Wellbore Tool Coating with Patterned Mechanical Interlocking

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Solution Overview

Problem

Wellbore tools face issues with formation cuttings adhering to their surfaces due to mechanical and chemical bonding, leading to balling and reduced drilling efficiency, especially in ductile formations, and are prone to erosion and corrosion from harsh downhole conditions.

Innovation Solution

A method of forming a coating on wellbore tools with a pattern of features that have varying widths at different elevations, where the coating material is applied using techniques like evaporation, sputtering, or chemical vapor deposition, to interlock with the tool surface and prevent separation, without the need for an adhesive.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a coating is applied to prevent formation cuttings adhesion, then the resistance to erosion and corrosion is improved, but the coating may separate from the tool surface

Engineering Contradiction:

Improvecoating adhesionVSAvoidcoating separation resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies preliminary action by forming a pattern of features on the tool surface before applying the coating. This pattern creates mechanical interlocking structures that prevent coating separation, addressing the issue of coating adhesion without requiring adhesives.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses composite materials by combining the coating material with the tool substrate through mechanical interlocking. The patterned features create a composite structure where the coating and substrate are physically integrated, enhancing both adhesion and separation resistance.

Inventive Principle:

Principle #40Composite materials

2Productivity

If formation cuttings adhere to tool surfaces through mechanical and chemical bonding, then balling occurs reducing drilling efficiency, but applying conventional coatings may not prevent adhesion

Engineering Contradiction:

Improvedrilling efficiencyVSAvoidformation cuttings adhesion

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by pre-forming a pattern of features on the tool surface before coating application. This pattern creates mechanical interlocking structures that enhance coating adhesion and prevent formation cuttings from adhering to the tool surface, thereby reducing balling and maintaining drilling efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies local quality by creating a pattern of features with specific geometries (varying widths at different elevations) that are optimized for mechanical interlocking. This localized structural modification enhances the coating's ability to resist formation cuttings adhesion at critical areas without requiring complete surface modification.

Inventive Principle:

Principle #3Local quality

3Duration of action of stationary object

If a coating is applied to protect against erosion and corrosion, then tool longevity is improved, but the coating application process becomes more complex

Engineering Contradiction:

Improvetool longevityVSAvoidcoating application process

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The patent applies the taking out principle by eliminating the need for adhesives in the coating application process. The pattern of features provides inherent mechanical interlocking that secures the coating without requiring additional adhesive materials or application steps, thereby simplifying the overall process while maintaining tool longevity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent applies preliminary action by forming the pattern of features on the tool surface before coating application. This pre-formed pattern enables direct coating application without requiring subsequent adhesive application steps, reducing process complexity while ensuring secure coating attachment for enhanced tool longevity.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If the coating material is applied with varying widths at different elevations, then interlocking with the tool surface is enhanced, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvecoating interlockingVSAvoidfeature width control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating features with varying widths at different elevations, where each region of the pattern has optimized dimensions for mechanical interlocking. This localized geometric variation enhances coating interlocking while allowing manufacturing processes to focus precision on critical interlocking regions rather than requiring uniform precision across the entire surface.

Inventive Principle:

Principle #3Local quality

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 coating effectively reduces the adhesion of formation cuttings and enhances the tools' resistance to erosion and corrosion, improving drilling efficiency and tool longevity.

Implementation Method 1

applying the coating material over the pattern of features by at least one of evaporation, sputtering, chemical vapor deposition, electroplating, spin coating, spray coating, blanket coating, and dip coating

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

Methodology Applied

Scientific EffectSputtering: Sputtering

Implementation Method 3

Methodology Applied

Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Implementation Method 4

Methodology Applied

Scientific EffectElectroplating: Electroplating

Implementation Method 5

The features of the pattern may serve to mechanically interlock the coating on the surface of the body

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Data Source

PatentEP2737155B1Methods of coating wellbore tools and components having such coatings

Publication Date: 2018.01.17 BAKER HUGHES CO

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AI summary

A method for forming a coating upon a wellbore tool includes forming a pattern of features supported by a body and forming a coating over the pattern of features. Forming the pattern of features includes forming a first feature and forming a second feature spaced from the first feature by a first width at a first elevation and by a second width at a second elevation, the second width being different than the first width, and the first elevation being further from an interior region of the body than the second elevation. Also disclosed is a wellbore tool comprising a coating covering a pattern of features and a method of utilizing a wellbore tool in a subterranean formation, the method including forming a pattern of features, forming a coating over the pattern, and disposing the wellbore tool in a borehole.