Thermally Triggered Polymeric Screen for Irregular Boreholes

Solution Overview

Problem

Conventional sand screens, particularly expandable metallic screens, face limitations in conforming to borehole irregularities and resisting collapse, with reduced expansion ratios and pressure resistance, leading to potential wellbore damage and reduced production efficiency.

Innovation Solution

A porous structural thermoset material that can be compressed for deployment and expanded downhole to conform to wellbore irregularities, featuring a selected glass transition temperature for thermal expansion, high mechanical strength, and adjustable permeability, allowing for effective sand control and formation support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If expandable metallic screens are used to reduce annulus space, then the screen can be installed in smaller boreholes, but the expansion ratio is limited and the screen cannot adequately conform to borehole irregularities

Engineering Contradiction:

Improveannulus spaceVSAvoidconformance to borehole irregularities

Core Design Contradiction:

Volume of moving objectVSAdaptability or versatility

Solution Approach 1:

The patent employs a polymeric screen material that undergoes parameter change through thermal expansion. The screen transitions from a compressed state during installation to an expanded state after deployment, changing its dimensional parameters to achieve both space reduction and conformability to borehole irregularities.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite polymeric materials with specific mechanical properties that enable both high expansion capability and structural integrity. The composite nature of the material allows the screen to expand significantly while maintaining strength to resist external pressures and conform to irregular borehole shapes.

Inventive Principle:

Principle #40Composite materials

2Volume of moving object

If expandable metallic screens are used to reduce annulus space, then the screen can be installed in smaller boreholes, but the ability to resist borehole collapse is reduced

Engineering Contradiction:

Improveannulus spaceVSAvoidresistance to external pressure

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The patent utilizes composite polymeric materials that provide both high expansion capability and exceptional strength to resist external pressures. The material composition is engineered to maintain structural integrity after expansion, enabling the screen to withstand borehole collapse pressures while achieving the desired space reduction.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The screen structure incorporates localized reinforcement and varying wall thicknesses to optimize strength distribution. Areas experiencing higher external pressures have enhanced structural properties, while other regions maintain flexibility for conforming to borehole irregularities.

Inventive Principle:

Principle #3Local quality

3Strength

If conventional metallic screens are used, then the screen can resist high external pressure, but the screen cannot expand to conform to borehole irregularities

Engineering Contradiction:

Improveresistance to external pressureVSAvoidconformance to borehole irregularities

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent employs a polymeric screen material that undergoes parameter change through thermal expansion. The screen transitions from a compressed state during installation to an expanded state after deployment, changing its dimensional parameters to achieve both space reduction and conformability to borehole irregularities.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If the screen is expanded downhole to conform to wellbore irregularities, then the conformance is improved, but the external pressure resistance is reduced due to plastic deformation

Engineering Contradiction:

Improveconformance to wellbore irregularitiesVSAvoidresistance to external pressure

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent employs a polymeric screen material that undergoes parameter change through thermal expansion. The screen transitions from a compressed state during installation to an expanded state after deployment, changing its dimensional parameters to achieve both space reduction and conformability to borehole irregularities.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite polymeric materials with specific mechanical properties that enable both high expansion capability and structural integrity. The composite nature of the material allows the screen to expand significantly while maintaining strength to resist external pressures and conform to irregular borehole shapes.

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

The thermoset material provides enhanced conformance to wellbore shapes, supports the formation during production, and maintains permeability, reducing the risk of collapse while effectively filtering out sand and ensuring sustained production.

Implementation Method 1

exposed to a temperature equal to or above the glass transition temperature of the porous structural thermoset material

Methodology Applied

Scientific EffectGlass transition temperature: Phase Change

Implementation Method 2

the sand screen to expand and directly contact

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20250327381A1Thermally triggered conformable polymeric screen

Publication Date: 2025.10.23 SCHLUMBERGER TECH CORP

AI summary

A porous structural thermoset media is described herein. A method includes generating a porous structural thermoset material comprising a glass transition temperature (Tg) that is greater than is greater than or equal to about 100° C. and a first diameter. The method also includes compressing the porous structural thermoset material to generate a compressed porous structural thermoset material comprising a second diameter that is smaller than the first diameter.