Fiber Reinforced Polymer Matrix Nanocomposite Downhole Member

• US 20130206273A1
• Filed: 02/10/2012
• Published: 08/15/2013
• Est. Priority Date: 02/10/2012
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Guest, Randall V., Chakraborty, Soma, Falkner, Joshua C.
• Granted Patent: US 9,488,027 B2
• Time in Patent Office: Days
• US Class Current: 138/174
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: E21B 33/12 Packers; Plugs used for cementing E21B33/134, E21B33/16
• CPC Class Codes: E21B 33/1208 characterised by the construction of the sealing or packing means E21B33/1277 takes precedence
• CPC Class Codes: E21B 33/1291 anchor set by wedge or cam in combination with frictional effect, using so-called drag-blocks E21B33/1295 takes precedence
• CPC Class Codes: E21B 33/134 Bridging plugs

Abstract

A downhole composite component is disclosed. The downhole composite component includes a tubular member, the tubular member comprising a fiber reinforced polymer matrix composite. The fiber reinforced polymer matrix composite includes a polymer matrix, the polymer matrix having an unfilled matrix compressive modulus of elasticity. The polymer matrix also includes a nanoparticle filler comprising a plurality of nanoparticles dispersed within the polymer matrix, the polymer matrix and dispersed nanoparticle filler having a filled matrix compressive modulus of elasticity, the filled matrix compressive modulus of elasticity being greater than the unfilled matrix compressive modulus of elasticity. The fiber reinforced polymer matrix composite also includes a plurality of reinforcing fibers, the plurality of reinforcing fibers embedded within the polymer matrix, the polymer matrix and plurality of reinforcing fibers having the form of the tubular member, the tubular member configured to receive a compressive stress.

Claims

1. A downhole composite component, comprising:

a tubular member, the tubular member comprising a fiber reinforced polymer matrix composite, the fiber reinforced polymer matrix composite comprising;

a polymer matrix, the polymer matrix having an unfilled matrix compressive modulus of elasticity;

a nanoparticle filler comprising a plurality of nanoparticles dispersed within the polymer matrix, the polymer matrix and dispersed nanoparticle filler having a filled matrix compressive modulus of elasticity, the filled matrix compressive modulus of elasticity being greater than the unfilled matrix compressive modulus of elasticity; and

a plurality of reinforcing fibers, the plurality of reinforcing fibers embedded within the polymer matrix, the polymer matrix and plurality of reinforcing fibers having the form of the tubular member, the tubular member configured to receive a compressive stress.

2. The downhole composite component of claim 1, wherein the tubular member comprises a hollow cylindrical mandrel of a bridge plug, the mandrel having an outer cylindrical surface that is configured to slidably receive a tapered cone, the tapered cone comprising an inner cylindrical surface that is configured for sealable sliding engagement on the outer surface of the mandrel, the tapered cone having a tapered outer surface, the tapered outer surface configured to slidably receive a tapered inner surface of a slip, the slip comprising a complementary tapered inner surface that is configured for sealable sliding engagement on the tapered outer surface of the cone and a substantially cylindrical surface, the outer surface comprising a plurality of circumferentially extending teeth that are configured to sealably engage an inner surface of a tubular casing, wherein the tapered cone and slip are configured to provide a seal between the outer surface of the mandrel and the inner surface of the casing upon actuation of the bridge plug by application of pressure to a pressure actuation end of cone causing sliding axial movement of the tapered cone, and wherein upon actuation of the bridge plug, the mandrel, tapered cone and slip configured to receive axial and radial compressive stresses, and wherein an ultimate compressive stress of the fiber reinforced polymer matrix composite with the nanoparticle filler is greater than the same fiber reinforced polymer matrix composite without the filler.

3. The downhole composite component of claim 1, wherein the tubular member comprises a hollow cylindrical mandrel of a frac plug, the mandrel having a plug seat proximate an end of the mandrel, the plug seat configured for sealable engagement with a plug member upon actuation of the frac plug, and wherein the ultimate compressive stress of the fiber reinforced polymer matrix composite with the nanoparticle filler is greater than the same fiber reinforced polymer matrix composite without the filler.

4. The downhole component of claim 1, wherein the tubular member comprises a cover that is configured to cover a portion of a cylindrical tool or a section of a tubular, and wherein the ultimate compressive stress of the fiber reinforced polymer matrix composite with the nanoparticle filler is greater than the same fiber reinforced polymer matrix composite without the filler.

5. The downhole component of claim 1, wherein the polymer matrix comprises a thermoset or a thermoplastic polymer, or a combination thereof.

6. The downhole component of claim 5, wherein the thermoset polymer comprises a phenolic, bismaleimide or an epoxy, or a combination thereof.

7. The downhole component of claim 5, wherein the thermoplastic polymer comprises polyetheretherketone.

8. The downhole component of claim 1, wherein the plurality of reinforcing fibers comprise glass, carbon, mineral, ceramic, metal or polymer fibers, or a combination thereof.

9. The downhole component of claim 1, wherein the plurality of reinforcing fibers are present in an amount, by volume fraction of the composite, of about 0.2 to about 0.8.

10. The downhole component of claim 9, wherein the plurality of reinforcing fibers are present in an amount, by volume fraction of the composite, of about 0.3 to about 0.6.

11. The downhole component of claim 1, wherein the nanoparticle filler comprises a plurality of graphene, nanotube, fullerene, graphite, graphene fiber, nanodiamond, silica, clay, mineral, metal or polyhedral oligomeric silsesquioxane nanoparticles, or a combination thereof.

12. The downhole component of claim 11, wherein the nanotubes are single or multiwall carbon, inorganic or metallated nanotubes, or a combination thereof.

13. The downhole component of claim 11, wherein the nanoparticles comprise derivatized nanoparticles that are derivatized to include a carboxy, epoxy, ether, ketone, amine, hydroxy, alkoxy, alkyl, aryl, aralkyl, alkaryl or lactone functional group, or a functionalized polymeric or oligomeric group, or a combination thereof.

14. The downhole component of claim 13, wherein the derivatized nanoparticle is a derivatized graphene, the functional group comprises an alkyl, aryl, aralkyl, alkaryl, functionalized polymeric or oligomeric groups, or a combination thereof, and the functional groups are attached directly to the derivatized nanoparticle by a carbon-carbon bond without intervening heteroatoms;

a carbon-oxygen bond;

or a carbon-nitrogen bond.

15. The downhole component of claim 1, wherein an aspect ratio of the nanoparticles comprises about 0.001 to about 200

16. The downhole component of claim 1, wherein the nanoparticle filler is present in an amount, by volume fraction of the composite, of about 0.005 to about 0.15.

17. The downhole component of claim 1, wherein the plurality of reinforcing fibers comprise a cloth, and wherein the cloth comprises a plurality of circumferentially wrapped cloth plies.

18. The downhole component of claim 17, wherein the cloth comprises a woven cloth.

19. The downhole component of claim 1, wherein the plurality of reinforcing fibers comprise a tow, roving or other consolidated form, and wherein the tow, roving or other consolidated form comprises a circumferentially oriented tow, roving or other consolidated form as one ply and a non-circumferentially oriented tow, roving or other consolidated form as a second ply.

20. The downhole component of claim 1, wherein the plurality of reinforcing fibers comprise a tow, roving or other consolidated form as one ply, and a cloth as a second ply.

21. The downhole component of claim 1, wherein the plurality of reinforcing fibers comprise randomly oriented fibers.

22. The downhole component of claim 2, wherein the cone also comprises a second fiber reinforced polymer matrix composite, comprising:

a cone polymer matrix, the cone polymer matrix having an unfilled matrix compressive modulus of elasticity;

a cone nanoparticle filler comprising a plurality of nanoparticles dispersed within the polymer matrix, the polymer matrix and dispersed nanoparticle filler having a filled matrix compressive modulus of elasticity, the filled matrix compressive modulus of elasticity greater than the unfilled matrix compressive modulus of elasticity; and

a plurality of cone reinforcing fibers, the plurality of cone reinforcing fibers embedded within the polymer matrix, the polymer matrix and plurality of cone reinforcing fibers having the form of the cone, and wherein the ultimate compressive stress of the second fiber reinforced polymer matrix composite with the nanoparticle filler is greater than the same fiber reinforced polymer matrix composite without the filler.

23. The downhole component of claim 22, wherein the cone polymer matrix comprises a thermoset or a thermoplastic polymer, or a combination thereof.

24. The downhole component of claim 22, wherein the plurality of cone reinforcing fibers comprise glass, carbon, mineral or polymer fibers, or a combination thereof.

25. The downhole component of claim 22 wherein the cone nanoparticle filler comprises a plurality of graphene, nanotube, fullerene, graphite, graphene fiber, nanodiamond, silica, clay, mineral, metal or polyhedral oligomeric silsesquioxane nanoparticles, or a combination thereof.

26. The downhole component of claim 25, wherein the nanoparticles comprise derivatized nanoparticles that are derivatized to include a carboxy, epoxy, ether, ketone, amine, hydroxy, alkoxy, alkyl, aryl, aralkyl, alkaryl or lactone functional group, or a functionalized polymeric or oligomeric group, or a combination thereof.

27. The downhole component of claim 22, wherein the plurality of reinforcing fibers comprise a cloth, and wherein the cloth comprises a plurality of circumferentially wrapped cloth plies.

28. The downhole component of claim 22, wherein the plurality of reinforcing fibers comprise a tow, roving or other consolidated form, and wherein the tow, roving or other consolidated form comprises a circumferentially oriented tow, roving or other consolidated form as one ply and a non-circumferentially oriented tow, roving or other consolidated form as a second ply.

29. The downhole component of claim 22, wherein the plurality of reinforcing fibers comprise a tow, roving or other consolidated form as one ply, and a cloth as a second ply.

30. The downhole component of claim 22, wherein the plurality of reinforcing fibers comprise randomly oriented fibers.