Disintegratable polymer composites for downhole tools

Patent metadata

Field	Value
Publication number	US-2016369083-A1
Application number	US-201615149237-A
Country	US
Kind code	A1
Filing date	May 9, 2016
Priority date	Jun 16, 2015
Publication date	Dec 22, 2016
Grant date	—

Abstract

A disintegrable polymer composite comprises: a polymer component comprising one or more of the following: a cured cyanate ester; a crosslinked unsaturated polyester; or a crosslinked vinyl ester resin; and dissolvable glass comprising about 55 to about 80 wt. % of SiO 2 , 0 to about 35 wt. % of Na 2 O, 0 to about 35 wt. % of K 2 O, 0 to about 20 wt. % of CaO, 0 to about 10 wt. % of MgO, provided that the sum of the weights of Na 2 O and K 2 O is about 20 wt. % to about 40 wt. %, wherein each weight percent is based on the total weight of the dissolvable glass.

First claim

What is claimed is:

1 . A disintegrable polymer composite comprising:
a polymer component comprising one or more of the following: a cured cyanate ester; a crosslinked unsaturated polyester; or a crosslinked vinyl ester resin and dissolvable glass comprising about 55 to about 80 wt. % of SiO 2 , 0 to about 35 wt. % of Na 2 O, 0 to about 35 wt. % of K 2 O, 0 to about 20 wt. % of CaO, 0 to about 10 wt. % of MgO, provided that the sum of the weights of Na 2 O and K 2 O is about 20 wt. % to about 40 wt. %, wherein each weight percent is based on the total weight of the dissolvable glass.

2 . The disintegrable polymer composite of claim 1 , wherein the weight ratio of the polymer component relative to the dissolvable glass is about 10:1 to about 1:2.

3 . The disintegrable polymer composite of claim 1 , wherein the dissolvable glass comprises one or more of the following: continuous glass fiber; chopped glass fiber; a glass fabric; a glass fiber mat; a glass fiber sheet; a glass fiber braid; a glass fiber roving; a glass fiber prepreg product; a glass powder; glass beads; or glass flakes.

4 . The disintegrable polymer composite of claim 1 , wherein the dissolvable glass comprises glass fiber.

5 . The disintegrable polymer composite of claim 4 , wherein the dissolvable glass fiber has an average diameter of about 5 microns to about 500 microns.

6 . The disintegrable polymer composite of claim 4 , wherein the dissolvable glass comprises continuous glass fiber.

7 . The disintegrable polymer composite of claim 1 , wherein the dissolvable glass comprises one or more of sodium silicate or potassium silicate.

8 . The disintegrable polymer composite of claim 1 , wherein the glass is sodium silicate of formula Na 2 O·SiO 2 , wherein the weight ratio of SiO 2 relative to Na 2 O is about 3.22:1 to about 1:1.

9 . The disintegrable polymer composite of claim 1 , wherein the polymer component comprises a cured cyanate ester.

10 . The disintegrable polymer composite of claim 9 , wherein at least 70 percent of the cyanate functional groups are cyclotrimerized.

11 . The disintegrable polymer composite of claim 9 , wherein the cured cyanate ester is derived from one or more of the following: resorcinol; p,p′-dihydroxydiphenyl; o,p′-dihydroxydiplienyl methane; 2,2-bis(4-hydroxyphenyl)propane (bisphenol A); tetramethylbisphenol F; hexafluorobisphenol A; bisphenol E; bisphenol M; dicyclopentadienyl bisphenol; o,p′-dihydroxydiphenyl methane; p,p′-dihydroxydiphenyl propane; p,p′-dihydroxydiphenyl sulfone; p,p′-dihydroxydiphenyl sulfide; p,p′-dihydroxydiphenyl oxide; 4,4′-methylenebis(2,6-dimethyl phenol); p,p′,p″-tri-hydroxy triphenyl ethane; dihydroxynaphthalene; or a novolac polymer containing more than two phenol moieties per moleculeor.

12 . The disintegrable polymer composite of claim 1 , wherein the polymer component comprises a crosslinked unsaturated polyester.

13 . The disintegrable polymer composite of claim 1 , wherein the polymer component comprises a crosslinked vinyl ester.

14 . The disintegrable polymer composite of claim 1 , wherein the composite further comprises an additive comprising one or more of the following: CaO; MgO; Ca(OH) 2 ; Mg(OH) 2 ; Mg; Zn; a formate of sodium or potassium; an octoate of Zn or Mn or Cu or Co; a naphthenate of Zn or Mn or Cu or Co; aramid fibers; nylon fibers; cellulosic biodegradable fibers; a water soluble or biodegradable polymer different from the polymer component.

15 . An article comprising a polymer composite of claim 1 .

16 . The article of claim 15 , wherein the article is a pumpable downhole tool comprising a plug, a direct connect plug, a bridge plug, a wiper plug, a frac plug, a component of a frac plug, a drill in sand control beaded screen plug, an inflow control device plug, a polymeric plug, a disappearing wiper plug, a cementing plug, a ball, a diverter ball, a shifting and setting ball, a swabbing element protector, a buoyant recorder, a pumpable collet, a float shoe, or a dart.

17 . The article of claim 15 , wherein the article is downhole tool that inhibits flow comprising a seal, a high pressure beaded frac screen plug, a screen basepipe plug, a coating for a balls and a seat, a compression packing element, an expandable packing element, an O-ring, a bonded seal, a bullet seal, a sub-surface safety valve seal, a sub-surface safety valve flapper seal, a dynamic seal, a V-ring, a backup ring, a drill bit seal, a liner port plug, an atmospheric disc, an atmospheric chamber disc, a debris barrier, a drill in stim liner plug, an inflow control device plug, a flapper, a seat, a ball seat, a direct connect disk, a drill-in linear disk, a gas lift valve plug, a fluid loss control flapper, an electric submersible pump seal, a shear out plug, a flapper valve, a gaslift valve, or a sleeve.

18 . A method to disintegrate an article of claim 15 , the method comprising:
exposing the article to an aqueous fluid at a temperature of about 25° C. to about 300° C.

19 . The method of claim 18 , wherein the article is exposed to the aqueous fluid at a pressure of about 100 psi to about 15,000 psi.

20 . The method of claim 18 , wherein the aqueous fluid is water or brine or an alkaline solution of one or more of the following: Na; K; Ca; Mg; Li; or Ce.

Assignees

• Khatiwada Suman
• Yuan Yusheng
• Sadana Anil K
• Baker Hughes Inc

Inventors

• Khatiwada Suman
• Yuan Yusheng
• Sadana Anil K

Classifications

• C08K7/14 Primary

  Glass · CPC title

• C08K7/02

  Fibres or whiskers · CPC title

• C09K8/12

  containing synthetic organic macromolecular compounds or their precursors · CPC title

• C08G63/91

  Polymers modified by chemical after-treatment · CPC title

• C08L67/00

  Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain (of polyester-amides C08L77/12; of polyester-imides C08L79/08); Compositions of derivatives of such polymers · CPC title