Multi-dimensional fiber composites and articles using the same

Abstract

A composite down-hole tool for use in oil and gas wells includes plurality of fibers which extend along at least a first fiber plane and a second fiber plane. The first fiber plane and the second fiber plane are arranged perpendicular. A matrix material substantially fills the area between and around the plurality of fibers. The down-hole tool is spherical or cylindrical and substantially all of the plurality of fibers extend substantially straight and uninterrupted between opposed sides of the spherical or cylindrical shape down-hole tool.

We claim: 
     
         1 . A composite down-hole tool comprising:
 a plurality of fibers, said fibers extending along at least a first fiber plane and a second fiber plane, said first fiber plane and said second fiber plane being arranged perpendicular;   a matrix material substantially filling the area between and around the plurality of fibers; and   wherein the down-hole tool is spherical or cylindrical and substantially all of said plurality of fibers extend substantially straight and uninterrupted between opposed sides of the spherical or cylindrical shape down-hole tool.   
     
     
         2 . The down-hole tool according to  claim 1  having a density less than about 1.8 g/cc. 
     
     
         3 . The down-hole tool according to  claim 1  having a density of from between about 1.0 g/cc and about 1.8 g/cc. 
     
     
         4 . The down-hole tool according to  claim 1  having uniform compressive strength. 
     
     
         5 . The down-hole tool according to  claim 1  wherein the compressive strength of the down-hole tool is different in the direction of said first fiber plane from said second fiber plane. 
     
     
         6 . The down-hole tool according to  claim 1  further comprising a third fiber plane arranged parallel to said first fiber plane and having a third fiber direction, said first fiber plane having a first fiber direction being 90 degrees offset from said third fiber direction. 
     
     
         7 . The down-hole tool according to  claim 1  further comprising a third fiber plane and a fourth fiber plane arranged parallel to said first fiber plane, said first fiber plane having a first fiber direction, said second fiber plane having a second fiber direction, said third fiber plan having a third fiber direction and said fourth fiber plane having a fourth fiber direction, said first fiber direction, being offset by 60 degrees from said third fiber direction and said fourth fiber direction being offset by 60 degrees from said third fiber direction. 
     
     
         8 . The down-hole tool according to  claim 1  having a fiber volume from between about 15% and about 55%. 
     
     
         9 . The down-hole tool according to  claim 1  having a fiber volume from between about 30% and about 40%. 
     
     
         10 . The down-hole tool according to  claim 1  having a compressive strength factor greater than about 80 ksi. 
     
     
         11 . The down-hole tool according to  claim 1  having a tensile strength factor greater than about 220 ksi. 
     
     
         12 . The down-hole tool according to  claim 1  wherein said plurality of fibers include one or more of PAN based carbon fibers, E glass fibers or S glass fibers. 
     
     
         13 . The down-hole tool according to  claim 1  wherein said matrix comprises epoxy or polyimide. 
     
     
         14 . The down-hole tool according to  claim 1  wherein said plurality of fibers includes radially extending fibers, circumferentially extending fibers and axially extending fibers. 
     
     
         15 . The down-hole tool according to  claim 1  having a diameter of from between about 0.5 to about 8.0 inches. 
     
     
         16 . A composite down-hole tool comprising
 a plurality of layers of fabric each layer comprises a plurality of fibers woven in two dimensions;   a matrix material substantially filling an area between adjacent fibers and between adjacent fabric layers; and   wherein the down-hole tool having a spherical or cylindrical shape.   
     
     
         17 . The tool of  claim 18  wherein the fabric layers constructed from more than one sized fiber tows, size of the tows range from 1000 to 24000. 
     
     
         18 . The tool of  claim 18  wherein the matrix material comprises at least one of an epoxy, phenolic, polyimide, pitch and combinations thereof. 
     
     
         19 . The tool of  claim 18  wherein the matrix material comprises a reinforcement, the reinforcement comprises at least one of single walled carbon nanotube, multi-walled carbon nanotubes and combinations thereof. 
     
     
         20 . The tool of  claim 21  wherein the matrix material comprises no more than five percent by weight of the resin. 
     
     
         21 . The tool of  claim 18  wherein the fabric layer may comprise one of a twill style weave, a plain weave or a unidirectional weave.