EP4731870A1 - Porous structural thermoset material - Google Patents

Abstract

A porous structural thermoset media is described herein. A method includes dispensing particles of a removable material into a mold, dispensing a structural thermoset material into the mold, curing the structural thermoset material having the particles of the removable material disposed therein to generate a cured structural thermoset material having the particles of the removable material disposed therein, and removing the particles of the removable material from the cured structural thermoset material to generate a porous structural thermoset.

Description

POROUS STRUCTURAL THERMOSET MATERIAL

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to US Provisional Patent Application having Serial No. 63/515,161, which was filed on July 24, 2023, US Provisional Patent Application having Serial No. 63/637,543, which was filed on April 23, 2024, US Provisional Patent Application having Serial No. 63/637,217, which was filed April 22, 2024, US Provisional Patent Application having Serial No. 63/550,716, which was filed on February 7, 2024, and US Provisional Patent Application having Serial No. 63/674,643, which was filed on July 23, 2024, each of which is incorporated herein by reference in its entirety.

BACKGROUND

[0002] The present disclosure generally relates to porous structural thermoset media.

[0003] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it may be understood that these statements are to be read in this light, and not as admissions of prior art.

[0004] In many hydrocarbon wells, inflowing fluid passes through a sand screen which filters out particulates from the inflowing oil or gas. The sand screen prevents sand from entering the wellbore and reduces damage that may occur by erosion. Conventionally, sand screens are made with a metallic mesh material. Once the sand screen is placed into the wellbore, gravel packs are pumped to fill the annulus between the screen and the formation.

[0005] In other instances, some metallic sand screens are expandable and are expanded downhole after placement in the wellbore. The result is a reduction in the annulus between the screen and the formation. The expandable screens in many instances have a limited expansion ratio, and the ability of the expandable screen to conform to borehole irregularities may not be satisfactory. Further, the ability of the expandable sand screen to resist borehole collapse may be reduced. Conventional sand screens are rated to resist greater external pressure than expandable sand screens. Expandable sand screens resist less external pressure because of plastic deformation experienced by their metallic components.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0007] FIG. l is a sectional view of a sand screen positioned in a wellbore, in accordance with an embodiment of the present disclosure;

[0008] FIG. 2 is a first embodiment of a method of generating the porous structural thermoset material of FIG. 1, in accordance with an embodiment of the present disclosure;

[0009] FIG. 3 is a second embodiment of a method of generating the porous structural thermoset material 110 of FIG. 1, in accordance with an embodiment of the present disclosure; and

[0010] FIG. 4 illustrates embodiments of structures that can be generated in accordance with an additively manufacturing technique, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0011] Certain embodiments commensurate in scope with the present disclosure are summarized below. These embodiments are not intended to limit the scope of the disclosure, but rather these embodiments are intended only to provide a brief summary of certain disclosed embodiments. Indeed, the present disclosure may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

[0012] As used herein, the term “coupled” or “coupled to” may indicate establishing either a direct or indirect connection (e.g., where the connection may not include or include intermediate or intervening components between those coupled), and is not limited to either unless expressly referenced as such. The term “set” may refer to one or more items. Wherever possible, like or identical reference numerals are used in the figures to identify common or the same elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale for purposes of clarification.

[0013] As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.”

[0014] Furthermore, when introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment,” “an embodiment,” or “some embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, the phrase A “based on” B is intended to mean that A is at least partially based on B. Moreover, unless expressly stated otherwise, the term “or” is intended to be inclusive (e.g., logical OR) and not exclusive (e.g., logical XOR). In other words, the phrase A “or” B is intended to mean A, B, or both A and B. [0015] Present embodiments described herein generally relate to making and using a porous structural thermoset material. In some embodiments, this porous structural thermoset material can be used in sand control applications, among other applications. For example, one or more embodiments of the present disclosure relate to a porous structural thermoset material that is able to expand once deployed downhole to conform to an irregularly shaped wellbore for sand control operations. As further described below, the porous structural thermoset material according to one or more embodiments of the present disclosure exhibits permeability, robustness, and an expansion ratio that are favorable for sand control operations by allowing for support of the formation during the production of oil.

[0016] Embodiments herein of present techniques and generated porous structural thermoset material have advantages to techniques of mixing of dissolvable particles into resin, in which it is very difficult to create and network the resultant product. These techniques reduce processability due to increased viscosity of the mixture. Present techniques described herein include a true injection or resin infusion process around the scaffold of the dissolvable network whereas mixing in dissolvable particles will tend to limit porosity and coat the dissolvable particles (making it difficult to remove after curing).

[0017] The present techniques can be performed on the surface (e.g., not downhole), as this maximizes consistency, increases porosity, and allows for more clearance during any running in hole (RIH) operation. With increased porosity, the porous structural thermoset material can be compressed uphole to a smaller diameter for RIH operations. This is in contrast to other techniques, which can involve attempts to dissolve components of a sand screen downhole, which requires more physical space and is more difficult to control relative to the present techniques and the porous structural thermoset material.

[0018] The present techniques are additionally different from “foam” or “foaming” methods. The fundamental difference between the porous structural thermoset material generated via present embodiments and foaming methods is that the present techniques are controllable in contrast to the unpredictable nature of foaming (e.g., triggered by volatilization of various components to create porosity). Additionally, present techniques provide increased repeatability, since with foams and foaming methods, it is difficult to both create repeatable sizes of pores and throats as well as to interconnect them (i.e., making an open cell vs. closed cell foam). The present techniques do not have these limitations of foam and foaming methods.

[0019] With the foregoing in mind, FIG. l is sectional view of a sand screen positioned in a wellbore according to one or more embodiments of the present disclosure is shown. Specifically, the wellbore 100 includes an open bore hole 102, a production tubing string 104, which may be a base pipe according to one or more embodiments, and a sand screen 106. While wellbore 100 is illustrated as being a substantially vertical, uncased well, it should be recognized that the subject disclosure is equally applicable for use in cased wellbores as well as in horizontal and/or inclined wellbores. The sand screen 106 includes a filter member 108 and a polymeric material, such as the porous structural thermoset material 110 according to one or more embodiments of the present disclosure. The sand screen 106 is shown positioned in the wellbore 100 adjacent a producing formation 114. In some embodiments, the sand screen 106 (and/or the porous structural thermoset material 110) can be, for example, an annular shaped member that can be disposed about the production tubing string 104. In addition, according to one or more embodiments of the present disclosure, the porous structural thermoset material 110 may be the only filtration agent without the use of any filter member 108. In one or more embodiments of the present disclosure, the filter member 108 can be configured for additional structural support of the porous structural thermoset material 110.

[0020] Still referring to FIG. 1, in a well completion method according to one or more embodiments of the present disclosure, at least one base pipe (e.g., production tubing string 104) may be covered with the porous structural thermoset material 110 according to one or more embodiments of the present disclosure. The porous structural thermoset material 110 covering the base pipe as the production tubing string 104 may be covered with a retainer before running the base pipe as the production tubing string 104 to a location in the wellbore 100. Upon exposure to a condition in the wellbore 100, the retainer may degrade and expose the porous structural thermoset material 110 to the wellbore fluids. In one or more embodiments, various methods are employed to trigger expansion of the structural thermoset material 110. As the porous structural thermoset material 110 expands into and fills the annulus, the porous structural thermoset material 110 conforms to a wall of the wellbore 100. Because the porous structural thermoset material 110 is able to conform to the wellbore 100 wall in this way and has a permeability that is about equivalent to or greater than the permeability of the surrounding formation, the porous structural thermoset material 110 is able to allow formation fluids into the base pipe as the production tubing string 104 while filter debris including sand from fluids from the producing formation 114. After the downhole operation is complete, the porous structural thermoset material 110 may be detached from the base pipe as the production tubing string 104, and the base pipe as the production tubing string 104 may be lifted out of the wellbore 100.

[0021] In this manner, the porous structural thermoset material 110 can have many beneficial applications for downhole tools in the oilfield, in particular for a conformable sand screen as sand screen 106 used in oil and/or in gas operations. The porous structural thermoset material 110 can also be applied to/relevant to downhole tools involving a porous medium, such as for filtering or sealing applications. The porous structural thermoset material 110 can be porous, allowing downhole fluids to be produced through it. Simultaneously, the pores can be small enough that erosive sand particles can be captured before they enter the completions equipment. Once in the proper location downhole (e.g., in the wellbore 100 adjacent a producing formation 114), the porous structural thermoset material 110 can expand and conform to the wellbore 100. The high strength of the porous structural thermoset material 110 can also allow it to support the wellbore 100. This support can be especially important, for example, during drawdown, as suction created by pumps drawing fluids from the producing formation 114 can destabilize the producing formation 114. The structural strength of the porous structural thermoset material 110 can allow it, for example, to inhibit collapse during drawdown, ensuring sustained production from the well.

[0022] In this manner, the high mechanical strength of the porous structural thermoset material 110 is a desirable property for use in oilfield operations, allowing porous structural thermoset material 110 to withstand large loads. In addition to the porous structural thermoset material 110 having high strength, it can also have desirable chemical compatibility. In some embodiments, the porous structural thermoset material 110, which is formed by irreversible chemical reactions to generate a crosslinked structure that does not melt (also called thermosetting polymers, thermoset resins, or thermosetting resins) can include (but are not limited to) the following chemistries and variants: polyesters, cyanate esters, epoxies, phenolics, methacrylates, melamines, vinyl esters, bismaleimides, thermoset cyclic polyolefins, polyimides, and benzoxazines. Furthermore, the compounds used in the generation of the porous structural thermoset material 110 can be thermally stable to high temperatures and can be resistant to chemical attack.

[0023] The present “structural thermoset” material can be mechanically as a rigid thermosetting polymer where the non-porous, bulk material (when cured to form a densely crosslinked network) has a modulus (compressive, flexural, tensile, or elastic) of at least, for example, approximately 0.7 GPa below the glass transition temperature (Tg). In other embodiments, structural thermosets typically have a Tg above ambient. Additionally, some embodiments, the structural thermoset can be reinforced with ceramic or metallic particles of various types and/or geometries to enhance the mechanical properties of the cured porous structural thermoset material 110. This can include spherical, non-spherical, or high aspect ratio silica (both crystalline and amorphous), boron nitride, aluminosilicate, alumina, aluminum nitride, and zirconium tungstate. Metallic reinforcements can include a variety of ferrous and non-ferrous, with preference to corrosion resistant materials (i.e. nickel alloys, stainless steels, etc.). In this manner, in some embodiments, the mechanical strength, thermal stability, and thermal conductivity of the porous structural thermoset material 110 can be modified and improved through the addition of additional materials.

[0024] The structural thermoset material 110 can be made to be porous. The porous structure can have a variety of purposes, including: to allow fluid to pass through the material, to filter solid particles, and/or to create an interpenetrating composite network. In some embodiments, the interpenetrating thermoset composite network can have two or more materials with vastly different thermal, viscous, mechanical, electrical, or magnetic properties. [0025] FIG. 2 illustrates a first embodiment of a method of generating the porous structural thermoset material 110. As will be described in greater detail, the method illustrated in FIG. 2 illustrates creation of the porous structural thermoset material 110 via encapsulating a removable material with a structural thermoset material, such as, but not limited to, a structural thermoset polymer. For example, in block 115, particles of a removable material 118 can be loaded into a mold 120. While the mold 120 is shown as an open mold, a closed mold can be used to facilitate resin injection (vs. potting in open mold). In some embodiments, mold 120 can be shaped and sized to fit within a desired sand screen 106 or the mold 120 can form a bulk porous structural thermoset material 110 shape, from which the sand screen form 106 is fabricated (machining, cutting, etc.). Moreover, while generation of the porous structural thermoset material 110 into a sand screen 106 is described, it should be noted that other devices and/or configurations are envisioned. For example, the porous structural thermoset material 110 can be shaped into forms for separation operations (e.g., as a separator used in separating oil and water), filtration operations (e.g., as a filter on a pump used in oil and gas operations, as an actuator or actuator device (e.g., to move to open and close a valve), or in similar operations.

[0026] The material selected as the removable material 118 can be chosen based on various properties, for example, its compressibility, the size of its particles, the manner in which it can be removed from the mold 120, and/or other characteristics. In some embodiments, the removable material 118 can be a dissolvable material. For example, salt, sugar, polyvinyl alcohol (PVA), or another liquid soluble material can be used as the removable material 118. The salt selected can include Sodium Chloride, however, additionally and/or alternatively other salts can be utilized, for example, Magnesium Chloride, Calcium Chloride, Potassium Chloride, or other suitable salts. Likewise, numerous types of sugars can be utilized as the removable material 118. The removable material 118 can be chosen to be dissolvable in the presence of water or a different liquid (e.g., a solvent). In still other embodiments, removable material 118 can be a material that melts instead of one that dissolves in the presence of a liquid. For example, removable material 118 can be, for example, paraffin wax, carnauba wax, or another material that can be removable upon exposure to heat (e.g., temperatures up to or over approximately 85° C). In further embodiments, the removable material 118 can be a solid material that sublimes upon exposure to heat (e.g., temperatures up to or over approximately 85° C). For example, naphthalene can be utilized as the removable material 118, since it sublimes at temperatures at or around 85° C. In some embodiment, the removable material 118 can be a mixture of two or more types of removable materials.

[0027] In conjunction with block 116, compression of the removable material 118 can be undertaken in some embodiments. This can assist in generating a desired network of removable particles, which can define a pore and pore throat network in the resulting porous structural thermoset material that is generated. In one or more embodiments, in conjunction with block 116, the removable material 118 can be compressed in the mold 120 (e.g., into a network or a layer or another structure of compressed removable material 118) prior to the porous structural thermoset material being applied to the mold 120. This can be accomplished via use of a press 121 or another suitable device. This compression process can increase the loading of removable material 118 in the mold 120. The compression can also, for example, improve the porosity of the final part, as the particles of the removable material 118 are forced to have more contact with each other, ensuring that when the removable material 118 is removed, the pores generated in the porous structural thermoset material 110 from the removal of the removable material 118 are connected.

[0028] This compression process can also alter the shape of the removable material 118, which can impact the shape of the pores generated in the porous structural thermoset material 110. That is, the pore size and/or shape in the resultant porous structural thermoset material 110 can be dictated by this compression process (e.g., the amount of compression applied, by applying different compressions to different portions of the removable material 118, etc.). For example, the compression process can be applied in different directions, for example, to provide anisotropic properties. Thus, in the case of manufacturing a sand screen 106 that is annular (i.e., has an annular shape), compression could be applied axially or radially, and the direction of compression applied would affect the pore morphology.

[0029] In some embodiments, sintering (e.g., binding) of the particles of the removable material 118 can also be undertaken. Likewise, liquid (e.g., water or a liquid solvent) can be applied to the removal material 118 (or removable materials 118 if two or more materials are utilized as the removable material 118), which can be dried thereafter to form a desired network (e.g., layout of pores) in the porous structural thermoset material that is generated. The network that is created can be generated layer by layer or in bulk. Image 122 provides an example of the removable material 118 that can be loaded in to the mold 120 in conjunction with block 115 and/or compressed in conjunction with block 116 when compression is undertaken.

[0030] In block 124, structural thermoset material 126 can be added to the mold 120. The structural thermoset material 126 can be added in an amount to wholly or partially cover the removable material 118. For example, the structural thermoset material 126 can encapsulate and fill the interstices of the particles of the removable material 118. The structural thermoset material 126 can be an uncured version of the porous structural thermoset material 110. That is, in conjunction with block 124, the structural thermoset material 126 may be in an uncured form of the porous structural thermoset material 110 when placed or otherwise added to the mold 120. Once added to the mold 120, the structural thermoset material 126 in its uncured state (e.g., as a soft solid or viscous liquid) may be cured (i.e., hardened). This curing can be accomplished by exposing the structural thermoset material 126 to heat, radiation (e.g., ultraviolet light), pressure, a curing agent, and/or a catalyst. The curing of the structural thermoset material 126 can result in an infusible and insoluble resultant porous structural thermoset material 110. Image 128 illustrates an example of the porous structural thermoset material 110 having been cured with the removable material 118 present therein (e.g., the removable material 118 encapsulated with the porous structural thermoset material 110).

[0031] Block 130 of FIG. 2 includes removal of the removable material 118. This removal can be effected by the application of a liquid (e.g., to dissolve the removable material 118), heat (e.g., to melt the removable material 118 or to sublime the removable material 118), and/or a catalyst to the removable material 118 and the porous structural thermoset material 110 in the mold 120. The removal process can be selected to match the material used as the removable material. In this manner, the removal process can include external stimulation that supports the removal of the particles of the removable material 118. Such external stimulation can include, for example, exposure to a solvent, a temperature change, a pressure change, agitation, and/or or ultrasonic waves. Upon removal of the removable material 118, pores 132 remain in the porous structural thermoset material 110. Image 134 illustrates an example of the porous structural thermoset material 110 having the removable material 118 removed.

[0032] As illustrated in block 130, the pores 132 of the porous structural thermoset material 110 can be interconnected (e.g., as a network), allowing fluid to move between pores 132 through connecting pore throats 131 and ultimately through the entire material. This can assist in generating a network, which can define a pore 132 and pore throat 131 network in the resulting porous structural thermoset material 110 that is generated. In some embodiments, the pores 132 can be, for example, approximately between approximately 1 micron and 1000 microns in diameter. The pore throats 131 range in size from approximate 0.1 microns to 100 microns. The pores 132 can be non-spherical and non-ellipsoidal, with each pore 132 potentially having multiple branches and/or nodes. The pores 132 could also be anisotropic. For example, in the case of the porous structural thermoset material 110 used in a sand screen 106 (or as sand screen 106), the length scale of the pore 132 could be larger in a radial direction relative to the length scale in the angular and axial directions. These differing length scales could facilitate high permeability in the radial direction while also supporting good sand retention properties. The dissolvable particle sizes and morphology are chosen in such a way to design the sizes of the pores 132 and pore throats 131. In some embodiments, a sand screen made from the porous thermoset can be designed specifically for the size distribution of sands in the formation.

[0033] The pore 132 sizes can also have a non-uniform distribution. For example, a portion of the pores 132 in the porous structural thermoset material 110 can have relatively smaller sizes, for example, to capturing sand more efficiently, while another portion of the pores 132 in the porous structural thermoset material 1 10 can have larger sizes relative to the smaller sized pores. These larger sized pores 132 would allow the porous structural thermoset material 110 to be more permeable relative to a porous structural thermoset material 110 made with only smaller sized pores 132. In some embodiments, different removable materials 118 (i.e., having different particle sizes) can be used, for example, in conjunction with one another to generate the porous structural thermoset material 110 having differently sized pores 132. In other embodiments, the removable material 118 can be selected as having a characteristic of different particle sizes therein, thus leading to different pore 132 sizes in the porous structural thermoset material 110 when the removable material 118 is removed.

[0034] In the case of a sand screen 106, for example, smaller sized pores 132 could be located close to the formation 114 (e.g., along an outer portion of the porous structural thermoset material 110 that would be disposed most closely to and/or in direct contact with the formation 114) to inhibit sand ingress, while larger sized pores 132 can be disposed in an inner region of the porous structural thermoset material 110 (e.g., in an inner portion of the porous structural thermoset material 110 that would be disposed most closely to and/or in direct contact with the production tubing string 104) to facilitate higher permeability. The distribution of pore sizes could be bimodal (a mixture of small and large pores), trimodal, or simply monomodal with a large standard deviation.

[0035] It is envisioned that other techniques for generating the porous structural thermoset material 110 are possible. For example, FIG. 3 illustrates a second embodiment of a method of generating the porous structural thermoset material 110. In block 136, the structural thermoset material 126 is added to the mold 120. In block 138, the removable material 118 is added to the structural thermoset material 126 in mold 120. In block 140, the removable material 118 is compressed to the bottom of the mold 120. This can be accomplished via use of a press 121 or another suitable device.

[0036] In block 144, additional removable material 118 is added to the to the structural thermoset material 126 in mold 120. In block 146, compression is applied (e.g., via the press 121) and the removable material 118 are formed into a second layer 148 of particles of removable material 118 disposed above a first layer 150 of particles of removable material 118 (i.e., generated in block 140). In some embodiments, blocks 144 and 146 may be repeatable to generate one or more additional layers of removable material 118. [0037] Once a desired amount of removable material 118 has been added via blocks 144 and 146 (with the structural thermoset material 126 in its uncured state as a soft solid, viscous liquid, or non-viscous liquid), the structural thermoset material 126 may be cured (i.e., hardened). This curing can be accomplished by exposing the structural thermoset material 126 to heat, radiation (e.g., ultraviolet light), pressure, curing agent, and/or a catalyst. The curing of the structural thermoset material 126 can result in an infusible and insoluble resultant porous structural thermoset material 110.

[0038] In block 152, the removable particles are extracted (in a manner similar to that described with respect to block 130 of FIG. 2), creating a porous network of pores 132 in the porous structural thermoset material 110. This extraction (e.g., removal process) can be performed in a similar manner to that described above with respect to block 130 of FIG. 2. As illustrated in block 152, the pores 132 of the porous structural thermoset material 110 can be interconnected, allowing fluid to move between pores 132 and ultimately through the entire material. The pores 132 can be non-spherical and non-ellipsoidal, with each pore 132 potentially having multiple branches and/or nodes. The pores 132 could also be anisotropic. For example, in the case of the porous structural thermoset material 110 used in a sand screen 106 (or as sand screen 106), the length scale of the pore 132 could be larger in a radial direction relative to the length scale in the angular and axial directions. These differing length scales could facilitate high permeability in the radial direction while also supporting good sand retention properties.

[0039] The pore 132 sizes can also have a non-uniform distribution. For example, a portion of the pores 132 in the porous structural thermoset material 110 can have relatively smaller sizes, for example, to capturing sand more efficiently, while another portion of the pores 132 in the porous structural thermoset material 110 can have larger sizes relative to the smaller sized pores. These larger sized pores 132 would allow the porous structural thermoset material 110 to be more permeable relative to a porous structural thermoset material 1 10 made with only smaller sized pores 132. In some embodiments, different removable materials 118 (i.e., having different particle sizes) can be used, for example, in conjunction with one another to generate the porous structural thermoset material 110 having differently sized pores 132. In other embodiments, the removable material 118 can be selected as having a characteristic of different particle sizes therein, thus leading to different pore 132 sizes in the porous structural thermoset material 110 when the removable material 118 is removed.

[0040] In the case of a sand screen 106, for example, smaller sized pores 132 could be located close to the formation 114 (e.g., along an outer portion of the porous structural thermoset material 110 that would be disposed most closely to and/or in direct contact with the formation 114) to inhibit sand ingress, while larger sized pores 132 can be disposed in an inner region of the porous structural thermoset material 110 (e g., in an inner portion of the porous structural thermoset material 110 that would be disposed most closely to and/or in direct contact with the production tubing string 104) to facilitate higher permeability. The distribution of pore sizes could be bimodal (a mixture of small and large pores), trimodal, or simply monomodal with a large standard deviation.

[0041] In another embodiment, a structure (e.g., sand screen 106) can be additively manufactured. For example, the structure can be generated using the removable material 118. Thereafter, the structural thermoset material 126 is utilized to encapsulate the structure. The structural thermoset material 126 can be cured and thereafter, the additively manufactured material (e.g., removable material 118) could be extracted utilizing the removal process described above with respect to FIGS. 2 and 3. This would result in a porous network matching the original additively manufactured structure.

[0042] FIG. 4 illustrates structure 154 that could be additively manufactured to produce a porous network in conjunction with the technique described above. FIG. 4 also illustrates structure 156 as a second example of a structure that could be additively manufactured to produce a porous network in conjunction with the technique described above. Compared to the particle approach discussed above with reference to FIGS. 2 and 3, the additive manufacturing approach described above in conjunction with FIG. 4 may enable better control of the pore 132 structure or even pore 132 designs that would be otherwise be difficult to achieve with a particle-based approach, such as those described above in conjunction with FIGS. 2 and 3. In one or more embodiments, the material for the additive manufacturing approach can include polyvinyl alcohol. [0043] In one or more embodiments, the sand screen 106 is customized to the formation 114. By altering the removable material 118, the pore 132 size and distribution of the final sand screen 106 can be adjusted. The pore 132 size may be customized to the sand particle sizes for each well, allowing for increased permeability while still ensuring sand retention performance and formation stability. Similarly, the properties of the porous structural thermoset material 110, such as, but not limited to material strength, can be adjusted based on the well conditions, the expected load from the formation 114 onto the sand screen 106, and/or other factors.

[0044] The technical effect of the disclosed embodiments includes improvements in making and using a porous structural thermoset material 110. In some embodiments, this porous structural thermoset material 110 can generated through removal of removable material 118 that was present in uncured structural thermoset material 126. Removal of the removable material 118 generate pores in the porous structural thermoset material 110. The sizing, location, density, etc. of the pores can be uniform or non-uniform, depending on the use of the porous structural thermoset material 110. For example, pores 132 of one size may be present in a first portion of the porous structural thermoset material 110 and pores 132 of a second (larger) size may be present in a second portion of the porous structural thermoset material 110. In this configuration, the porous structural thermoset material 110 can be particularly useful as a sand screen 106.

[0045] The subject matter described in detail above may be defined as set forth below.

[0046] A method includes dispensing particles of a removable material into a mold, dispensing a structural thermoset material into the mold, curing the structural thermoset material having the particles of the removable material disposed therein to generate a cured structural thermoset material having the particles of the removable material disposed therein, and removing the particles of the removable material from the cured structural thermoset material to generate a porous structural thermoset material. [0047] The method of the preceding clause, wherein dispensing the particles of the removable material into the mold is performed prior to dispensing the structural thermoset material into the mold.

[0048] The method any preceding clause, further comprising compressing the particles of the removable material into a first layer of removable particles.

[0049] The method any preceding clause, further comprising dispensing additional particles of the removable material into the mold, and compressing the additional particles of the removable material into a second layer of removable particles, wherein removing the particles of the removable material from the cured structural thermoset material comprises removing the particles of the first layer of removable particles and the second layer of removable particles.

[0050] The method any preceding clause, wherein removing the particles of the removable material comprises applying a liquid solvent to the cured structural thermoset material having the particles of the removable material disposed therein.

[0051] The method any preceding clause, wherein dispensing particles of the removable material into the mold comprises utilizing at least one of PVA (polyvinyl alcohol), salt, sugar, or another dissolvable material as the removable material.

[0052] The method any preceding clause, wherein removing the particles of the removable material comprises melting the particles of the removable material.

[0053] The method any preceding clause, wherein dispensing particles of the removable material into the mold comprises utilizing at least one of synthetic waxes or naturally occurring waxes as the removable material.

[0054] The method any preceding clause, wherein removing the particles of the removable material comprises applying heat to the cured structural thermoset material having the particles of the removable material disposed therein to sublime the particles of the removable material. [0055] The method any preceding clause, wherein dispensing particles of the removable material into the mold comprises utilizing naphthalene as the removable material.

[0056] The method any preceding clause, wherein dispensing particles of the removable material into the mold is performed subsequent to dispensing the structural thermoset material into the mold.

[0057] The method any preceding clause, comprising compressing the particles of the removable material into a first layer of removable particles.

[0058] The method any preceding clause, comprising dispensing additional particles of the removable material into the mold, and compressing the additional particles of the removable material into a second layer of removable particles, wherein removing the particles of the removable material from the cured structural thermoset material comprises removing the particles of the first layer of removable particles and the second layer of removable particles.

[0059] The method any preceding clause, wherein dispensing the particles of the removable material into the mold comprises dispensing the particles of the removable material into an annular shaped sand screen as the mold.

[0060] A device includes a porous structural thermoset material shaped into an annular shape, wherein the porous structural thermoset material comprises pores formed via removal of a removable material, wherein the porous structural thermoset material includes a first region comprising a first set of the pores, and a second region comprising a second set of the pores, wherein the first set of the pores have at least one characteristic that differs from the second set of the pores.

[0061] The device of the preceding clause, comprising a sand screen comprising the porous structural thermoset material.

[0062] The device of any preceding clause, wherein the first region comprises an outer portion of the annular shape. [0063] The device of any preceding clause, wherein the second region comprises an inner portion of the annular shape, wherein the second set of the pores are larger in size relative to the first set of pores.

[0064] A method includes generating a structure comprising a removable material, encapsulating the removable material with a structural thermoset material, and curing the structural thermoset material.

[0065] The method of the preceding clause, comprising extracting the removable material to generate a porous structural thermoset material as a sand screen.

[0066] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and/or within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” or “generally perpendicular” and “substantially perpendicular” refer to a value, amount, or characteristic that departs from exactly parallel or perpendicular, respectively, by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or degree.

[0067] The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. Moreover, the order in which the elements of the methods described herein are illustrated and described may be re-arranged, and/or two or more elements may occur simultaneously. The embodiments were chosen and described in order to best explain the principals of the disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the disclosure and various embodiments with various modifications as are suited to the particular use contemplated.

[0068] Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims.

Claims

1. A method, comprising: dispensing particles of a removable material into a mold; dispensing a structural thermoset material into the mold; curing the structural thermoset material having the particles of the removable material disposed therein to generate a cured structural thermoset material having the particles of the removable material disposed therein; and removing the particles of the removable material from the cured structural thermoset material to generate a porous structural thermoset material.

2. The method of claim 1, wherein dispensing the particles of the removable material into the mold is performed prior to dispensing the structural thermoset material into the mold.

3. The method of claim 2, comprising compressing the particles of the removable material into a first layer of removable particles.

4. The method of claim 3, comprising: dispensing additional particles of the removable material into the mold; and compressing the additional particles of the removable material into a second layer of removable particles, wherein removing the particles of the removable material from the cured structural thermoset material comprises removing the particles of the first layer of removable particles and the second layer of removable particles.

5. The method of claim 1, wherein removing the particles of the removable material comprises applying a liquid solvent to the cured structural thermoset material having the particles of the removable material disposed therein.

6. The method of claim 5, wherein dispensing particles of the removable material into the mold comprises utilizing at least one of PVA (polyvinyl alcohol), salt, sugar, or another dissolvable material as the removable material.

7. The method of claim 1, wherein removing the particles of the removable material comprises melting the particles of the removable material.

8. The method of claim 7, wherein dispensing particles of the removable material into the mold comprises utilizing at least one of synthetic waxes or naturally occurring waxes as the removable material.

9. The method of claim 1, wherein removing the particles of the removable material comprises applying heat to the cured structural thermoset material having the particles of the removable material disposed therein to sublime the particles of the removable material.

10. The method of claim 9, wherein dispensing particles of the removable material into the mold comprises utilizing naphthalene as the removable material.

11. The method of claim 1, wherein dispensing particles of the removable material into the mold is performed subsequent to dispensing the structural thermoset material into the mold.

12. The method of claim 11, comprising compressing the particles of the removable material into a first layer of removable particles.

13. The method of claim 12, comprising: dispensing additional particles of the removable material into the mold; and compressing the additional particles of the removable material into a second layer of removable particles, wherein removing the particles of the removable material from the cured structural thermoset material comprises removing the particles of the first layer of removable particles and the second layer of removable particles.

14. The method of claim 1, wherein dispensing the particles of the removable material into the mold comprises dispensing the particles of the removable material into an annular shaped sand screen as the mold.

15. A device, comprising: a porous structural thermoset material shaped into an annular shape, wherein the porous structural thermoset material comprises pores formed via removal of a removable material, wherein the porous structural thermoset material comprises: a first region comprising a first set of the pores; and a second region comprising a second set of the pores, wherein the first set of the pores have at least one characteristic that differs from the second set of the pores.

16. The device of claim 15, comprising a sand screen comprising the porous structural thermoset material.

17. The device of claim 16, wherein the first region comprises an outer portion of the annular shape.

18. The device of claim 17, wherein the second region comprises an inner portion of the annular shape, wherein the second set of the pores are larger in size relative to the first set of pores.

19. A method, comprising: generating a structure comprising a removable material; encapsulating the removable material with a structural thermoset material; and curing the structural thermoset material.

20. The method of claim 19, comprising extracting the removable material to generate a porous structural thermoset material as a sand screen.