System and Method for Utilizing Nano-Scale Filler in Downhole Applications

Abstract

A system and method is provided for improving the life and/or function of downhole tools that operate in adverse subterranean environments. Polymeric components, such as seals, are formed with nano-scale filler material. The nano-scale filler material is dispersed in the polymeric material to substantially improve desired material properties.

1 . A system for use in a wellbore, comprising: 
 a downhole tool having a seal member, the seal member comprising a polymer material having a nano-scale filler dispersed therein.    
   
   
       2 . The system as recited in  claim 1 , wherein the downhole tool comprises a packer.  
   
   
       3 . The system as recited in  claim 1 , wherein the downhole tool comprises a valve.  
   
   
       4 . The system as recited in  claim 1 , wherein the downhole tool comprises a sliding sleeve.  
   
   
       5 . The system as recited in  claim 1 , wherein the downhole tool comprises a pump.  
   
   
       6 . The system as recited in  claim 1 , wherein the seal member comprises an O-ring.  
   
   
       7 . The system as recited in  claim 1 , wherein the seal member comprises a T-seal.  
   
   
       8 . The system as recited in  claim 1 , wherein the seal member comprises a seal stack.  
   
   
       9 . The system as recited in  claim 1 , wherein the seal member comprises a spring energized seal.  
   
   
       10 . The system as recited in  claim 1 , wherein the seal member comprises a soft seat.  
   
   
       11 . The system as recited in  claim 1 , wherein the seal member comprises a bonded seal.  
   
   
       12 . The system as recited in  claim 1 , wherein the nano-scale filler comprises carbon nanotubes.  
   
   
       13 . The system as recited in  claim 1 , wherein the nano-scale filler comprises nano-fibers.  
   
   
       14 . The system as recited in  claim 1 , wherein the nano-scale filler comprises nano-clay.  
   
   
       15 . The system as recited in  claim 1 , wherein the nano-scale filler comprises nano-particles.  
   
   
       16 . A system for use in a wellbore, comprising: 
 a downhole tool having a polymer component, the polymer component comprising a nano-scale filler dispersed therein to modify material properties of the polymer component.    
   
   
       17 . The system as recited in  claim 16 , wherein the polymer component comprises a seal.  
   
   
       18 . The system as recited in  claim 17 , wherein the nano-scale filler comprises carbon nanotubes.  
   
   
       19 . The system as recited in  claim 17 , wherein the nano-scale filler comprises nano-fibers.  
   
   
       20 . The system as recited in  claim 17 , wherein the nano-scale filler comprises nano-clay.  
   
   
       21 . The system as recited in  claim 17 , wherein the nano-scale filler comprises nano-particles.  
   
   
       22 . A method of improving a downhole component, comprising: 
 distributing a nano-scale filler through a polymeric downhole component; and    delivering the polymeric downhole component to a desired location within a wellbore.    
   
   
       23 . The method as recited in  claim 22 , wherein distributing comprises distributing the nano-scale filler in a seal.  
   
   
       24 . The method as recited in  claim 23 , wherein distributing comprises distributing the nano-scale filler in a packer seal element.  
   
   
       25 . A method, comprising: 
 using a seal, having a nano-scale filler, in a downhole component; and    operating the downhole component in a wellbore.    
   
   
       26 . The method as recited in  claim 25 , wherein using comprises using the seal in a packer.  
   
   
       27 . The method as recited in  claim 25 , wherein using comprises using an O-ring seal.  
   
   
       28 . The method as recited in  claim 25 , wherein using comprises using a T-seal.  
   
   
       29 . The method as recited in  claim 25 , wherein using comprises using a seal stack.  
   
   
       30 . The method as recited in  claim 26 , wherein operating comprises expanding a packer.  
   
   
       31 . The method as recited in  claim 25 , wherein operating comprises adjusting a valve.  
   
   
       32 . The method as recited in  claim 25 , wherein operating comprises operating a pump.  
   
   
       33 . The method as recited in  claim 25 , wherein operating comprises producing a fluid.  
   
   
       34 . The method as recited in  claim 25 , wherein using comprises using the seal with a nano-tube filler.  
   
   
       35 . The method as recited in  claim 25 , wherein using comprises using the seal having a nano-fiber filler.  
   
   
       36 . The method as recited in  claim 25 , wherein using comprises using the seal having a nano-clay filler.  
   
   
       37 . The method as recited in  claim 25 , wherein using comprises using the seal having a nano-particle filler.  
   
   
       38 . The method as recited in  claim 25 , wherein using comprises using the seal as a soft seat.  
   
   
       39 . The method as recited in  claim 25 , wherein using comprises bonding the seal to a carrier.  
   
   
       40 . A system for use in a wellbore, comprising: 
 means for forming a seal in a seal region of the downhole component; and    means for utilizing a nano-scale filler material at the seal region.    
   
   
       41 . The system as recited in  claim 40 , wherein the means for forming comprises deploying a polymeric material to form the seal.  
   
   
       42 . The system as recited in  claim 41 , wherein the means for utilizing comprises a dispersion of nano-scale filler material throughout the polymeric material.