Disintegratable carbon composites, methods of manufacture, and uses thereof

Patent metadata

Field	Value
Publication number	US-10233376-B2
Application number	US-201615273843-A
Country	US
Kind code	B2
Filing date	Sep 23, 2016
Priority date	Sep 23, 2016
Publication date	Mar 19, 2019
Grant date	Mar 19, 2019

Abstract

A carbon composite is disclosed, including a plurality of carbon grains, wherein each of the plurality of carbon grains includes a plurality of pores, and a binder disposed between the plurality of carbon grains to bond the plurality of carbon grains, wherein the binder is a disintegrable binder.

First claim

The invention claimed is:

1. A carbon composite comprising:
a plurality of carbon grains, wherein each of the plurality of carbon grains is a form of carbon and includes a plurality of pores to allow for elasticity of the carbon grains; and
a binder disposed between the plurality of carbon grains to bond the plurality of carbon grains, wherein the binder is a disintegrable binder.

2. The carbon composite of claim 1 , wherein the carbon comprises amorphous carbon, natural graphite, carbon fiber, or a combination comprising at least one of the foregoing material.

3. The carbon composite of claim 1 , wherein the plurality of carbon grains are a plurality of graphite grains.

4. The carbon composite of claim 3 , wherein each of the plurality of graphite grains are between 5 to 500 micrometers in diameter.

5. The carbon composite of claim 3 , wherein each of the plurality of graphite grains between are 0.01 to 500 micrometers in thickness.

6. The carbon composite of claim 1 , wherein the binder is an ester polymer.

7. The carbon composite of claim 1 , wherein the binder is an amide polymer.

8. The carbon composite of claim 1 , wherein the binder is an ether polymer.

9. The carbon composite of claim 1 , wherein the binder is polyurethane.

10. The carbon composite of claim 1 , wherein the binder is between 10 to 90 percent of the carbon composite by volume.

11. The carbon composite of claim 1 , wherein the binder is a magnesium alloy with a nickel catalyst.

12. The carbon composite of claim 11 , wherein the binder is a controlled electrolytic metallic material.

13. The carbon composite of claim 12 , wherein the binder is at least one of a magnesium alloy, a magnesium silicon alloy, a magnesium aluminum alloy, a magnesium zinc alloy, a magnesium manganese alloy, a magnesium aluminum zinc alloy, a magnesium aluminum manganese alloy, a magnesium zinc zirconium alloy, and a magnesium rare earth element alloy.

14. The carbon composite of claim 11 , wherein the binder is a low melting point metal or a low melting point alloy.

15. The carbon composite of claim 14 , wherein the binder is at least one of bismuth, tin, and lead.

16. The carbon composite of claim 11 , wherein the binder further comprises a cathode catalyst element.

17. The carbon composite of claim 14 , wherein the cathode catalyst element is at least one of nickel, iron, copper, cobalt, zinc, aluminum and tungsten.

18. The carbon composite of claim 1 , wherein the binder comprises a brittle material.

19. The carbon composite of claim 18 , wherein the brittle material is between 5 to 100 percent of the binder.

20. The carbon composite of claim 18 , wherein the brittle material is Mg2Ni.

21. The carbon composite of claim 1 , wherein the carbon composite is an article.

22. The article of claim 21 , wherein the article comprises at least one of a ball, a plug, a seat, a compression packing element, an expanding packing element, an O-ring, a bonded seal, a bullet seal, a dynamic seal, a flapper seal, a V ring, a back up ring, a drill bit seal, a mud motor stator, a PCP stator, a ESP seal, and a ESP space out sub.

23. A downhole system, comprising:
a downhole element including a carbon composite, the carbon composite including:
a plurality of carbon grains, wherein each of the plurality of carbon grains is a form of carbon and includes a plurality of pores to allow for elasticity of the carbon grains; and
a binder disposed between the plurality of carbon grains to bond the plurality of carbon grains, wherein the binder is a disintegrable binder.

24. The downhole system of claim 23 , wherein the downhole element is at least one of a ball, a plug, a seat, a compression packing element, an expanding packing element, an O-ring, a bonded seal, a bullet seal, a dynamic seal, a flapper seal, a V ring, a back up ring, a drill bit seal, a mud motor stator, a PCP stator, a ESP seal, and a ESP space out sub.

25. The downhole system of claim 23 , wherein the plurality of carbon grains includes a plurality of graphite grains and the binder includes a magnesium alloy with a nickel catalyst.

Assignees

• Zhao Lei
• Xu Zhiyue
• Baker Hughes A Ge Co Llc

Inventors

• Zhao Lei
• Xu Zhiyue

Classifications

• E21B33/12

  Packers; Plugs (used for cementing E21B33/134, E21B33/16) · CPC title

• C22C38/06

  containing aluminium · CPC title

• C22C21/00

  Alloys based on aluminium · CPC title

• C09K8/665

  containing inorganic compounds (proppants C09K8/80) · CPC title

• C22C19/007

  with a light metal (alkali metal Li, Na, K, Rb, Cs; earth alkali metal Be, Mg, Ca, Sr, Ba, Al Ga, Ge, Ti) or B, Si, Zr, Hf, Sc, Y, lanthanides, actinides, as the next major constituent · CPC title