Sealing material to metal bonding compositions and methods for bonding a sealing material to a metal surface

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

BACKGROUND[0001]1. Field of Invention[0002]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.[0003]2. Description of Art[0004]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...

AI Technical Summary

Benefits of technology

[0008]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.

Problems solved by technology

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.

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.

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