Composite hollow profiles for downhole
Methods and apparatuses including a hollow profile for downhole in a borehole, the hollow profile including a composite of an aromatic copolyester thermoset (ACT) and a reinforcement material, wherein the reinforcement material includes fibers or particles, or both.
1 . An apparatus comprising:
a hollow profile for downhole in a borehole, wherein the hollow profile is a filament-wound composite of an aromatic copolyester thermoset (ACT) vitrimer and continuous fibers impregnated with the ACT vitrimer, wherein the ACT vitrimer of the filament-wound composite is cured ACT vitrimer that is a cross-linked network reprocessable by dynamic bond exchange, wherein the composite is resistant to compounds including hydrogen sulfide, hydrogen, carbon dioxide, brines, and water in experiencing less than 6 weight percent loss of mass upon exposure of the composite to the compounds for one year at 150° C., and wherein the ACT vitrimer comprises a tensile strength of at least 60 megapascal (MPa), a tensile modulus of at least 2.5 gigapascal (GPa), and an elongation at break of at least 1.5%.
2 . The apparatus of claim 1 , wherein the ACT vitrimer comprises an aromatic thermosetting copolyester (ATSP) resin comprising an aromatic polyester backbone, and wherein the continuous fibers are glass fibers.
3 . The apparatus of claim 1 , wherein the filament-wound composite comprises the continuous fibers impregnated with the ACT vitrimer wound in a predetermined direction in the filament-wound composite.
4 . The apparatus of claim 3 , wherein the ACT vitrimer comprises an aromatic polyester backbone, and wherein the continuous fibers wound in the predetermined direction in the filament-wound composite comprises predetermined fiber angles.
5 . The apparatus of claim 1 , wherein the continuous fibers comprise glass, aramid, boron, basalt, metal, polyethylene, polypropylene, poly(p-phenylene-2,6-benzobisoxazole) (PBO), or natural fibers, or any combinations thereof, and wherein the natural fibers comprise flax or jute, or both.
6 . The apparatus of claim 1 , wherein the apparatus is a downhole tubular configured for use downhole in the borehole, or wherein the apparatus is a casing or a production tubing each comprising multiple tubulars joined longitudinally end-to-end as the hollow profile.
7 . The apparatus of claim 1 , wherein the apparatus is a downhole tool comprising the hollow profile as tubing, piping, a pressure housing, a valve body, or a tool mandrel, or any combinations thereof.
8 . The apparatus of claim 1 , wherein the filament-wound composite comprises the continuous fibers impregnated with the ACT vitrimer wound in a predetermined direction in the filament-wound composite giving the filament-wound composite as anisotropic.
9 . The apparatus of claim 1 , wherein the downhole tool comprises a mandrel comprising the hollow profile, and wherein the downhole tool is a packer or a plug.
10 . The apparatus of claim 1 , wherein the continuous fibers impregnated with the ACT vitrimer are in the form of prepreg tapes or towpregs.
11 . The apparatus of claim 1 , wherein the apparatus is the hollow profile that is a pressure housing for instrumentation.
12 . The apparatus of claim 1 , wherein the apparatus comprises a tubular as the hollow profile, and wherein the apparatus comprises a metallic liner coupled to the tubular.
13 . The apparatus of claim 1 , wherein filament layers of the filament-wound composite are cross plied to increase strength of the filament-wound composite.
14 . An apparatus comprising:
a first tubular for downhole in a borehole, the first tubular comprising a filament-wound composite of a first aromatic copolyester thermoset (ACT) vitrimer and continuous fibers, wherein the continuous fibers are impregnated with the first ACT vitrimer; and
a second tubular coupled to the first tubular via a coating of a second ACT vitrimer on a joint tongue of the second tubular, wherein the coating provides for reversible bonding to bond and debond, wherein the first ACT vitrimer comprises a first aromatic thermosetting copolyester (ATSP) resin, and wherein the second ACT vitrimer comprises a second ATSP resin.
15 . The apparatus of claim 14 , wherein the second tubular is a metallic tubular, and wherein the continuous fibers are glass fibers.