Low-density floats including one or more hollow ceramic shells for use in a downhole environment

Abstract

Provided is a float for use with a fluid flow control device, a fluid flow control device, a method for manufacturing a fluid flow control device, and a well system. The float, in one aspect, includes a base material having one or more hollow ceramic shells therein, the base material and the one or more hollow ceramic shells creating a net density for the float that is between a first density of a desired fluid and a second density of an undesired fluid, such that the float may control fluid flow through a flow control device when encountering the desired fluid or the undesired fluid.

What is claimed is: 
     
         1 . A float for use with a fluid flow control device, comprising:
 a base material having one or more hollow ceramic shells therein, the base material and the one or more hollow ceramic shells creating a net density for the float that is between a first density of a desired fluid and a second density of an undesired fluid, such that the float may control fluid flow through a flow control device when encountering the desired fluid or the undesired fluid.   
     
     
         2 . The float as recited in  claim 1 , wherein the base material and the one or more hollow ceramic shells create the net density for the float that is above the first density of the desired fluid and below the second density of the undesired fluid. 
     
     
         3 . The float as recited in  claim 1 , wherein the base material is a polymer base material having the one or more hollow ceramic shells therein. 
     
     
         4 . The float as recited in  claim 3 , wherein the base material has four or more substantially equally spaced hollow ceramic shells. 
     
     
         5 . The float as recited in  claim 3 , wherein the base material has four or more gradiently spaced hollow ceramic shells positioned to alter a center of gravity of the float. 
     
     
         6 . The float as recited in  claim 3 , wherein the base material has four or more substantially equally sized hollow ceramic shells. 
     
     
         7 . The float as recited in  claim 1 , further including a fluid impermeable exterior surrounding the base material having the one or more hollow ceramic shells therein. 
     
     
         8 . The float as recited in  claim 7 , wherein the fluid impermeable exterior forms a hermetic seal around the base material having one or more hollow ceramic shells therein. 
     
     
         9 . The float as recited in  claim 1 , wherein the float includes a critical density area and a non-critical density area. 
     
     
         10 . The float as recited in  claim 9 , wherein the critical density area includes the base material and the one or more hollow ceramic shells, and the non-critical density area comprises a different base material.