Disintegratable carbon composites, methods of manufacture, and uses thereof
A carbon composite is disclosed, including a plurality of carbon grains, wherein each of the plurality of carbon grains includes a plurality of pores, and a binder disposed between the plurality of carbon grains to bond the plurality of carbon grains, wherein the binder is a disintegrable binder.
1. A carbon composite comprising:
a plurality of carbon grains, wherein each of the plurality of carbon grains is a form of carbon and includes a plurality of pores to allow for elasticity of the carbon grains; and
a binder disposed between the plurality of carbon grains to bond the plurality of carbon grains, wherein the binder is a disintegrable binder.
2. The carbon composite of claim 1 , wherein the carbon comprises amorphous carbon, natural graphite, carbon fiber, or a combination comprising at least one of the foregoing material.
3. The carbon composite of claim 1 , wherein the plurality of carbon grains are a plurality of graphite grains.
4. The carbon composite of claim 3 , wherein each of the plurality of graphite grains are between 5 to 500 micrometers in diameter.
5. The carbon composite of claim 3 , wherein each of the plurality of graphite grains between are 0.01 to 500 micrometers in thickness.
6. The carbon composite of claim 1 , wherein the binder is an ester polymer.
7. The carbon composite of claim 1 , wherein the binder is an amide polymer.
8. The carbon composite of claim 1 , wherein the binder is an ether polymer.
9. The carbon composite of claim 1 , wherein the binder is polyurethane.
10. The carbon composite of claim 1 , wherein the binder is between 10 to 90 percent of the carbon composite by volume.
11. The carbon composite of claim 1 , wherein the binder is a magnesium alloy with a nickel catalyst.
12. The carbon composite of claim 11 , wherein the binder is a controlled electrolytic metallic material.
13. The carbon composite of claim 12 , wherein the binder is at least one of a magnesium alloy, a magnesium silicon alloy, a magnesium aluminum alloy, a magnesium zinc alloy, a magnesium manganese alloy, a magnesium aluminum zinc alloy, a magnesium aluminum manganese alloy, a magnesium zinc zirconium alloy, and a magnesium rare earth element alloy.
14. The carbon composite of claim 11 , wherein the binder is a low melting point metal or a low melting point alloy.
15. The carbon composite of claim 14 , wherein the binder is at least one of bismuth, tin, and lead.
16. The carbon composite of claim 11 , wherein the binder further comprises a cathode catalyst element.
17. The carbon composite of claim 14 , wherein the cathode catalyst element is at least one of nickel, iron, copper, cobalt, zinc, aluminum and tungsten.
18. The carbon composite of claim 1 , wherein the binder comprises a brittle material.
19. The carbon composite of claim 18 , wherein the brittle material is between 5 to 100 percent of the binder.
20. The carbon composite of claim 18 , wherein the brittle material is Mg2Ni.
21. The carbon composite of claim 1 , wherein the carbon composite is an article.
22. The article of claim 21 , wherein the article comprises at least one of a ball, a plug, a seat, a compression packing element, an expanding packing element, an O-ring, a bonded seal, a bullet seal, a dynamic seal, a flapper seal, a V ring, a back up ring, a drill bit seal, a mud motor stator, a PCP stator, a ESP seal, and a ESP space out sub.
23. A downhole system, comprising:
a downhole element including a carbon composite, the carbon composite including:
a plurality of carbon grains, wherein each of the plurality of carbon grains is a form of carbon and includes a plurality of pores to allow for elasticity of the carbon grains; and
a binder disposed between the plurality of carbon grains to bond the plurality of carbon grains, wherein the binder is a disintegrable binder.
24. The downhole system of claim 23 , wherein the downhole element is at least one of a ball, a plug, a seat, a compression packing element, an expanding packing element, an O-ring, a bonded seal, a bullet seal, a dynamic seal, a flapper seal, a V ring, a back up ring, a drill bit seal, a mud motor stator, a PCP stator, a ESP seal, and a ESP space out sub.
25. The downhole system of claim 23 , wherein the plurality of carbon grains includes a plurality of graphite grains and the binder includes a magnesium alloy with a nickel catalyst.