US20080224413A1 - Sealing material to metal bonding compositions and methods for bonding a sealing material to a metal surface - Google Patents
Sealing material to metal bonding compositions and methods for bonding a sealing material to a metal surface Download PDFInfo
- Publication number
- US20080224413A1 US20080224413A1 US11/724,367 US72436707A US2008224413A1 US 20080224413 A1 US20080224413 A1 US 20080224413A1 US 72436707 A US72436707 A US 72436707A US 2008224413 A1 US2008224413 A1 US 2008224413A1
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- US
- United States
- Prior art keywords
- sealing material
- downhole tool
- metal surface
- component
- plastic layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000003566 sealing material Substances 0.000 title claims abstract description 132
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 117
- 239000002184 metal Substances 0.000 title claims abstract description 117
- 238000000034 method Methods 0.000 title claims description 23
- 239000000203 mixture Substances 0.000 title 1
- 239000000463 material Substances 0.000 claims abstract description 102
- 229920003023 plastic Polymers 0.000 claims abstract description 64
- 239000004033 plastic Substances 0.000 claims abstract description 64
- 230000004913 activation Effects 0.000 claims abstract description 6
- 239000000376 reactant Substances 0.000 claims description 21
- 229910000765 intermetallic Inorganic materials 0.000 claims description 17
- 239000003832 thermite Substances 0.000 claims description 16
- 239000002245 particle Substances 0.000 claims description 15
- 150000001875 compounds Chemical class 0.000 claims description 8
- 238000007789 sealing Methods 0.000 claims description 8
- 230000008018 melting Effects 0.000 claims description 7
- 238000002844 melting Methods 0.000 claims description 7
- 229920001971 elastomer Polymers 0.000 claims description 5
- 229920000459 Nitrile rubber Polymers 0.000 claims description 4
- HQQADJVZYDDRJT-UHFFFAOYSA-N ethene;prop-1-ene Chemical group C=C.CC=C HQQADJVZYDDRJT-UHFFFAOYSA-N 0.000 claims description 4
- 239000005060 rubber Substances 0.000 claims description 4
- 229920002943 EPDM rubber Polymers 0.000 claims description 3
- 229920005549 butyl rubber Polymers 0.000 claims description 3
- 229920003211 cis-1,4-polyisoprene Polymers 0.000 claims description 3
- 229920001084 poly(chloroprene) Polymers 0.000 claims description 3
- 239000005077 polysulfide Substances 0.000 claims description 3
- 229920001021 polysulfide Polymers 0.000 claims description 3
- 150000008117 polysulfides Polymers 0.000 claims description 3
- 229920003225 polyurethane elastomer Polymers 0.000 claims description 3
- 229920002379 silicone rubber Polymers 0.000 claims description 3
- 239000004945 silicone rubber Substances 0.000 claims description 3
- 229920003048 styrene butadiene rubber Polymers 0.000 claims description 3
- 229920001897 terpolymer Polymers 0.000 claims description 3
- 229920002397 thermoplastic olefin Polymers 0.000 claims description 3
- 229920001774 Perfluoroether Polymers 0.000 claims description 2
- 230000000977 initiatory effect Effects 0.000 abstract description 5
- 238000006243 chemical reaction Methods 0.000 description 11
- 238000009826 distribution Methods 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- 239000012530 fluid Substances 0.000 description 5
- 230000003014 reinforcing effect Effects 0.000 description 4
- 239000012815 thermoplastic material Substances 0.000 description 4
- 239000004812 Fluorinated ethylene propylene Substances 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000007767 bonding agent Substances 0.000 description 3
- 229920009441 perflouroethylene propylene Polymers 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 229920001187 thermosetting polymer Polymers 0.000 description 3
- 230000015556 catabolic process Effects 0.000 description 2
- UUAGAQFQZIEFAH-UHFFFAOYSA-N chlorotrifluoroethylene Chemical group FC(F)=C(F)Cl UUAGAQFQZIEFAH-UHFFFAOYSA-N 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- -1 e.g. Inorganic materials 0.000 description 2
- 229920000840 ethylene tetrafluoroethylene copolymer Polymers 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- JKQOBWVOAYFWKG-UHFFFAOYSA-N molybdenum trioxide Chemical compound O=[Mo](=O)=O JKQOBWVOAYFWKG-UHFFFAOYSA-N 0.000 description 2
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229920007925 Ethylene chlorotrifluoroethylene (ECTFE) Polymers 0.000 description 1
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- 229910005887 NiSn Inorganic materials 0.000 description 1
- 229920006169 Perfluoroelastomer Polymers 0.000 description 1
- 239000004696 Poly ether ether ketone Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 238000005229 chemical vapour deposition Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000002706 hydrostatic effect Effects 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229920002530 polyetherether ketone Polymers 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
- E21B33/1208—Packers; Plugs characterised by the construction of the sealing or packing means
Definitions
- the invention is directed to materials and methods for bonding a sealing material to a metal surface of downhole tools, such as a packer having a sealing element and, in particular, materials and methods for bonding a sealing material to a metal surface of downhole tools that remain effective at temperatures greater than 400° F.
- Sealing materials are routinely bonded or adhered to a metal surface of downhole tools.
- the prior art tools used chemical bonding or adhesion components to secure the sealing material to the steel housing.
- These chemical compounds become less effective as the temperature increases, especially where the temperature increases above 400° F., such as those temperatures found in deep oil and gas well.
- Current technology limits the ability to bond a sealing material such as rubber to steel at such high temperatures.
- high temperature chemical adhesion compounds these compounds do not work effectively for sealing material-to-metal contact.
- the adhesion of the sealing material to the outer surface of the downhole tool is compromised and the sealing material is released from the outer surface of the downhole tool. Accordingly, the tool becomes inoperable or ineffective.
- the flowing fluids may dissolve or otherwise prevent the chemical compound from maintaining its bonding capabilities.
- the flowing fluids may force themselves, together with debris carried in the flowing fluids, between the interface of the sealing material with the metal surface of the downhole tool. Therefore, the flowing fluid, either alone or in combination with elevated temperatures within the well, can cause the bond of the sealing material to the metal surface to weaken, thereby causing the seal to leak and, thus, rendering the tool inoperable or ineffective.
- costs are increased for replacing and repairing, if possible, the damaged downhole tool having an insufficiently secured sealing material to metal wall surface of the downhole tool.
- the art has sought downhole tools having a sealing material secured to a metal wall surface of a downhole tool that: increase the life of the downhole tool by increasing the length of time the sealing material remains bonded to the metal wall surface of the downhole tools and, thus, decrease the costs associated with replacing and repairing the downhole tools; and provide more effective bonding of the sealing material at elevated temperatures.
- the downhole tools disclosed herein include a sealing material secured to a metal surface of the downhole tool through the use of an energetic material disposed between the sealing material and the metal surface and subsequently initiating the energetic material to bond the sealing material to the metal surface.
- the sealing material is bonded directly to the metal surface.
- the sealing material is first bonded to a plastic material, such as through the use of a high-temperature chemical bonding agent or the energetic material, and the plastic material is then bonded to the metal surface using the energetic material.
- a plastic material is first bonded to the metal surface using the energetic material and the sealing material is then bonded to the plastic.
- the sealing material is bonded to the plastic simultaneously with the plastic being bonded to the metal surface.
- the foregoing downhole tools having a sealing material secured to a metal wall surface of a downhole tool have the advantages of: increasing the life of the downhole tool by increasing the length of time the sealing material remains bonded to the metal wall surface of the downhole tools and, thus, decreasing the costs associated with replacing and repairing the downhole tools; and providing more effective bonding of the sealing material at elevated temperatures.
- the component comprises a metal surface, a sealing material, and an energetic material, wherein the energetic material bonds the sealing material to the metal surface through activation, e.g., combustion or chemical reaction, of the energetic material.
- a further feature of the downhole tool component is that the energetic material may comprise a thermite.
- the thermite may comprise sub-micron thermite particles.
- the energetic material may comprise at least one reactant for forming an intermetallic compound.
- at least one of the at least one reactants for forming the intermetallic compound may comprise sub-micron reactant compound particles.
- a further feature of the downhole tool component is that the sealing material may be selected from the group consisting of styrene-butadiene copolymer, neoprene, nitrile rubber, butyl rubber, polysulfide rubber, cis-1,4-polyisoprene, ethylene-propylene terpolymers, EPDM rubber, silicone rubber, polyurethane rubber, and thermoplastic polyolefin rubbers.
- the durometer hardness of the sealing material may be in the range from about 60 to 100 Shore A.
- the metal surface may be disposed on an outer surface of a housing of the downhole tool.
- the downhole tool may be a sealing device.
- the sealing device may be a packer.
- the sealing material may be bonded directly to the metal surface by the energetic material, and the energetic material may be capable of generating sufficient heat to cause the sealing material to at least partially melt and become bonded to the metal surface without an outer surface of the sealing material melting.
- the downhole tool component may further comprise a plastic layer disposed between the sealing material and the metal surface, the plastic layer being bonded directly to the metal surface by the energetic material.
- one or more of the foregoing advantages may also be achieved through the present method of bonding a sealing material to a metal surface of a component of a downhole tool.
- the method comprises the steps of: (a) disposing an energetic material between a sealing material and a metal surface of a component of a downhole tool; and (b) energizing the energetic material to create sufficient heat to cause the sealing material to be bonded to the metal surface of the component of the downhole tool.
- a further feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that wherein the sealing material may be first bonded to a plastic layer and the energetic material is disposed between the plastic layer and the metal surface of the component of the downhole tool prior to step (b).
- Another feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that the metal surface of the component of the downhole tool may be first bonded to a plastic layer by disposing the energetic material between the plastic layer and the metal surface of the component of the downhole tool; the energetic material may then be energized to bond the plastic layer to the metal surface of the component of the downhole tool; and the sealing material may then be bonded to the plastic layer.
- An additional feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that the plastic layer may be a perfluoroalkoxy material. Still another feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that the sealing material may be bonded to the plastic layer by disposing additional energetic material between the sealing material and the plastic layer and energizing the energetic material. A further feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that the energetic material may comprise a thermite.
- Another feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that the energetic material may comprise at least one reactant for forming an intermetallic compound.
- An additional feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that a bonding metal may be disposed on a bonding surface of the sealing material prior to step (b).
- FIG. 1 is a partial cross-sectional view of a packer showing a seal ring disposed on the outer surface of the downhole tool, the seal ring having a metal surface with a sealing material bonded thereto.
- FIG. 2 is partial cross-sectional top view of one specific embodiment of a seal ring of the downhole tool of FIG. 1 showing an energetic material disposed between a sealing material and a metal surface of the seal ring prior to bonding the sealing material to the metal surface.
- FIG. 3 is a partial cross-sectional top view of the seal ring shown in FIG. 2 after initiation of the energetic material and, thus, bonding of the sealing material to the metal surface.
- FIG. 4 is partial cross-sectional top view of another specific embodiment of a seal ring of the downhole tool of FIG. 1 showing a sealing material bonded to a plastic layer and an energetic material disposed between the plastic layer and a metal surface of the seal ring prior to bonding the plastic layer to the metal surface.
- FIG. 5 is a partial cross-sectional top view of the seal ring shown in FIG. 4 after initiation of the energetic material and, thus, bonding of the sealing material to the metal surface.
- FIG. 6 is partial cross-sectional top view of an additional specific embodiment of a seal ring of the downhole tool of FIG. 1 showing a sealing material bonded to a plastic layer and an energetic material disposed between the plastic layer and a metal surface, as well as between the plastic layer and the sealing material, of the seal ring prior to bonding the plastic layer to the metal surface.
- FIG. 7 is partial cross-sectional top view of an additional specific embodiment of a seal ring of the downhole tool of FIG. 1 showing a sealing material bonded to a metal layer and an energetic material disposed between the metal layer and a metal surface of the seal ring prior to bonding the sealing material to the metal surface.
- a downhole tool such as a packer 10
- a downhole tool such as a packer 10
- Housing 12 is generally cylindrical but may be any shape desired or necessary to form the downhole tool.
- An actuating member 14 is mounted to housing 12 for axial movement relative to housing 12 .
- actuating member 14 engages a lower end of seal ring 22 for pushing seal ring 22 upward on a stationary cam surface 16 of housing 12 to cause seal ring 22 to expand radially into the set position.
- Cam surface 16 is preferably conical.
- Actuating member 14 may be an annular collet that is radially expansible, or it could be other configurations.
- actuating member 14 is secured to a piston (not shown) supplied with hydraulic pressure for moving seal ring 22 relative to cam surface 16 .
- Tool 10 may be of a conventional design, and actuating member 14 may be moved by a variety of means other than hydraulic pressure, such as employing the weight of the running string (not shown) for tool 10 , hydrostatic wellbore pressure, wireline movement, or explosives.
- seal ring 22 is shown moving upward onto stationary cam surface 16 , the arrangement could be reversed, with seal ring 22 being moved downward. Further, seal ring 22 could be held axially stationary and cam surface 16 be moved relative to seal ring 22 .
- actuating member 14 may actually be held stationary while the running string and housing 12 move downward relative to seal ring 22 , pushing seal ring 22 farther onto conical cam surface 16 . Alternately, actuating member 14 may move upward relative to seal 22 .
- seal ring 22 and cam surface 16 move axially relative to each other to deform seal ring 22 radially outward to a larger diameter for engaging an inner wall surface of an outer tubular member (not shown) into which tool 10 is lowered.
- Outer tubular member may be a string of casing.
- tool 10 in this example also has a set of slips 20 that expand outward and frictionally grip the inner wall surface of the outer tubular member.
- seal ring 22 has an internal metal reinforcing element 23 , thus providing a metal surface.
- reinforcing element 23 is formed of a carbon steel.
- a sealing material 26 is bonded to the metal surface of reinforcing element 23 through the use of an energetic material (discussed in greater detail below).
- Sealing material 26 may be any material known to persons of ordinary skill in the art.
- sealing material 26 is a resilient, elastomeric or polymeric material of a commercially available type that will withstand high temperatures that occur in some wells.
- sealing material 26 may be a perfluoro elastomer, a styrene-butadiene copolymer,
- sealing material 26 is in the range from about 60 to 100 Shore A and more particularly from 85 to 95 Shore A. In one embodiment, the durometer hardness is about 90 Shore A.
- suitable sealing materials 26 include Teflon® (polytetrafluroethylene or fluorinated ethylene-propylene) and polyether ether ketone. Sealing material 26 also could be nitrile rubber. Further, sealing material 26 may be any other thermoset material, thermoplastic material, or vulcanized material, provided such sealing materials are resilient and capable of withstanding high temperatures, e.g., greater than 400° F.
- Energetic material 30 is any material that is capable of quickly generating and, thus, releasing large amounts of energy in a localized area such that any material contacting the energetic material is heated to a temperature sufficiently high to bond the material to a metal surface.
- Energetic materials include, but are not limited to, thermite materials and reactants for forming intermetallic compounds.
- the foregoing examples show aluminum as the metal for the reaction, persons of ordinary skill in the art will recognize that similar thermite reactions of other materials exist, e.g., tungsten, zirconium, copper, magnesium, and manganese.
- the oxide of the reaction may be any suitable and known oxide.
- the thermite material is made up of thermite particles having a sub-micron particle size distribution and, more preferably, a nanometer size distribution.
- the sub-micron sized thermite particles have a substantially lower activation energy requirement and react faster, usually more than an order of magnitude faster, than thermite particles having a micron or greater particle size distribution.
- Intermetallic compound reactions are known in the art. Briefly, intermetallic compound reactions involve two metal reactants reacting together to form a solid state intermetallic compound and which, in the process, release energy. Generally, intermetallic compound reactions can be characterized by the formula:
- both reactants for forming the intermetallic compounds are disposed together on the same surface. It is to be understood, however, that the reactants may initially be disposed on separate surfaces, e.g., one on the metal surface and the other on sealing material 26 , provided that all of the reactants necessary to form the intermetallic compound are placed in contact with each other, or in close proximity to each other, prior to activation of the reactants.
- At least one, and more preferably all, of the reactants for forming the intermetallic compounds is made up of reactant particles having a sub-micron particle size distribution and, more preferably, a nanometer size distribution.
- the sub-micron sized reactant particles have a substantially lower activation energy requirement and react faster, usually more than an order of magnitude faster, than reactant particles having a micron or greater particle size distribution.
- Both thermite materials and the reactants for forming the intermetallic compounds are available in powder or sheet form from NovaCentrix of Austin, Tex., Sigma-Aldrich of St. Louis, Mo., and Reactive Nanotechnologies, Inc. of Hunt Valley, Md.
- the powdered form at least one of the components typically has particles that are sub-micron to nano-scale range.
- the components are typically layered in sub-micron to nano-scale layers.
- sealing material 26 is bonded directly to metal surface 32 of reinforcing ring 22 by placing energetic material 30 between sealing material 26 and metal surface 32 as shown in FIG. 2 .
- Energetic material 30 is initiated or ignited through means known to persons of ordinary skill in the art. For example, an electric charge or radiant heat may be used to energize energetic material 30 , causing the energy releasing reaction to begin. The energy released by the energetic material is in the form of heat. Therefore, the temperature along metal surface 32 and bonding surface 34 of the sealing material 26 increases until sealing material 26 bonds to metal surface 32 ( FIG. 3 ).
- the bonding of the sealing material 26 may be achieved through localized melting (where sealing material 26 is formed of a meltable material such as a thermoplastic material) or thermal degradation (where sealing material 26 is non-meltable material such as a vulcanized, elastomeric, or thermoset material) of sealing material 26 or melting of metal surface 32 .
- energetic material 30 is a high temperature, fast burning or chemically reactive material such that energetic material 30 reacts or combusts in a short amount of time, yet releases a large amount of energy to create a high localized temperature.
- One advantage of heating sealing material 26 in this manner is that bonding surface 34 is heated quickly such that the heat dissipates before the entire sealing material 26 melts or undergoes thermal degradation.
- outer surface 38 of sealing material 26 maintains its integrity and resilience. Persons skilled in the art, without undue experimentation, can easily determine the optimum type and volume of energetic material 30 for use with the desired sealing material 26 or plastic layer 50 (discussed in greater detail below).
- layer 29 of metal can be deposited on bonding surface 34 of sealing material 26 to provide a metal to metal bonding through the use of energetic material 30 .
- a thin layer of metal (not shown) is deposited on bonding surface 34 through sputter or chemical vapor deposition processes known to persons of ordinary skill in the art.
- the metal being deposited on bonding surface 34 can be a common metal alloy or a material such as solder or brazing compound.
- Energetic material 30 is then disposed between metal surface 32 and sealing material 26 such that bonding surface 34 with the metal layer deposited thereon is in contact with energetic material 30 .
- Energetic material 30 can then be initiated or ignited, thereby releasing heat and causing metal surface 32 to bond to sealing material 26 through the interface of the metal deposited on bonding surface 34 of sealing material 26 .
- plastic layer 50 is disposed between sealing material 26 and metal surface 32 .
- Energetic material 30 is disposed between plastic layer 50 and metal surface 32 and, therefore, plastic layer 50 is bonded to metal surface 32 in the same manner as discussed above with respect to the embodiment shown in FIGS. 2-3 .
- Plastic layer 50 is preferably formed of a melt processable material.
- melt processable is used herein to mean a material that is capable of melting and shaping, but becomes thermally stable, i.e., not able to melt, as the downhole application temperature.
- the “melt processable” materials after bonding sealing material 26 to metal surface 32 do not re-melt when the tool 10 is disposed downhole.
- Such “melt processable” materials include thermoset materials as well as thermoplastic materials, provided the melting point, or melting temperature, of the thermoplastic materials is greater than the downhole wellbore temperature where tool 10 is to be operated.
- a preferred plastic layer 50 is formed of a perfluroalkoxy material (“PFA”).
- PFA perfluroalkoxy material
- Polyamidazole may also be used to form plastic layer 50 .
- Plastic layer may also be formed out of fluorinated ethylene propylene (FEP); Chlorotrifluorethylene (CTFE); Ethylenechlorotrifluoroethylene (ECTFE); Ethylenetetrafluoroethylene (ETFE); or Polyvinylidine fluoride (PVF 2 ). Regardless of the material or type of plastic layer 50 utilized, plastic layer 50 will always be different from sealing material 26 .
- FEP fluorinated ethylene propylene
- CTFE Chlorotrifluorethylene
- ECTFE Ethylenechlorotrifluoroethylene
- ETFE Ethylenetetrafluoroethylene
- PVF 2 Polyvinylidine fluoride
- sealing material 26 is bonded to plastic layer 50 by placing a second layer of energetic material 31 ( FIG. 6 ) between sealing material 26 and plastic layer 50 .
- Sealing material 26 is bonded to plastic layer 50 in the same manner as discussed above with respect to plastic layer 50 being bonded to metal surface 32 .
- the resulting seal ring 22 has a cross-section as shown in FIG. 5 .
- sealing material 26 may be bonded to plastic layer 50 with conventional chemical or adhesive bonding. Because the bonding of sealing material 26 is to the plastic layer 50 , known high temperature chemical bonding agents that are capable of withstanding temperatures greater than 400° F. when bonding plastic and elastomers, but are unable to withstand such temperatures when bonding plastic/sealing materials to metal surfaces, can be used.
- plastic layer 50 may be bonded to sealing material 26 prior to plastic layer 50 being bonded to metal surface 32 .
- plastic layer 50 may be bonded to metal surface 32 prior to plastic layer 50 being bonded to sealing material 26 .
- plastic layer 50 is bonded to both sealing material 26 and metal surface 32 simultaneously, such as through simultaneous initiation of energetic material 30 disposed between both plastic layer 50 and metal surface 32 and plastic layer 50 and sealing material 26 .
- Sealing material 26 bonded to metal surface 32 in accordance with the foregoing embodiments are capable of remaining bonded to metal surface 32 at temperatures in excess of 400° F. and, preferably, at temperatures in excess of 450° F.
- the energetic material may be used to bond a sealing material to any component of a downhole hole having a metal surface to which a sealing material is bonded.
- the component of the downhole tool may be any structural component of the downhole tool, such as the outer wall surface of the downhole tool itself, and is not limited to the seal ring discussed herein.
- chemical bonding agents may be used in combination with the energetic material to bond the sealing material to a plastic layer which is bonded to the metal surface.
- sealing material may be any material known to persons of ordinary skill in the art that is capable of providing the necessary function of the sealing material with respect to the specific downhole tool to which it is bonded. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
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Abstract
A downhole well tool having a component with a metal surface to which a sealing material is adhered is disclosed. The sealing material is bonded to the metal surface through the use of an energetic material disposed between the sealing material and the metal surface. Upon activation or initiation of the energetic material, the sealing material becomes bonded to the metal surface. A plastic layer may be disposed between the sealing material and the metal surface to facilitate bonding sealing material to the metal surface. The energetic material is used to bond the plastic layer to the metal surface and may be used to bond the plastic layer to the sealing material.
Description
- 1. Field of Invention
- The invention is directed to materials and methods for bonding a sealing material to a metal surface of downhole tools, such as a packer having a sealing element and, in particular, materials and methods for bonding a sealing material to a metal surface of downhole tools that remain effective at temperatures greater than 400° F.
- 2. Description of Art
- Sealing materials are routinely bonded or adhered to a metal surface of downhole tools. To adhere or bond the sealing material to the steel housing of a downhole tool, for example, the prior art tools used chemical bonding or adhesion components to secure the sealing material to the steel housing. These chemical compounds, however, become less effective as the temperature increases, especially where the temperature increases above 400° F., such as those temperatures found in deep oil and gas well. Current technology limits the ability to bond a sealing material such as rubber to steel at such high temperatures. For example, even though there are high temperature chemical adhesion compounds, these compounds do not work effectively for sealing material-to-metal contact. As a result, the adhesion of the sealing material to the outer surface of the downhole tool is compromised and the sealing material is released from the outer surface of the downhole tool. Accordingly, the tool becomes inoperable or ineffective.
- Additionally, fluids within the well that flow around and past the downhole tools, either flowing up the well or down the well, slowly undermine the chemical compound securing the sealing material to the outer surface of the downhole tools. The flowing fluids may dissolve or otherwise prevent the chemical compound from maintaining its bonding capabilities. Further, the flowing fluids may force themselves, together with debris carried in the flowing fluids, between the interface of the sealing material with the metal surface of the downhole tool. Therefore, the flowing fluid, either alone or in combination with elevated temperatures within the well, can cause the bond of the sealing material to the metal surface to weaken, thereby causing the seal to leak and, thus, rendering the tool inoperable or ineffective. As a result, costs are increased for replacing and repairing, if possible, the damaged downhole tool having an insufficiently secured sealing material to metal wall surface of the downhole tool.
- Accordingly, prior to the development of the materials and downhole tools disclosed herein, there have been no downhole tools having a sealing material secured to the metal outer wall surface of a downhole tool that: increases the life of the downhole tool by increasing the length of time the sealing material remains bonded to a metal wall surface of the downhole tools and, thus, decreases the costs associated with replacing and repairing the downhole tools; and provides more effective bonding of the sealing material at elevated temperatures. Therefore, the art has sought downhole tools having a sealing material secured to a metal wall surface of a downhole tool that: increase the life of the downhole tool by increasing the length of time the sealing material remains bonded to the metal wall surface of the downhole tools and, thus, decrease the costs associated with replacing and repairing the downhole tools; and provide more effective bonding of the sealing material at elevated temperatures.
- Broadly, the downhole tools disclosed herein include a sealing material secured to a metal surface of the downhole tool through the use of an energetic material disposed between the sealing material and the metal surface and subsequently initiating the energetic material to bond the sealing material to the metal surface. In one embodiment, the sealing material is bonded directly to the metal surface. In another embodiment, the sealing material is first bonded to a plastic material, such as through the use of a high-temperature chemical bonding agent or the energetic material, and the plastic material is then bonded to the metal surface using the energetic material. In an additional specific embodiment, a plastic material is first bonded to the metal surface using the energetic material and the sealing material is then bonded to the plastic. In yet another specific embodiment, the sealing material is bonded to the plastic simultaneously with the plastic being bonded to the metal surface.
- The foregoing downhole tools having a sealing material secured to a metal wall surface of a downhole tool have the advantages of: increasing the life of the downhole tool by increasing the length of time the sealing material remains bonded to the metal wall surface of the downhole tools and, thus, decreasing the costs associated with replacing and repairing the downhole tools; and providing more effective bonding of the sealing material at elevated temperatures.
- In accordance with the disclosure herein, one or more of the foregoing advantages may also be achieved through the present component of a downhole tool. The component comprises a metal surface, a sealing material, and an energetic material, wherein the energetic material bonds the sealing material to the metal surface through activation, e.g., combustion or chemical reaction, of the energetic material.
- A further feature of the downhole tool component is that the energetic material may comprise a thermite. Another feature of the downhole tool component is that the thermite may comprise sub-micron thermite particles. An additional feature of the downhole tool component is that the energetic material may comprise at least one reactant for forming an intermetallic compound. Still another feature of the downhole tool component is that at least one of the at least one reactants for forming the intermetallic compound may comprise sub-micron reactant compound particles. A further feature of the downhole tool component is that the sealing material may be selected from the group consisting of styrene-butadiene copolymer, neoprene, nitrile rubber, butyl rubber, polysulfide rubber, cis-1,4-polyisoprene, ethylene-propylene terpolymers, EPDM rubber, silicone rubber, polyurethane rubber, and thermoplastic polyolefin rubbers. Another feature of the downhole tool component is that the durometer hardness of the sealing material may be in the range from about 60 to 100 Shore A. An additional feature of the downhole tool component is that the metal surface may be disposed on an outer surface of a housing of the downhole tool. Still another feature of the downhole tool component is that the downhole tool may be a sealing device. A further feature of the downhole tool component is that the sealing device may be a packer. Another feature of the downhole tool component is that the sealing material may be bonded directly to the metal surface by the energetic material, and the energetic material may be capable of generating sufficient heat to cause the sealing material to at least partially melt and become bonded to the metal surface without an outer surface of the sealing material melting. An additional feature of the downhole tool component is that the downhole tool component may further comprise a plastic layer disposed between the sealing material and the metal surface, the plastic layer being bonded directly to the metal surface by the energetic material.
- In accordance with the disclosure herein, one or more of the foregoing advantages may also be achieved through the present method of bonding a sealing material to a metal surface of a component of a downhole tool. The method comprises the steps of: (a) disposing an energetic material between a sealing material and a metal surface of a component of a downhole tool; and (b) energizing the energetic material to create sufficient heat to cause the sealing material to be bonded to the metal surface of the component of the downhole tool.
- A further feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that wherein the sealing material may be first bonded to a plastic layer and the energetic material is disposed between the plastic layer and the metal surface of the component of the downhole tool prior to step (b). Another feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that the metal surface of the component of the downhole tool may be first bonded to a plastic layer by disposing the energetic material between the plastic layer and the metal surface of the component of the downhole tool; the energetic material may then be energized to bond the plastic layer to the metal surface of the component of the downhole tool; and the sealing material may then be bonded to the plastic layer. An additional feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that the plastic layer may be a perfluoroalkoxy material. Still another feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that the sealing material may be bonded to the plastic layer by disposing additional energetic material between the sealing material and the plastic layer and energizing the energetic material. A further feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that the energetic material may comprise a thermite. Another feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that the energetic material may comprise at least one reactant for forming an intermetallic compound. An additional feature of the method of bonding a sealing material to a metal surface of a component of a downhole tool is that a bonding metal may be disposed on a bonding surface of the sealing material prior to step (b).
-
FIG. 1 is a partial cross-sectional view of a packer showing a seal ring disposed on the outer surface of the downhole tool, the seal ring having a metal surface with a sealing material bonded thereto. -
FIG. 2 is partial cross-sectional top view of one specific embodiment of a seal ring of the downhole tool ofFIG. 1 showing an energetic material disposed between a sealing material and a metal surface of the seal ring prior to bonding the sealing material to the metal surface. -
FIG. 3 is a partial cross-sectional top view of the seal ring shown inFIG. 2 after initiation of the energetic material and, thus, bonding of the sealing material to the metal surface. -
FIG. 4 is partial cross-sectional top view of another specific embodiment of a seal ring of the downhole tool ofFIG. 1 showing a sealing material bonded to a plastic layer and an energetic material disposed between the plastic layer and a metal surface of the seal ring prior to bonding the plastic layer to the metal surface. -
FIG. 5 is a partial cross-sectional top view of the seal ring shown inFIG. 4 after initiation of the energetic material and, thus, bonding of the sealing material to the metal surface. -
FIG. 6 is partial cross-sectional top view of an additional specific embodiment of a seal ring of the downhole tool ofFIG. 1 showing a sealing material bonded to a plastic layer and an energetic material disposed between the plastic layer and a metal surface, as well as between the plastic layer and the sealing material, of the seal ring prior to bonding the plastic layer to the metal surface. -
FIG. 7 is partial cross-sectional top view of an additional specific embodiment of a seal ring of the downhole tool ofFIG. 1 showing a sealing material bonded to a metal layer and an energetic material disposed between the metal layer and a metal surface of the seal ring prior to bonding the sealing material to the metal surface. - While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
- Referring now to
FIG. 1 , a downhole tool, such as apacker 10, includes a body orhousing 12 and a sealing member orseal ring 22 disposed on the outer surface ofhousing 12 for sealing against a surrounding well casing.Housing 12 is generally cylindrical but may be any shape desired or necessary to form the downhole tool. An actuatingmember 14 is mounted tohousing 12 for axial movement relative tohousing 12. In this example, actuatingmember 14 engages a lower end ofseal ring 22 for pushingseal ring 22 upward on astationary cam surface 16 ofhousing 12 to causeseal ring 22 to expand radially into the set position.Cam surface 16 is preferably conical. Actuatingmember 14 may be an annular collet that is radially expansible, or it could be other configurations. In this embodiment, actuatingmember 14 is secured to a piston (not shown) supplied with hydraulic pressure for movingseal ring 22 relative tocam surface 16. -
Tool 10 may be of a conventional design, and actuatingmember 14 may be moved by a variety of means other than hydraulic pressure, such as employing the weight of the running string (not shown) fortool 10, hydrostatic wellbore pressure, wireline movement, or explosives. Also, althoughseal ring 22 is shown moving upward ontostationary cam surface 16, the arrangement could be reversed, withseal ring 22 being moved downward. Further,seal ring 22 could be held axially stationary andcam surface 16 be moved relative toseal ring 22. For example, actuatingmember 14 may actually be held stationary while the running string andhousing 12 move downward relative toseal ring 22, pushingseal ring 22 farther ontoconical cam surface 16. Alternately, actuatingmember 14 may move upward relative to seal 22. Regardless of the arrangement, while being set,seal ring 22 andcam surface 16 move axially relative to each other to deformseal ring 22 radially outward to a larger diameter for engaging an inner wall surface of an outer tubular member (not shown) into whichtool 10 is lowered. Outer tubular member may be a string of casing. As shown inFIG. 1 ,tool 10 in this example also has a set ofslips 20 that expand outward and frictionally grip the inner wall surface of the outer tubular member. - With reference to
FIG. 2 ,seal ring 22 has an internalmetal reinforcing element 23, thus providing a metal surface. Preferably reinforcingelement 23 is formed of a carbon steel. A sealingmaterial 26 is bonded to the metal surface of reinforcingelement 23 through the use of an energetic material (discussed in greater detail below). - Sealing
material 26 may be any material known to persons of ordinary skill in the art. In the preferred embodiment, sealingmaterial 26 is a resilient, elastomeric or polymeric material of a commercially available type that will withstand high temperatures that occur in some wells. For example, sealingmaterial 26 may be a perfluoro elastomer, a styrene-butadiene copolymer, - neoprene, nitrile rubber, butyl rubber, polysulfide rubber, cis-1,4-polyisoprene, ethylene-propylene terpolymers, EPDM rubber, silicone rubber, polyurethane rubber, or thermoplastic polyolefin rubbers. Preferably, the durometer hardness of sealing
material 26 is in the range from about 60 to 100 Shore A and more particularly from 85 to 95 Shore A. In one embodiment, the durometer hardness is about 90 Shore A. Othersuitable sealing materials 26 include Teflon® (polytetrafluroethylene or fluorinated ethylene-propylene) and polyether ether ketone. Sealingmaterial 26 also could be nitrile rubber. Further, sealingmaterial 26 may be any other thermoset material, thermoplastic material, or vulcanized material, provided such sealing materials are resilient and capable of withstanding high temperatures, e.g., greater than 400° F. -
Energetic material 30 is any material that is capable of quickly generating and, thus, releasing large amounts of energy in a localized area such that any material contacting the energetic material is heated to a temperature sufficiently high to bond the material to a metal surface. Energetic materials include, but are not limited to, thermite materials and reactants for forming intermetallic compounds. - Thermite reactions typically consist of a metal reacting with a metal oxide to produce a metal and metal oxide with the release of a substantial amount of energy and can typically be characterized by the formula:
-
aX+bYZ→cY+dXZ+ΔE kJ - Examples of such reactions include, but are not limited to:
-
4Al+3BiO2→3Bi+2Al2O3 -
2Al+MoO3→Mo Al2O3 -
4Al+3FeO2→3Fe+2Al2O3 - Although the foregoing examples show aluminum as the metal for the reaction, persons of ordinary skill in the art will recognize that similar thermite reactions of other materials exist, e.g., tungsten, zirconium, copper, magnesium, and manganese. Likewise, the oxide of the reaction may be any suitable and known oxide.
- In a preferred embodiment, the thermite material is made up of thermite particles having a sub-micron particle size distribution and, more preferably, a nanometer size distribution. The sub-micron sized thermite particles have a substantially lower activation energy requirement and react faster, usually more than an order of magnitude faster, than thermite particles having a micron or greater particle size distribution.
- Other
energetic materials 30 include reactants that form an intermetallic compounds upon the reactants being activated or energized. Intermetallic compound reactions are known in the art. Briefly, intermetallic compound reactions involve two metal reactants reacting together to form a solid state intermetallic compound and which, in the process, release energy. Generally, intermetallic compound reactions can be characterized by the formula: -
aX+bY→dXY+ΔE kJ or -
aX+bY+cZ→dXYZ+ΔE kJ - One of the most common intermetallic compound reactions is:
-
Ni+Sn→NiSn - In a preferred embodiment, both reactants for forming the intermetallic compounds, e.g., Ni and Sn in the example above, are disposed together on the same surface. It is to be understood, however, that the reactants may initially be disposed on separate surfaces, e.g., one on the metal surface and the other on sealing
material 26, provided that all of the reactants necessary to form the intermetallic compound are placed in contact with each other, or in close proximity to each other, prior to activation of the reactants. - In another preferred embodiment, at least one, and more preferably all, of the reactants for forming the intermetallic compounds, is made up of reactant particles having a sub-micron particle size distribution and, more preferably, a nanometer size distribution. The sub-micron sized reactant particles have a substantially lower activation energy requirement and react faster, usually more than an order of magnitude faster, than reactant particles having a micron or greater particle size distribution.
- Both the thermite materials and the reactants for forming the intermetallic compounds are available in powder or sheet form from NovaCentrix of Austin, Tex., Sigma-Aldrich of St. Louis, Mo., and Reactive Nanotechnologies, Inc. of Hunt Valley, Md. In the powdered form, at least one of the components typically has particles that are sub-micron to nano-scale range. In sheet form, the components are typically layered in sub-micron to nano-scale layers.
- As illustrated in
FIGS. 2-3 , in one specific embodiment, sealingmaterial 26 is bonded directly tometal surface 32 of reinforcingring 22 by placingenergetic material 30 between sealingmaterial 26 andmetal surface 32 as shown inFIG. 2 .Energetic material 30 is initiated or ignited through means known to persons of ordinary skill in the art. For example, an electric charge or radiant heat may be used to energizeenergetic material 30, causing the energy releasing reaction to begin. The energy released by the energetic material is in the form of heat. Therefore, the temperature alongmetal surface 32 andbonding surface 34 of the sealingmaterial 26 increases until sealingmaterial 26 bonds to metal surface 32 (FIG. 3 ). The bonding of the sealingmaterial 26 may be achieved through localized melting (where sealingmaterial 26 is formed of a meltable material such as a thermoplastic material) or thermal degradation (where sealingmaterial 26 is non-meltable material such as a vulcanized, elastomeric, or thermoset material) of sealingmaterial 26 or melting ofmetal surface 32. - Preferably,
energetic material 30 is a high temperature, fast burning or chemically reactive material such thatenergetic material 30 reacts or combusts in a short amount of time, yet releases a large amount of energy to create a high localized temperature. One advantage ofheating sealing material 26 in this manner is that bondingsurface 34 is heated quickly such that the heat dissipates before theentire sealing material 26 melts or undergoes thermal degradation. Thus,outer surface 38 of sealingmaterial 26 maintains its integrity and resilience. Persons skilled in the art, without undue experimentation, can easily determine the optimum type and volume ofenergetic material 30 for use with the desired sealingmaterial 26 or plastic layer 50 (discussed in greater detail below). - In an additional embodiment shown in
FIG. 7 ,layer 29 of metal can be deposited onbonding surface 34 of sealingmaterial 26 to provide a metal to metal bonding through the use ofenergetic material 30. In this embodiment, a thin layer of metal (not shown) is deposited onbonding surface 34 through sputter or chemical vapor deposition processes known to persons of ordinary skill in the art. The metal being deposited onbonding surface 34 can be a common metal alloy or a material such as solder or brazing compound.Energetic material 30 is then disposed betweenmetal surface 32 and sealingmaterial 26 such thatbonding surface 34 with the metal layer deposited thereon is in contact withenergetic material 30.Energetic material 30 can then be initiated or ignited, thereby releasing heat and causingmetal surface 32 to bond to sealingmaterial 26 through the interface of the metal deposited onbonding surface 34 of sealingmaterial 26. - In another embodiment shown in
FIGS. 4-5 ,plastic layer 50 is disposed between sealingmaterial 26 andmetal surface 32.Energetic material 30 is disposed betweenplastic layer 50 andmetal surface 32 and, therefore,plastic layer 50 is bonded tometal surface 32 in the same manner as discussed above with respect to the embodiment shown inFIGS. 2-3 . -
Plastic layer 50 is preferably formed of a melt processable material. The term “melt processable” is used herein to mean a material that is capable of melting and shaping, but becomes thermally stable, i.e., not able to melt, as the downhole application temperature. Thus, the “melt processable” materials after bonding sealingmaterial 26 tometal surface 32, do not re-melt when thetool 10 is disposed downhole. Such “melt processable” materials include thermoset materials as well as thermoplastic materials, provided the melting point, or melting temperature, of the thermoplastic materials is greater than the downhole wellbore temperature wheretool 10 is to be operated. - A
preferred plastic layer 50 is formed of a perfluroalkoxy material (“PFA”). Polyamidazole may also be used to formplastic layer 50. Plastic layer may also be formed out of fluorinated ethylene propylene (FEP); Chlorotrifluorethylene (CTFE); Ethylenechlorotrifluoroethylene (ECTFE); Ethylenetetrafluoroethylene (ETFE); or Polyvinylidine fluoride (PVF2). Regardless of the material or type ofplastic layer 50 utilized,plastic layer 50 will always be different from sealingmaterial 26. - In one specific embodiment, sealing
material 26 is bonded toplastic layer 50 by placing a second layer of energetic material 31 (FIG. 6 ) between sealingmaterial 26 andplastic layer 50. Sealingmaterial 26 is bonded toplastic layer 50 in the same manner as discussed above with respect toplastic layer 50 being bonded tometal surface 32. The resultingseal ring 22 has a cross-section as shown inFIG. 5 . - In yet another embodiment, sealing
material 26 may be bonded toplastic layer 50 with conventional chemical or adhesive bonding. Because the bonding of sealingmaterial 26 is to theplastic layer 50, known high temperature chemical bonding agents that are capable of withstanding temperatures greater than 400° F. when bonding plastic and elastomers, but are unable to withstand such temperatures when bonding plastic/sealing materials to metal surfaces, can be used. - In
bonding sealing material 26 tometal surface 32 in accordance with the embodiment shown inFIGS. 4-5 , the order of bonding is not critical. For example,plastic layer 50 may be bonded to sealingmaterial 26 prior toplastic layer 50 being bonded tometal surface 32. Alternatively,plastic layer 50 may be bonded tometal surface 32 prior toplastic layer 50 being bonded to sealingmaterial 26. In still another embodiment,plastic layer 50 is bonded to both sealingmaterial 26 andmetal surface 32 simultaneously, such as through simultaneous initiation ofenergetic material 30 disposed between bothplastic layer 50 andmetal surface 32 andplastic layer 50 and sealingmaterial 26. - Sealing
material 26 bonded tometal surface 32 in accordance with the foregoing embodiments are capable of remaining bonded tometal surface 32 at temperatures in excess of 400° F. and, preferably, at temperatures in excess of 450° F. - It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. For example, as mentioned, the energetic material may be used to bond a sealing material to any component of a downhole hole having a metal surface to which a sealing material is bonded. Moreover, the component of the downhole tool may be any structural component of the downhole tool, such as the outer wall surface of the downhole tool itself, and is not limited to the seal ring discussed herein. Additionally, chemical bonding agents may be used in combination with the energetic material to bond the sealing material to a plastic layer which is bonded to the metal surface. Further, the sealing material may be any material known to persons of ordinary skill in the art that is capable of providing the necessary function of the sealing material with respect to the specific downhole tool to which it is bonded. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
Claims (20)
1. A component of a downhole tool, the component comprising:
a metal surface;
a sealing material; and
an energetic material, wherein the energetic material bonds the sealing material to the metal surface through activation of the energetic material.
2. The downhole tool component of claim 1 , wherein the energetic material comprises a thermite.
3. The downhole tool component of claim 2 , wherein the thermite comprises sub-micron thermite particles.
4. The downhole tool component of claim 1 , wherein the energetic material comprises at least one reactant for forming an intermetallic compound.
5. The downhole tool component of claim 4 , wherein at least one of the at least one reactants for forming the intermetallic compound comprises sub-micron reactant compound particles.
6. The downhole tool component of claim 1 , wherein the sealing material is selected from the group consisting of styrene-butadiene copolymer, neoprene, nitrile rubber, butyl rubber, polysulfide rubber, cis-1,4-polyisoprene, ethylene-propylene terpolymers, EPDM rubber, silicone rubber, polyurethane rubber, and thermoplastic polyolefin rubbers.
7. The downhole tool component of claim 6 , wherein the durometer hardness of the sealing material is in the range from about 60 to 100 Shore A.
8. The downhole tool component of claim 1 , wherein the metal surface is disposed on an outer surface of a housing of the downhole tool.
9. The downhole tool component of claim 8 , wherein the downhole tool is a sealing device.
10. The downhole tool component of claim 9 , wherein the sealing device is a packer.
11. The downhole tool component of claim 1 , wherein the sealing material is bonded directly to the metal surface by the energetic material, and the energetic material is capable of generating sufficient heat to cause the sealing material to at least partially melt and become bonded to the metal surface without an outer surface of the sealing material melting.
12. The downhole tool component of claim 1 , further comprising a plastic layer disposed between the sealing material and the metal surface, the plastic layer being bonded directly to the metal surface by the energetic material.
13. A method of bonding a sealing material to a metal surface of a component of a downhole tool, the method comprising the steps of:
(a) disposing an energetic material between a sealing material and a metal surface of a component of a downhole tool; and
(b) energizing the energetic material to create sufficient heat to cause the sealing material to be bonded to the metal surface of the component of the downhole tool.
14. The method of claim 13 , wherein the sealing material is first bonded to a plastic layer and the energetic material is disposed between the plastic layer and the metal surface of the component of the downhole tool prior to step (b).
15. The method of claim 13 , wherein the metal surface of the component of the downhole tool is first bonded to a plastic layer by disposing the energetic material between the plastic layer and the metal surface of the component of the downhole tool;
the energetic material is then energized to bond the plastic layer to the metal surface of the component of the downhole tool; and
the sealing material is then bonded to the plastic layer.
16. The method of claim 15 , wherein the plastic layer is a perfluoroalkoxy material.
17. The method of claim 15 , wherein the sealing material is bonded to the plastic layer by disposing additional energetic material between the sealing material and the plastic layer and energizing the energetic material.
18. The method of claim 15 , wherein the energetic material comprises a thermite.
19. The method of claim 15 , wherein the energetic material comprises at least one reactant for forming an intermetallic compound.
20. The method of claim 13 , wherein a bonding metal is disposed on a bonding surface of the sealing material prior to step (b).
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US12/655,270 US20100108308A1 (en) | 2007-03-15 | 2009-12-28 | Sealing material to metal bonding compositions and methods for bonding a sealing material to a metal surface |
US12/655,272 US20100108253A1 (en) | 2007-03-15 | 2009-12-28 | Sealing material to metal bonding compositions and methods for bonding a sealing material to a metal surface |
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US12/655,272 Abandoned US20100108253A1 (en) | 2007-03-15 | 2009-12-28 | Sealing material to metal bonding compositions and methods for bonding a sealing material to a metal surface |
US12/655,270 Abandoned US20100108308A1 (en) | 2007-03-15 | 2009-12-28 | Sealing material to metal bonding compositions and methods for bonding a sealing material to a metal surface |
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US12/655,270 Abandoned US20100108308A1 (en) | 2007-03-15 | 2009-12-28 | Sealing material to metal bonding compositions and methods for bonding a sealing material to a metal surface |
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US9938771B2 (en) | 2014-11-03 | 2018-04-10 | Baker Hughes, A Ge Company, Llc | Initiator nanoconstituents for elastomer crosslinking and related methods |
Also Published As
Publication number | Publication date |
---|---|
US20100108253A1 (en) | 2010-05-06 |
US20100108308A1 (en) | 2010-05-06 |
WO2008112330A1 (en) | 2008-09-18 |
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