid's removal or dilution in the wellbore naturally triggers the device to return to its original geometric shape, completing the deployment process without requiring recovery or recycling of the fluid.
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
Enables precise and flexible deployment of wellbore devices, ensuring flawless installation and operation by controlling the deployment timing and extent, and restoring original Tg and rigidity after use.
Implementation Method 1
a deployment fluid contacting the polymeric shape-memory material in an amount effective to have an effect selected from the group consisting of lowering the Tg and/or decreasing the rigidity
Implementation Method 2
Shape Memory Materials are smart materials that have the ability to return from a deformed or compressed state (temporary shape) to their original (permanent) shape induced by an external stimulus or trigger (e.g. temperature change)
Implementation Method 3
Viscoelastic materials such as shape-memory polymers typically exist in two distinct states. They exhibit the properties of a glass (high modulus) and those of a rubber (low modulus). By scanning the temperature during a DMA experiment this change of state, the transition from the glass state to the rubber state, may be characterized
Data Source
AI summary
Actuation and control of the deployment of a polymeric memory-shape material on a wellbore device on a downhole tool may be accomplished by treating a compacted or compressed polymeric memory-shape material with an optional deployment fluid to lower its Tg and/or decrease its rigidity, thereby softening the polymeric shape-memory material at a given temperature and triggering its expansion or recovery at a lower temperature. Recovering the polymeric shape-memory material may occur by its being exposed to a particular temperature range. Alternatively, the deployment of the compacted or compressed polymeric memory-shape material may be prevented or inhibited by shielding the material with an environment of a fluid that does not substantially lower its Tg, decrease its rigidity or both, and then subsequently contacting the material with a deployment fluid. The deployment fluid may be removed during the method.