CN111055412B - 一种用弹性体材料生产螺杆钻具定子的成型方法 - Google Patents

一种用弹性体材料生产螺杆钻具定子的成型方法 Download PDF

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CN111055412B
CN111055412B CN201811211495.7A CN201811211495A CN111055412B CN 111055412 B CN111055412 B CN 111055412B CN 201811211495 A CN201811211495 A CN 201811211495A CN 111055412 B CN111055412 B CN 111055412B
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elastomer material
stator
curing
heating
prepolymer
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CN111055412A (zh
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郭丁瑜
张洪瑞
朱明慧
刘屹然
刘颛瑞
张光顺
刘孝波
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Shanghai Pujia Drilling And Production Technology Co ltd
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Shanghai Pujia Drilling And Production Technology Co ltd
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Priority to PCT/CN2019/082764 priority patent/WO2020077965A1/zh
Priority to CA3077891A priority patent/CA3077891C/en
Priority to US16/843,908 priority patent/US11673297B2/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
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    • B29C33/56Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
    • B29C33/58Applying the releasing agents
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
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    • B29C33/60Releasing, lubricating or separating agents
    • B29C33/62Releasing, lubricating or separating agents based on polymers or oligomers
    • B29C33/64Silicone
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29C37/006Degassing moulding material or draining off gas during moulding
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C39/003Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor characterised by the choice of material
    • B29C39/006Monomers or prepolymers
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Abstract

本发明提供了一种用弹性体材料生产螺杆钻具定子的成型方法,包括如下步骤:S1、对定子管的内表面依次进行粗化、清洗、烘干处理;将胶粘剂与稀释剂混合后涂覆在烘干后的定子管的内表面上,加热后备用;S2、将脱模剂均匀涂覆在芯轴模具表面,加热或自然干后备用;S3、将处理后的定子管与处理后的芯轴模具进行组装得组合模具;S4、将预聚体与消泡剂均匀混合后进行负压真空脱泡处理;S5、将脱泡后的预聚体与固化剂均匀混合,所得混合液灌注至步骤S3的组合模具中,密封、分级加热固化;待固化结束后冷却,抽出芯轴模具,即得。通过本发明工艺,可获得硬度、撕裂强度、拉伸强度、断裂伸长率、永久变形率等性能优良的螺杆钻具定子。

Description

一种用弹性体材料生产螺杆钻具定子的成型方法
技术领域
本发明涉及有机高分子成型加工技术领域,具体地,涉及一种用弹性体材料生产螺杆钻具定子的成型方法,应用于钻井技术领域。
背景技术
随着钻、探井环境复杂程度和开采难度的不断提高,钻井作业的工作条件愈加苛刻,这对螺杆钻具用弹性体材料及其成型制备工艺提出新的要求,对螺杆钻具用弹性体材料综合性能的要求越来越高。同时,螺杆钻具用弹性体材料的拉伸强度、撕裂强度、剥离强度、耐磨性、硬度、耐温特性等在特定使用条件下将直接影响材料的使用寿命和钻井成本;而其成型加工工艺的简易化将直接影响用户成本。因此,改善材料与金属的界面胶粘强度(特别是流体渗流条件下的界面胶粘强度的建立和保持)的工艺、简化材料加工流程以及优化成型生产工艺成为目前钻井用弹性体材料的研究热点及重要的发展方向之一。
目前,传统螺杆钻具用弹性体材料大多数为橡胶材质,其耐高温力学性能较低,抗拉伸强度和撕裂强度等亦并不出色,与金属表面粘接能力不足,尤其是其加工成型工艺繁琐,通常需要混炼制备成半成品、经过硫化、二次硫化等工序得到成品材料,整个生产过程存在高耗能、高污染等一系列问题,越发无法满足节能环保的国际要求;再与钻井设备进行匹配组装才能进行钻井作业。因此传统的螺杆钻具用橡胶材料不仅工序繁琐、能耗较大,同时其损耗速率较快,使用寿命较短,这极大程度上降低了钻井开发的经济效益,无法满足目前降本增效的钻井作业工艺的要求及发展趋势。
因此,对螺杆钻具用弹性体材料的成型生产工艺的研发在科学研究和应用领域方面都具有重大意义。
发明内容
针对现有技术中的缺陷,本发明的目的是提供一种用弹性体材料生产螺杆钻具定子的成型方法。旨在克服传统螺杆钻具用弹性体材料加工成型工艺繁琐、耗能高、污染大、耐温性弱、撕裂强度及界面剥离强度低等不足,提供一种新型螺杆钻具用弹性体材料的成型生产方法;简化生产工艺,实现快速成型、节能环保,明显提高螺杆钻具用弹性体材料各项性能,特别兼具耐高温、高撕裂强度、高硬度、材料与金属界面的高剥离强度等特性。
本发明提供了一种用弹性体材料生产螺杆钻具定子的成型方法,提供的弹性材料既具有传统橡胶材料的耐磨、耐腐蚀等优点,又兼具硬度高、耐温高、撕裂强度高等优势;提供的成型工艺可以很好的解决螺杆钻具用弹性体材料与定子管的界面粘接性问题,实现材料界面剥离强度的大幅度提高,延长了螺杆钻具定子的使用寿命,可更好的满足如今温度高、体积小动力大、寿命长等严苛的钻井作业环境要求;同时,提供的成型工艺具备低耗能,低污染的生产特性,极大的满足了节能环保的要求。
本发明的目的是通过以下技术方案来实现的:
本发明提供一种用弹性体材料生产螺杆钻具定子的成型方法,包括如下步骤:
S1、对定子管的内表面进行粗化处理,然后进行清洗、烘干;将胶粘剂与稀释剂均匀混合后涂覆在烘干后的定子管的内表面上,加热处理后备用;
S2、将脱模剂均匀涂覆在芯轴模具表面,加热或自然干燥后备用;
S3、将经步骤S1处理后的定子管与经步骤S2处理后的芯轴模具进行组装得组合模具;
S4、将弹性体材料的预聚体与消泡剂均匀混合后进行负压真空脱泡处理;
S5、将步骤S4中脱泡后的弹性体材料的预聚体与固化剂均匀混合,所得混合液灌注至步骤S3的组合模具中,密封、分级加热固化;待固化结束后冷却,抽出芯轴模具,即得。
优选地,步骤S1中,所述胶粘剂包括环氧树脂;环氧树脂来源广泛、成本较低,但产品附加值高,在作为胶粘剂应用中表现出良好的粘接性、韧性及尺寸稳定性,是综合性能较好的胶粘剂组分之一;此外,在本弹性体制备过程中,环氧树脂能够与预聚体发生后固化交联反应,且两者交联反应的加工条件匹配性较好,可进一步增强弹性体与定子管内壁间的粘接作用。如选用其他种类胶粘剂,需同时考虑胶粘剂自身的粘接特性以及胶粘剂与本弹性体材料的预聚体间的相容性/共聚反应等特性,可能会大幅增加成品的生产加工成本和难度。
优选地,步骤S1中,所述稀释剂包括丁二醇、丙三醇中的至少一种;所述胶粘剂与稀释剂的质量比为(0.72~0.91):(0.09~0.28)。胶粘剂与稀释剂的比值选择范围是经系统实验探索后的结果,在该范围内,体系的粘接性和加工特性表现最为优异。
优选地,步骤S1中,所述加热处理的条件为:80-100℃热处理1-3小时。
更优选地,步骤S1中,所述加热处理的条件为:90℃加热处理1h。
优选地,步骤S2中,所述脱模剂包括硅树脂甲基支链硅油、甲基硅油、硅橡胶甲苯溶液、氟树脂涂料中的一种或两种。
优选地,步骤S2中,所述表面为芯轴模具的外表面。
优选地,步骤S4中,所述弹性体材料的预聚体包括A组分和B组分,其中,所述A组分包括质量比为(0.2~1.0):(0.2~1.0):(0.2~1.0)的端羟基液体橡胶、聚四氢呋喃二醇和聚醚多元醇;所述B组分包括异氰酸酯、氰酸酯、氰基化合物中的至少一种。端羟基液体橡胶的作用为封端和提供交联点,聚四氢呋喃二醇和聚醚多元醇的作用为封端,三者的比例在该范围内调节,有利于控制预聚体的黏度、交联反应程度以及最终弹性体的综合性能。超出该范围的配比会导致预聚体黏度过大或过小,或者弹性体的最终性能不满足应用要求。
优选地,所述端羟基液体橡胶包括端羟基液体丁腈橡胶(HTBN)。通过选择端羟基液体丁腈橡胶不仅可增加弹性体的流动性,而且能用于封端和增加交联点,从而提高弹性体的交联程度和最终强度;若选用其他端羟基液体橡胶,由于不具备共交联反应的活性基团,难以实现交联程度的提高,从而影响弹性体的综合性能。
优选地,所述异氰酸酯包括甲苯二异氰酸酯(TDI)、异佛尔酮二异氰酸酯(IPDI)中的至少一种。若采用其他类型的异氰酸酯,如二苯基甲烷二异氰酸酯、二环己基甲烷二异氰酸酯等,会导致反应速率过快和反应产物综合性能不符合本发明的性能要求,不适用于本发明。
优选地,所述聚醚多元醇包括丙二醇聚醚、三羟甲基丙烷聚醚和聚乙二醇中的至少一种。通过调节聚醚多元醇的种类和分子量,可有效控制预聚体的黏度和最终弹性体的硬度以及回复性。
更优选地,所述聚醚多元醇包括重均分子量为800~2000的丙二醇聚醚、重均分子量为400~4000的三羟甲基丙烷聚醚和重均分子量为400~2000聚乙二醇中的至少一种。
优选地,所述A组分和B组分的质量比为(0.9:1.1)~(0.85:1.25)。A组分和B组分的比值为该范围时,两组分的封端反应较完全,反应程度较优异,最终预聚体的分子结构规整、可控。
更优选地,所述A组分和B组分的质量比为1:1。A组分:B组分=1:1时,两组分的封端反应最为完全,反应程度最为优异,最终预聚体的分子结构最为规整和可控。
优选地,所述弹性体材料的预聚体的制备方法,包括如下步骤:
A1、将B组分置于反应容器中,升温、进行负压脱水处理;
A2、将A组分加入经步骤S1处理后的B组分中,在50-95℃温度下进行聚合反应;冷却至室温,即得。
优选地,步骤A1中,所述负压脱水处理的条件为:反应温度为50~70℃,脱水时间为0.5~2h。
优选地,步骤A2中,所述聚合反应的时间为3-8小时。
优选地,步骤S4中,所述消泡剂包括聚二甲基硅氧烷、聚氧丙烯甘油醚、硅醚共聚物中的至少一种;所述弹性体材料的预聚体与消泡剂的质量比为(100~167):1。若弹性体材料的预聚体与消泡剂的质量比低于100,脱泡效果不明显;高于167,对弹性体性能有降低的影响。
优选地,步骤S4中,所述脱泡处理的时间为0.5~2h。
优选地,步骤S5中,所述固化剂为芳香二元胺与多元醇的共混物;所述芳香二元胺包括4,4'-二氨基二苯砜、4-硝基苯胺、对二邻氯苯胺甲烷中的至少一种;所述多元醇包括聚四氢呋喃醚二醇、双三羟甲基丙烷、乙二醇中的至少一种。
优选地,步骤S5中,所述弹性体材料的预聚体与固化剂的质量比为1:(0.2~0.5)。固化剂与预聚体反应基团是在一定摩尔比范围内进行固化扩链反应,当固化剂用量在0.2~0.5范围内制备得到的产品性能最佳。当低于此范围时,预聚体系固化不完全,综合性能较差;如高于此范围,则导致预聚体局部反应过度,体系内部出现相分离,最终导致综合性能较差。
优选地,步骤S5中,所述分级加热固化的条件为:逐级升温固化,包括2级至6级加热,固化的温度为60℃~160℃,每级固化的时间为1.5~5h。固化温度过低,固化不完全,强度达不到;固化温度过高,材料分解、失效。
更优选地,步骤S5中,所述分级加热固化的温度选自60℃、80℃、100℃、120℃、140℃和160℃中的几种。分级升温固化是控制固化反应速率,先采用低温段预聚,高温段增加交联度。如果采用单一温度固化,温度过低导致固化不完全,导致性能无法达到最佳;温度过高导致反应剧烈,出现爆聚现象,从而无法得到性能和尺寸稳定的产品。
更优选地,所述分级加热固化的温度为60℃、80℃、100℃、120℃。
优选地,所述定子管包括螺杆钻具定子管,也包括在内壁上粘结本发明弹性体材料的其他管材,所述其他管材为金属或非金属管材。
本发明针对本弹性体材料提供的制备工艺具体为:以弹性体材料的预聚体和固化剂体系为材料基体,通过对螺杆钻具定子管进行内表面胶粘剂涂覆处理,在本预聚体成型过程中通过原位聚合反应,增强弹性体材料与定子管间的界面粘接强度。通过控温固化处理制造出性能可控的耐高温、硬度高、单位长度上动力大等新型螺杆钻具定子。
本发明提供的本弹性体材料的成型生产工艺的特点在于:针对本发明中弹性体材料采用一次成型灌注法,分段温度控制固化法,使最终得到的弹性体材料具备硬度可控、耐高温、高撕裂强度及高界面剥离强度等优异特点。
本发明提供一种用新型弹性体材料生产螺杆钻具定子的成型方法。该弹性体材料既具有传统橡胶材料的耐磨、耐腐蚀等优点,又兼具硬度高、耐高温、高撕裂强度等优势;同时,本发明公布的一次成型工艺可以提高螺杆钻具用弹性体材料与定子管的界面粘接性问题,实现材料界面剥离强度的提高,延长了螺杆钻具定子的使用寿命,可更好的满足如今高温力学性、体积小、动力大、寿命长等要求;更为重要的是,一次成型生产工艺能够有效的简化成型工艺,缩短加工流程以及节省能耗,这使得在不牺牲环境质量的前提下进一步提升生产商和用户的经济效益成为可能。
与现有技术相比,本发明具有如下的有益效果:
采用本发明的用新型弹性体材料生产螺杆钻具定子的成型方法,可以简便地生产制造具有弹性体硬度高、耐温高、单位长度上动力大等特性的螺杆钻具定子。通过调节弹性体材料的预聚体和固化剂结构类型和配比,改变固化温度及时间等,可得到弹性体拉伸强度、撕裂强度、硬度和永久变形率等性能可调可控的弹性体材料,适用于多种作业环境。此外,该弹性体材料在传统橡胶材料基础上其硬度、撕裂强度、耐温性和界面剥离强度均有较大提升,使该材料及工艺生产的螺杆钻具定子能够更好的适应当下温度高、体积小,动力大等严苛的钻井环境要求,且易实现工业化。
具体实施方式
下面结合具体实施例对本发明进行详细说明。以下实施例将有助于本领域的技术人员进一步理解本发明,但不以任何形式限制本发明。应当指出的是,对本领域的普通技术人员来说,在不脱离本发明构思的前提下,还可以做出若干变化和改进。这些都属于本发明的保护范围。
实施例1
本实施例提供一种用弹性体材料生产螺杆钻具定子的成型方法,包括如下步骤:
一、制备弹性材料的预聚体原浆,包括如下步骤:
步骤(1)将20kg的甲苯二异氰酸酯(TDI)置于反应釜中,升温至50℃后进行负压脱水处理1h;
步骤(2)分别称取端羟基液体丁腈橡胶(10kg)、聚四氢呋喃二醇(6kg)、聚醚多元醇为分子量2000的聚乙二醇(4kg),按顺序依次逐渐滴加至步骤(1)中,在50℃下持续反应8小时;
步骤(3)待步骤(2)反应结束后,自然冷却至室温,即得弹性体材料的预聚体原浆;
二、弹性体材料的预聚体原浆的成型工艺,包括如下步骤:
步骤(1)对钻具定子管的内表面粗化处理,并将其清洗后烘干;
步骤(2)把500g环氧树脂与100g丁二醇混合后均匀涂覆在步骤(1)得到的钻具定子管内表面,90℃加热处理1h后备用;把硅树脂甲基支链硅油均匀涂覆到芯轴模具表面,自然晾干后备用;将处理完毕后的钻具定子管与芯轴进行组装后备用;
步骤(3)将25kg弹性体材料的预聚体原浆与250g消泡剂混合均匀后在50℃进行负压真空脱泡1h,自然冷却至室温;
步骤(4)将步骤(3)得到的25kg脱泡后弹性体材料的预聚体原浆与10kg 4,4'-二氨基二苯砜/乙二醇体系固化剂混合均匀后灌注至组合模具中,密封;
步骤(5)将步骤(4)得到基体材料连同模具置于分级升温装置中进行固化处理;处理温度分别为60℃,80℃,100℃和120℃,处理时间均为2h。
步骤(6)待步骤(5)固化完毕并自然冷却至室温后,抽出芯轴模具即可得到所生产的产品。
本实施例通过步骤(6)固化后得到产品的胶体表面平整,无气泡等缺陷。测试结果如下:测试拉伸强度为18.2MPa,断裂伸长率为638%,永久变形率(拉伸300%后回复)5.7%,撕裂强度76kN/m,邵氏硬度为84A,所有数据均高于螺杆钻具用弹性体材料的标准(HG/T 4382-2012)要求。本实施例中弹性体材料与定子管的界面粘接性好,硬度达到80A-90A仍能保持优异的粘结性,弹性体材料剥离强度高,螺杆钻具定子的使用寿命长。
实施例2
本实施例提供用一种弹性体材料生产螺杆钻具定子的成型方法,包括如下步骤:
一、制备弹性材料的预聚体原浆,包括如下步骤:
步骤(1)将20kg双酚M型氰酸酯置于反应釜中,升温至50℃后进行负压脱水处理1h;
步骤(2)分别称取端羟基液体丁腈橡胶(10kg)、聚四氢呋喃二醇(6kg)、分子量4000的三羟甲基丙烷聚醚(4kg),按顺序依次逐渐滴加至步骤(1)中,在50℃下持续反应8小时;
步骤(3)待步骤(2)反应结束后,自然冷却至室温,即得弹性体材料的预聚体原浆。
二、弹性体材料的预聚体原浆的成型工艺,包括如下步骤:
步骤(1)对定子管的表面粗化处理,并将其清洗后烘干;
步骤(2)把500g环氧树脂与70g丙三醇混合后均匀涂覆在步骤(1)得到的定子管内表面,90℃加热处理1h后备用;把甲基硅油均匀涂覆到芯轴模具表面自然晾干后备用;将处理完毕后的定子管与芯轴进行组装后备用;
步骤(3)将25kg弹性体材料的预聚体原液与200g消泡剂混合均匀后在50℃进行负压真空脱泡1h,自然冷却至室温;
步骤(4)将步骤(3)得到的25kg脱泡后弹性体材料的预聚体原液与10.63kg 4-硝基苯胺/双三羟甲基丙烷体系固化剂混合均匀后灌注至组合模具中,密封;
步骤(5)将步骤(4)得到基体材料连同模具置于分级升温装置中进行固化处理;处理温度为60℃,80℃,100℃和120℃,处理时间均为3h。
步骤(6)待步骤(5)固化完毕并自然冷却至室温后,抽出芯轴模具即可得到所生产的产品。
本实施例通过步骤(6)固化后得到产品的胶体表面平整,无气泡等缺陷;测试结果如下:测试拉伸强度为20.1MPa,断裂伸长率为430%,永久变形率(拉伸300%后回复)3.6%,撕裂强度52kN/m,邵氏硬度为82A,所有数据均高于螺杆钻具用弹性体材料的标准(HG/T 4382-2012)要求。本实施例中弹性体材料与定子管的界面粘接性好,硬度达到80A-90A仍能保持优异的粘结性,弹性体材料剥离强度高,螺杆钻具定子的使用寿命长。
实施例3
本实施例提供一种用弹性体材料生产螺杆钻具定子的成型方法,包括如下步骤:
一、制备弹性材料的预聚体原浆,包括如下步骤:
步骤(1)将20kg的端腈基聚醚腈置于反应釜中,升温至50℃后进行负压脱水处理1h;
步骤(2)分别称取端羟基液体丁腈橡胶(6kg)、聚四氢呋喃二醇(10kg)、分子量2000的丙二醇聚醚(4kg),按顺序依次逐渐滴加至步骤(1)中,在60℃下持续反应8小时;
步骤(3)待步骤(2)反应结束后,自然冷却至室温,即得弹性体材料的预聚体原浆。
二、聚氨酯预聚体原浆的成型工艺,包括如下步骤:
步骤(1)对定子管的表面粗化处理,并将其清洗后烘干;
步骤(2)把500g环氧树脂与90g丁二醇/丙三醇按质量比1:1共混体系的稀释剂混合后均匀涂覆在步骤(1)得到的定子管内表面,90℃加热处理1h后备用;把硅橡胶甲苯溶液均匀涂覆到芯轴模具表面自然晾干后备用;将处理完毕后的定子管与芯轴进行组装后备用;
步骤(3)将25kg聚氨酯预聚体原液与150g消泡剂混合均匀后在50℃进行负压真空脱泡1h,自然冷却至室温;
步骤(4)将步骤(3)得到的25kg脱泡后聚氨酯预聚体原液与10.63kg对二邻氯苯胺甲烷/双三羟甲基丙烷体系固化剂混合均匀后灌注至组合模具中,密封;
步骤(5)将步骤(4)得到基体材料连同模具置于分级升温装置中进行固化处理;处理温度为60℃,80℃,100℃和120℃,处理时间均为4h。
步骤(6)待步骤(5)固化完毕并自然冷却至室温后,抽出芯轴模具即可得到所生产的产品。
本实施例通过步骤(6)固化后得到产品的胶体表面平整,无气泡等缺陷;测试结果如下:测试拉伸强度为20.1MPa,断裂伸长率为408%,永久变形率(拉伸300%后回复)3.96%,撕裂强度72kN/m,邵氏硬度为88A,所有数据均高于螺杆钻具用弹性体材料的标准(HG/T 4382-2012)要求。本实施例中弹性体材料与定子管的界面粘接性好,硬度达到80A-90A仍能保持优异的粘结性,弹性体材料剥离强度高,螺杆钻具定子的使用寿命长。
实施例4
本实施例提供一种用弹性体材料生产螺杆钻具定子的成型方法,包括如下步骤:
一、制备弹性材料的预聚体原浆,包括如下步骤:
步骤(1)将20kg的双酚M型氰酸酯置于反应釜中,升温至50℃后进行负压脱水处理1h;
步骤(2)分别称取端羟基液体丁腈橡胶(5kg)、聚四氢呋喃二醇(8kg)、分子量1000的三羟甲基丙烷聚醚(7kg),按顺序依次逐渐滴加至步骤(1)中,在60℃下持续反应5小时;
步骤(3)待步骤(2)反应结束后,自然冷却至室温,即得弹性体材料的预聚体原浆。
二、聚氨酯预聚体原浆的成型工艺,包括如下步骤:
步骤(1)对定子管的表面粗化处理,并将其清洗后烘干;
步骤(2)把500g环氧树脂与80g丁二醇混合后均匀涂覆在步骤(1)得到的定子管内表面,90℃加热处理1h后备用;把甲基硅油均匀涂覆到芯轴模具表面自然晾干后备用;将处理完毕后的定子管与芯轴进行组装后备用;
步骤(3)将25kg聚氨酯预聚体原液与180g消泡剂混合均匀后在50℃进行负压真空脱泡1h,自然冷却至室温;
步骤(4)将步骤(3)得到的25kg脱泡后聚氨酯预聚体原液与11.25kg 4-硝基苯胺/双三羟甲基丙烷体系固化剂混合均匀后灌注至组合模具中,密封;
步骤(5)将步骤(4)得到基体材料连同模具置于分级升温装置中进行固化处理;处理温度为60℃,80℃,100℃和120℃,处理时间均为5h。
步骤(6)待步骤(5)固化完毕并自然冷却至室温后,抽出芯轴模具即可得到所生产的产品。
本实施例通过步骤(6)固化后得到产品的胶体表面平整,无气泡等缺陷;测试结果如下:测试拉伸强度为24.7MPa,断裂伸长率为505%,永久变形率(拉伸300%后回复)3.6%,撕裂强度90kN/m,邵氏硬度为87A,所有数据均高于螺杆钻具用弹性体材料的标准(HG/T 4382-2012)要求。本实施例中弹性体材料与定子管的界面粘接性好,硬度达到80A-90A仍能保持优异的粘结性,弹性体材料剥离强度高,螺杆钻具定子的使用寿命长。
实施例5
本实施例提供一种用弹性体材料生产螺杆钻具定子的成型方法,具体步骤与实施例1基本一致,不同之处仅在于:本实施例的步骤(5)中,固化处理的温度为60℃、160℃,处理时间分别为3h、5h。
本实施例制备的产品的胶体表面平整,无气泡等缺陷。产品的拉伸强度、断裂伸长率、永久变形率(拉伸300%后回复)、撕裂强度、邵氏硬度均高于螺杆钻具用弹性体材料的标准(HG/T 4382-2012)要求,但稍差于实施例1的结果。
实施例6
本实施例提供一种用弹性体材料生产螺杆钻具定子的成型方法,具体步骤与实施例1基本一致,不同之处仅在于:本实施例的步骤(5)中,固化处理的温度为60℃、80℃、100℃、120℃、140℃和160℃,处理时间均为1.5h。
本实施例制备的产品的胶体表面平整,无气泡等缺陷。产品的拉伸强度、断裂伸长率、永久变形率(拉伸300%后回复)、撕裂强度、邵氏硬度均高于螺杆钻具用弹性体材料的标准(HG/T 4382-2012)要求,但稍差于实施例1的结果。
对比例1
本对比例提供一种用常规弹性体材料生产螺杆钻具定子的成型方法,具体步骤与实施例1基本一致,不同之处仅在于:本对比例中,采用常规的PTMG型聚氨酯预聚体。
本对比例固化后得到产品表面平整,无明显气泡;测试结果如下:拉伸强度为12.6MPa,断裂伸长率为798%,永久变形率(拉伸300%后回复)为5.8%,撕裂强度为48kN/m,邵氏硬度为82A。拉伸强度强度低于螺杆钻具用弹性体材料的标准(HG/T4382-2012)要求;普通聚氨酯预聚体的耐水性差,尤其是温度超过70℃后,不能适用于工况环境。
对比例2
本对比例提供一种用弹性体材料生产螺杆钻具定子的成型方法,具体步骤与实施例1基本一致,不同之处仅在于:本对比例中,步骤(5)中,将步骤(4)得到基体材料连同模具置于升温装置中进行固化处理;处理温度为120℃,处理时间为8h。
本对比例固化后得到产品表面较平整,内部气泡明显,有明显分相现象;测试结果如下:拉伸强度为14.8MPa,断裂伸长率为459%,永久变形率(拉伸300%后回复)为3.8%,撕裂强度为52kN/m,邵氏硬度约为85A。拉伸强度强度低于螺杆钻具用弹性体材料的标准(HG/T 4382-2012)要求。
对比例3
本对比例提供一种用弹性体材料生产螺杆钻具定子的成型方法,具体步骤与实施例1基本一致,不同之处仅在于:本对比例中,步骤(5)中,将步骤(4)得到基体材料连同模具置于升温装置中进行固化处理;处理温度分别为50℃,70℃,90℃和110℃,处理时间均为2h。
本对比例固化后得到产品表面平整,无气泡等缺陷;测试结果如下:拉伸强度为12.6MPa,断裂伸长率为627%,永久变形率(拉伸300%后回复)为5.8%,撕裂强度为43kN/m,邵氏硬度为78A。拉伸强度强度、撕裂强度等低于螺杆钻具用弹性体材料的标准(HG/T4382-2012)要求。
对比例4
本对比例提供一种用弹性体材料生产螺杆钻具定子的成型方法,具体步骤与实施例1基本一致,不同之处仅在于:本对比例中,步骤(4)中,25kg脱泡后聚氨酯预聚体原浆与9kg 4,4'-二氨基二苯砜/乙二醇体系固化剂混合。
本对比例固化后得到产品表面较平整,有少量气泡和微相分离现象;测试结果如下:拉伸强度为10.2MPa,断裂伸长率为690%,永久变形率(拉伸300%后回复)为5.1%,撕裂强度为58kN/m,邵氏硬度为82A。拉伸强度强度低于螺杆钻具用弹性体材料的标准(HG/T4382-2012)要求。
对比例5
本对比例提供一种用弹性体材料生产螺杆钻具定子的成型方法,具体步骤与实施例1基本一致,不同之处仅在于:本对比例中,步骤(4)中,采用邻苯二甲酸酐体系固化剂代替4,4'-二氨基二苯砜/乙二醇体系固化剂。
本对比例固化后得到产品表面较平整,有微量小气泡残留在体系内部;测试结果如下:拉伸强度为11.8MPa,断裂伸长率为498%,永久变形率(拉伸300%后回复)为5.3%,撕裂强度为51kN/m,邵氏硬度为72A。拉伸强度强度低于螺杆钻具用弹性体材料的标准(HG/T 4382-2012)要求。
五个对比例得到产品力学性能中,拉伸强度、撕裂强度等均低于实施例产品性能,其中拉伸强度均达不到螺杆钻具用弹性体材料的标准(HG/T 4382-2012)要求;同时,对比例1用的常规弹性体在耐温、耐温水等性能方面均不能满足钻井工况要求。
本发明提供一种用新型弹性体材料生产螺杆钻具定子的成型方法,主要包括螺杆钻具用钢管(定子管)及芯轴的表界面处理、组装、新型材料注射、固化成型等流程。所述生产工艺所需的原材料包括预聚体原浆、固化剂、消泡剂、脱模剂、胶粘剂、稀释剂。通过新型弹性体材料的引入,有效简化了生产工艺及流程,实现了一次成型生产工艺。首先将胶粘剂与稀释剂按(0.72~0.91):(0.09~0.28)混合后均匀涂敷在定子管内表面并加温初步固化,将脱膜剂均匀涂附在芯轴外表面并自然晾干或烘干,然后组装定子管与芯轴。最后,通过改变预聚体原浆与固化剂的比例混合,经高压注入定子管与芯轴的组合体内并按程序升温固化,实现一次成型并得到能满足设计要求如:硬度、撕裂强度、拉伸强度、断裂伸长率、永久变形率以及耐温、耐油、耐温水等性能的螺杆钻具定子。该材料的一次成型生产工艺属于有机高分子加工技术领域,具体可作为弹性体材料应用于钻井技术领域。
以上对本发明的具体实施例进行了描述。需要理解的是,本发明并不局限于上述特定实施方式,本领域技术人员可以在权利要求的范围内做出各种变化或修改,这并不影响本发明的实质内容。在不冲突的情况下,本申请的实施例和实施例中的特征可以任意相互组合。

Claims (2)

1.一种用弹性体材料生产螺杆钻具定子的成型方法,其特征在于,包括如下步骤:
S1、对定子管的内表面进行粗化处理,然后进行清洗、烘干;将胶粘剂与稀释剂均匀混合后涂覆在烘干后的定子管的内表面上,加热处理后备用;所述胶粘剂包括环氧树脂;其中,所述加热处理的条件为:80-100℃加热处理1-3小时;所述稀释剂包括丁二醇、丙三醇中的至少一种;所述胶粘剂与稀释剂的质量比为(0.72~0.91):(0.09~0.28);
S2、将脱模剂均匀涂覆在芯轴模具表面,加热或自然干燥后备用;所述脱模剂包括硅树脂甲基支链硅油、甲基硅油、硅橡胶甲苯溶液、氟树脂涂料中的一种或两种;
S3、将经步骤S1处理后的定子管与经步骤S2处理后的芯轴模具进行组装得组合模具;
S4、将弹性体材料的预聚体与消泡剂均匀混合后进行负压真空脱泡处理;所述弹性体材料的预聚体包括A组分和B组分,其中,所述A组分包括质量比为(0.2~1.0):(0.2~1.0):(0.2~1.0)的端羟基液体橡胶、聚四氢呋喃二醇和聚醚多元醇;所述B组分包括异氰酸酯、氰酸酯、氰基化合物中的至少一种;其中,所述端羟基液体橡胶为端羟基液体丁腈橡胶;所述异氰酸酯为甲苯二异氰酸酯、异佛尔酮二异氰酸酯中的至少一种;所述聚醚多元醇包括丙二醇聚醚、三羟甲基丙烷聚醚和聚乙二醇中的至少一种;所述A组分和B组分的质量比为(0.9:1.1)~(0.85:1.25);
S5、将步骤S4中脱泡后的弹性体材料的预聚体与固化剂均匀混合,所得混合液灌注至步骤S3的组合模具中,密封、分级加热固化;待固化结束后冷却,抽出芯轴模具,即得;所述分级加热固化的条件为:逐级升温固化,包括2级至6级加热,固化的温度为60℃~160℃,每级固化的时间为1.5~5h;所述固化剂为芳香二元胺与多元醇的共混物;所述弹性体材料的预聚体与固化剂的质量比为1:(0.2~0.5)。
2.根据权利要求1所述的用弹性体材料生产螺杆钻具定子的成型方法,其特征在于,步骤S4中,所述消泡剂包括聚二甲基硅氧烷、聚氧丙烯甘油醚、硅醚共聚物中的至少一种;所述弹性体材料的预聚体与消泡剂的质量比为(100~167):1;所述脱泡处理的时间为0.5~2h。
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