EP3377302A1 - Low density subsea buoyancy and insulation material and method of manufacturing - Google Patents
Low density subsea buoyancy and insulation material and method of manufacturingInfo
- Publication number
- EP3377302A1 EP3377302A1 EP15908920.0A EP15908920A EP3377302A1 EP 3377302 A1 EP3377302 A1 EP 3377302A1 EP 15908920 A EP15908920 A EP 15908920A EP 3377302 A1 EP3377302 A1 EP 3377302A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- voids
- layers
- printing
- sequential
- forming
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/01—Risers
- E21B17/012—Risers with buoyancy elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B41/00—Equipment or details not covered by groups E21B15/00 - E21B40/00
- E21B41/0007—Equipment or details not covered by groups E21B15/00 - E21B40/00 for underwater installations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
- B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING
- B63B22/00—Buoys
- B63B2022/006—Buoys specially adapted for measuring or watch purposes
Definitions
- Low density/high strength materials are used in subsea industries in a wide variety of applications.
- the primary purpose of the materials is to lend buoyancy and/or thermal insulation to equipment and structures to reduce load and/or minimize heat loss.
- the material of choice for this purpose is epoxy and glass microsphere-based syntactic foam.
- the epoxy provides strength to withstand the extreme pressures subsea.
- the hollow glass microspheres provide buoyancy and insulative value.
- a first drawback is that the bulk processing methodology relies on random arrangement of both microspheres and/or macrospheres (both of which contain a distribution of sizes) to create voids within the epoxy. As such, theoretical maximum packing of voids is never achieved. For example, an object with regularly- sized spheres, carefully packed, can achieve a void density of 74%. Maximum void density achieved by random packing of microspheres yields approximately 64%. With the addition of macrospheres to the syntactic foam, void density can be increased further but will never result in optimum sphere packing.
- a second drawback is that the spheres are permitted to touch one another or have only a minimum thickness of epoxy between them. Ideally, there would be a carefully calculated thickness of epoxy between each void space to maximize composite strength and insulative value, and minimize density.
- a third drawback is that random packing and batch processing technology allows for areas of castings to be void of epoxy. These spaces have microspheres or macrospheres that are not properly encapsulated in epoxy, resulting in weak sections in the objects.
- the present invention relates to both a material construction and manufacturing method resulting in low density materials, especially for use as subsea buoyancy and insulation.
- the products are made by an additive manufacturing process, creating thin plural sequential layers of material while leaving voids of precisely controlled predetermined shapes, sizes and distribution, and with precisely controlled predetermined material thicknesses between the voids.
- Each sequential layer is produced as a liquid and then hardened, partially cured or fully cured.
- the resulting products provide optimized strength, buoyancy and insulative value with minimal material usage and density.
- the present invention provides material with optimized void spaces created by additive manufacturing, such as 3D printing.
- the result is a low density material suitable for use in high pressure/force applications using a methodology of precisely arranging voids and precisely controlling material thicknesses around and between voids to minimize density whilst maximizing strength.
- Material is selected and designed by beginning with the application' s geometric, pressure, density and/or insulative constraints.
- the solution is modeled in 3D CAD, and the void spaces are optimized.
- the strength of the result can be verified through finite element analysis (FEA).
- FEA finite element analysis
- the 3D CAD model is prepared for manufacturing.
- the material is printed layer by layer using the additive manufacturing process. The material is uniform or varied within the layers and/or within adjacent layers.
- void space is achieved through varying void size and shape, void placement, wall thickness between voids and external wall thicknesses in accordance with the requirements of a particular application.
- the voids are spheres, and the spheres are of varied sizes chosen for optimum packing, strength and/or insulative value. In another embodiment, the voids are oblate spheroids. Void shapes are unlimited and are based on the density, strength and/or insulative project requirements.
- the material is printed at atmospheric pressure.
- the material incorporating the void volumes is printed in increased or reduced ambient pressures, the latter also being referred to herein as vacuum.
- the void spaces may be filled with gases other than air which are present by filling the printer enclosure with selected, usually inert, gases.
- the printed material is unitary. In another embodiment the void spaces are encapsulated by specific printed materials, and the balance of the printed material is a different material. In another embodiment an additional material is printed as an external shell. In another embodiment reinforcing materials, either printed or placed, are added to increase strength.
- the invention provides the potential to supplant all instances of use of syntactic foam in subsea buoyancy and insulation material.
- An inherent value of the invention is the resultant material structure of precisely arranged predetermined voids in solid material.
- the material structure can be manufactured practically by using additive manufacturing processes.
- a low density material suitable for use in high pressure/force applications uses a methodology of precisely arranging predetermined voids and precisely controlling material thicknesses around and between the voids to minimize density while maximizing strength.
- a wide list of materials to print and materials to add includes as examples epoxy, vinyl esters, thermoplastics, polyurethanes, syntactic foam, styrenes, nanoparticles, glass fibers, carbon fibers, microspheres and natural fibers. Manufacturing process can also be performed under atmospheric pressure, increased or reduced pressure for controlling internal pressures in the voids and controlling air or gas content in the voids.
- the invention provides strong low density objects with minimized density with maximized strength for use in high pressure/force applications.
- Objects have precisely controlled voids at predetermined locations and precisely controlled predetermined material thickness between the precisely controlled voids.
- the material is preferably a polymer containing fibers, nanoparticles, glass fibers, carbon fibers, microspheres, natural fibers, or combinations thereof.
- the polymer material is preferably a polymer such as: epoxy, vinyl, esters, thermoplastics, polyurethanes, syntactic foam, styrenes or combinations thereof. In one embodiment the polymer may be a solid polymer.
- the voids contain a gas or mixture of gases under atmospheric pressure, increased pressure or reduced pressure (the latter being also known as vacuum).
- the gas is air, an inert gas or a low density gas.
- the material is a first material, and the predetermined voids are surrounded by a second material between the first material and the voids.
- the first material and the second material are formed in thin plural sequential layers.
- the sequential layers of the first material and the second material are sequential layers deposited by an additive manufacturing process.
- the material is formed in thin plural sequential layers having predetermined material thickness between the predetermined locations of the voids.
- a shell is formed around an outside of the material.
- a new method forms a low density three-dimensional high pressure and force -resistant subsea buoyancy object by forming a material in additive layers around predetermined and precisely controlled sizes and positions of voids, while precisely controlling predetermined thicknesses of the material around and between the voids.
- the method uses an additive manufacturing process, such as three-dimensional printing.
- the method includes printing the material in an enclosure having a vacuum or a gas under a controlled pressure, wherein the voids contain the vacuum or the gas under the controlled pressure.
- the material is a first material and a second material is deposited in the thin plural sequential layers between the first material and the predetermined voids, thereby forming surfaces of the second material surrounding the voids between the voids and the first material.
- An outer material layer is formed outside the first material around the object.
- Figure 1 shows a cross-section of microspheres randomly mixed in an epoxy.
- Figure 2 shows microspheres and macrospheres together in a casting as well as some loose macrospheres.
- Figure 3 shows a cutaway of a plastic shell filled with foam and a mold containing syntactic foam.
- Figure 4 shows an example of the invention in a cutaway of a printed part showing a solid material with different sized voids inside.
- Figure 5 shows an example of the invention with a printed part that demonstrates naked voids and voids encapsulated by a material that is different from the primary solid material.
- Figure 6 shows an example of a cutaway of a new printed part showing a solid material with different sized voids inside and a printed exterior shell of a secondary material.
- Figure 7 is a schematic example of a part being printed.
- Figure 1 is a microscopic image of a cross-section of microspheres 12 randomly mixed in epoxy 10. The image shows both the variation in size and shape of the microspheres 12, as well as the random packing of those spheres in the epoxy 10.
- Figure 2 shows macrospheres 14 of different sizes together with microsphere-filled foam in prior art syntactic foam casting 10 as well as some loose macrospheres 14. The image shows both the variation in size and shape of the macrospheres 14, as well as the random packing 16 of those spheres.
- Figure 3 shows a cutaway of a plastic shell 30 filled with foam 32 and a mold 34 containing syntactic foam 32.
- the plastic housing has a fill port 31 through which the housing is filled. Once poured and cured, the object may undergo secondary operations (like drilling of mounting holes) before being ready for shipment.
- the mold shown 34 is typical. Molds are often made of wood or metal. The foam would be poured into open area of the mold and cured. After curing the foam 32 would be removed from the mold 34 and finished.
- Figure 4 shows a cutaway of a printed part 40 of one embodiment of the invention, showing a solid material 42 with different sized voids 44 inside.
- the void sizes, shapes and placement and the thickness of the solid material 46 between the voids are determined prior to additive manufacturing and optimized to produce the best density/strength ratio for the application.
- Figure 5 shows a printed part 50 of the invention that demonstrates naked voids 54 and voids 56 encapsulated by a material that is different from the primary solid material 52.
- a secondary material may be used to increase accuracy of void shape and size or to increase processing speeds by allowing the void shapes 56 to be printed precisely and the primary solid material 52 to be printed more rapidly.
- Figure 6 shows a cutaway of a printed part 60 showing a solid material 62 with different sized voids 64 inside and a printed exterior shell 68 of a secondary material. Printing of an exterior shell creates a protective or decorative external surface and can eliminate the need for a secondary finishing process.
- Figure 7 shows a part 50 being printed.
- the machine 70 includes components 72, 74 that allow for multiple axis movement of dispensing equipment 76 and/or printed part 50. The movements are computer controlled.
Abstract
Description
Claims
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US2015/060980 WO2017086923A1 (en) | 2015-11-17 | 2015-11-17 | Low density subsea buoyancy and insulation material and method of manufacturing |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3377302A1 true EP3377302A1 (en) | 2018-09-26 |
EP3377302A4 EP3377302A4 (en) | 2019-07-10 |
Family
ID=58718110
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP15908920.0A Pending EP3377302A4 (en) | 2015-11-17 | 2015-11-17 | Low density subsea buoyancy and insulation material and method of manufacturing |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP3377302A4 (en) |
AU (1) | AU2015414725B2 (en) |
BR (1) | BR112018010081B1 (en) |
CA (1) | CA3005429C (en) |
WO (1) | WO2017086923A1 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11866594B2 (en) | 2017-06-27 | 2024-01-09 | Lawrence Livermore National Security, Llc | Elastomeric shape memory polymer composites |
BR112023021785A2 (en) * | 2021-06-21 | 2023-12-26 | Halliburton Energy Services Inc | ADDITIVE MANUFACTURING FLOATS FOR USE IN A DOWNWELL ENVIRONMENT |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1372846A (en) | 1971-12-15 | 1974-11-06 | Vickers Ltd | Syntactic foam elements |
EP1268165B1 (en) * | 2000-03-24 | 2004-10-06 | GENERIS GmbH | Method and apparatus for manufacturing a structural part by a multi-layer deposition technique, and mold or core as manufactured by the method |
US7121767B1 (en) * | 2001-11-14 | 2006-10-17 | Cuming Corporation | Rugged foam buoyancy modules and method of manufacture |
AUPS085502A0 (en) * | 2002-03-01 | 2002-03-28 | University Of Newcastle Research Associates Limited, The | Syntactic foam |
US20070036964A1 (en) * | 2005-08-15 | 2007-02-15 | Lockheed Martin Corporation | Direct manufacturing using thermoplastic and thermoset |
US8815408B1 (en) * | 2009-12-08 | 2014-08-26 | Imaging Systems Technology, Inc. | Metal syntactic foam |
US20140120196A1 (en) * | 2012-10-29 | 2014-05-01 | Makerbot Industries, Llc | Quick-release extruder |
US9156194B2 (en) * | 2013-03-14 | 2015-10-13 | Palo Alto Research Center Incorporated | Digital 3D fabrication using multi-layered mold |
-
2015
- 2015-11-17 CA CA3005429A patent/CA3005429C/en active Active
- 2015-11-17 AU AU2015414725A patent/AU2015414725B2/en active Active
- 2015-11-17 WO PCT/US2015/060980 patent/WO2017086923A1/en active Application Filing
- 2015-11-17 EP EP15908920.0A patent/EP3377302A4/en active Pending
- 2015-11-17 BR BR112018010081-1A patent/BR112018010081B1/en active IP Right Grant
Also Published As
Publication number | Publication date |
---|---|
WO2017086923A8 (en) | 2018-05-17 |
BR112018010081B1 (en) | 2022-11-22 |
WO2017086923A1 (en) | 2017-05-26 |
CA3005429A1 (en) | 2017-05-26 |
EP3377302A4 (en) | 2019-07-10 |
AU2015414725A1 (en) | 2018-06-07 |
CA3005429C (en) | 2023-05-02 |
BR112018010081A2 (en) | 2018-11-13 |
AU2015414725B2 (en) | 2021-09-09 |
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A4 | Supplementary search report drawn up and despatched |
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RIC1 | Information provided on ipc code assigned before grant |
Ipc: B33Y 10/00 20150101ALI20190606BHEP Ipc: E21B 17/01 20060101ALI20190606BHEP Ipc: B33Y 80/00 20150101ALI20190606BHEP Ipc: E21B 41/00 20060101AFI20190606BHEP Ipc: B29C 64/106 20170101ALI20190606BHEP Ipc: B33Y 70/00 20150101ALI20190606BHEP Ipc: B33Y 30/00 20150101ALI20190606BHEP |
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