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Dissolvable Metal-Polymer Composite Parts

IP.com Disclosure Number: IPCOM000241271D
Publication Date: 2015-Apr-10
Document File: 1 page(s) / 14K

Publishing Venue

The IP.com Prior Art Database

Abstract

This invention arises from the development of dissolvable thermosets. The idea of the invention is to make a reinforced part using both dissolvable metal and dissolvable thermoset to allow the manufacture of a part from a high-strength composite material that completely dissolves away when stimulated with selective acidic solutions. This opens up possibilities for the development of several downhole tools such as a perforating gun that can be dissolved away without a direct intervention after their primary job is completed. Two different types of composites can be made with this system. The first type of composite encloses the thermoset body around a scaffold or skeleton. The skeleton will add strength to the system that will counter the problems that are common to polymers at elevated temperature, such as sag or creep. The second type of composite is the thermoset matrix reinforced with either shavings from the manufacture of dissolvable parts or unforged dissolvable powder. First a billet is machined into long thin pieces that are similar to an ice-cream stick, for example. Next the sticks are laid out in a scaffold pattern and welded together. The scaffold is placed in a mold and then dissolvable thermoset is molded around the scaffold so that the scaffold is internal to the part. Lastly, the thermoset is machined into its final form, if required. The scaffold can be prepared using additive manufacturing or 3D printing. The metal parts could also be screwed together. The thermosets could be formed in multiple parts and assembled on the scaffold. The scaffold could be affixed to the outside of the polymer part. Cross members of the scaffold could be used to restrain the polymer. A direct waste created during manufacturing of the frac balls is shavings of this valuable metal. Here, we propose that these shavings be used as-is or with minimal further processing as reinforcement materials for dissolvable thermosets. This will increase the mechanical strength and toughness of the thermoset. Alternatively, unforged powder or pure magnesium powder could be used instead of the shavings. The dissolvable thermosets could include a dissolvable epoxy, a dissolvable PHT [poly(hexhydrotriazine)] or a combination of both. The dissolvable epoxy can be dissolved away in dilute organic acids such as acetic acid or sulfamic acid. PHT can be dissolved away in dilute hydrochloric acid. Both fluids promote dissolution of dissolvable metal.

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Dissolvable Metal-Polymer Composite Parts

This invention arises from the development of dissolvable thermosets.  The idea of the invention is to make a reinforced part using both dissolvable metal and dissolvable thermoset to allow the manufacture of a part from a high-strength composite material that completely dissolves away when stimulated with selective acidic solutions.  This opens up possibilities for the development of several downhole tools such as a perforating gun that can be dissolved away without a direct intervention after their primary job is completed.  Two different types of composites can be made with this system.  The first type of composite encloses the thermoset body around a scaffold or skeleton.  The skeleton will add strength to the system that will counter the problems that are common to polymers at elevated temperature, such as sag or creep.  The second type of composite is the thermoset matrix reinforced with either shavings from the manufacture of dissolvable parts or unforged dissolvable powder.

First a billet is machined into long thin pieces that are similar to an ice-cream stick, for example.  Next the sticks are laid out in a scaffold pattern and welded together.  The scaffold is placed in a mold and then dissolvable thermoset is molded around the scaffold so that the scaffold is internal to the part.  Lastly, the thermoset is machined into its final form, if required.  The scaffold can be prepared using additive manufacturing or 3D...