Deformable downhole structures including carbon nanotube materials, and methods of forming and using such structures

Abstract

A deformable downhole article for use in a wellbore includes a tubular component configured for placement in a wellbore, a deformable material disposed around an outer surface of the tubular component, and an electrically conductive element comprising a carbon nanotube (CNT) material bonded to the deformable material. To form such a deformable downhole article, a deformable material is disposed around an outer surface of a tubular component, and an electrically conductive element comprising a carbon nanotube (CNT) material is bonded to the deformable material. In use, the deformable downhole article may be positioned within a wellbore, and the deformable material may be expanded to an expanded state. Expansion of the deformable material may strain the carbon nanotube (CNT) material of the electrically conductive element, and an electrical property of the electrically conductive element may be measured to deduce information about the state of the deformable material.

1 . A deformable downhole article for use in a wellbore, comprising:
 a tubular component configured for placement in a wellbore;   a deformable material disposed around an outer surface of the tubular component; and   an electrically conductive element comprising a carbon nanotube (CNT) material bonded to the deformable material.   
     
     
         2 . The deformable downhole article of  claim 1 , wherein the electrically conductive element is located and configured such that stress will be applied to the electrically conductive element upon swelling of the deformable material and the electrically conductive element is strained responsive to the applied stress. 
     
     
         3 . The deformable downhole article of  claim 1 , further comprising an electronic device operably coupled to the electrically conductive element and configured to measure at least one electrical property of the electrically conductive element. 
     
     
         4 . The deformable downhole article of  claim 1 , wherein the CNT material extends radially outward from at least a portion of the tubular component. 
     
     
         5 . The deformable downhole article of  claim 1 , wherein the CNT material extends circumferentially around at least a portion of the tubular component. 
     
     
         6 . The deformable downhole article of  claim 1 , wherein the electrically conductive element is covalently bonded to the deformable material. 
     
     
         7 . The deformable downhole article of  claim 1 , wherein the CNT material comprises crosslinked carbon nanotubes (CNTs), and wherein CNTs of the CNT material are covalently bonded to the deformable material. 
     
     
         8 . The deformable downhole article of  claim 1 , wherein CNTs of the CNT material are impregnated with metal nanoparticles. 
     
     
         9 . The deformable downhole article of  claim 8 , wherein the metal nanoparticles comprise palladium nanoparticles. 
     
     
         10 . The deformable downhole article of  claim 7 , wherein CNTs of the CNT material are crosslinked with benzoquinone. 
     
     
         11 . The deformable downhole article of  claim 1 , wherein the deformable material comprises a shape memory polymer. 
     
     
         12 . The deformable downhole article of  claim 11 , wherein the shape memory polymer comprises polyurethane. 
     
     
         13 . A method of forming a deformable downhole article for use in a wellbore, comprising:
 disposing a deformable material around an outer surface of a tubular component configured for placement in a wellbore; and   bonding an electrically conductive element comprising a carbon nanotube (CNT) material to the deformable material.   
     
     
         14 . The method of  claim 13 , wherein disposing the deformable material around the outer surface of the tubular component comprises molding the deformable material around the tubular component. 
     
     
         15 . The method of  claim 14 , wherein molding the deformable material around the tubular component comprises a reaction injection molding process. 
     
     
         16 . The method of  claim 13 , wherein bonding the electrically conductive element comprising the carbon nanotube (CNT) material to the deformable material comprises covalently bonding the electrically conductive element to the deformable material. 
     
     
         17 . A method of using a deformable downhole article in a wellbore, comprising:
 positioning a deformable downhole article in a wellbore, the deformable downhole article includes a tubular component, a deformable material disposed around an outer surface of the tubular component, and an electrically conductive element comprising a carbon nanotube (CNT) material bonded to the deformable material;   expanding the deformable material to an expanded state in the wellbore, expansion of the deformable material straining the carbon nanotube (CNT) material of the electrically conductive element; and   measuring an electrical property of the electrically conductive element.   
     
     
         18 . The method of  claim 17 , wherein measuring the electrical property of the electrically conductive element comprises measuring a resistivity or inductance of the electrically conductive element. 
     
     
         19 . The method of  claim 17 , further comprising correlating a measurement obtained by the measuring of the electrical property of the electrically conductive element to a degree of expansion of the deformable material. 
     
     
         20 . The method of  claim 17 , wherein the electrically conductive element is covalently bonded to the deformable material.