Material and method of manufacture for engineered reactive matrix compositions

Abstract

A high strength engineered reactive matrix composite that includes a core material and a reactive binder matrix combined in high volumes and with controlled spacing and distribution to produce both high strength and controlled reactivity. The engineered reactive matrix composite includes a repeating metal, ceramic, or composite particle core material and a reactive binder/matrix, and wherein the reactive/matrix binder is distributed relatively homogeneously around the core particles, and wherein the reactivity of the reactive binder/matrix is engineered by controlling the relative chemistry and interfacial surface area of the reactive components. These reactive materials are useful for oil and gas completions and well stimulation processes, enhanced oil and gas recovery operations, as well as in defensive and mining applications requiring high energy density and good mechanical properties.

1 - 31 . (canceled) 
     
     
         32 . A dissolvable reactive matrix composite comprising a plurality of porous preformed particles that are contained in a metal material; each of said porous preformed particles formed of a plurality of coated particles that have been sintered together or compressed together; each of said coated particles formed of a primary core and a reactive binder coated on said primary core; said primary core and said reactive binder formed of different materials; said coating thickness of said reactive binder is less than a particle diameter of said primary core; said primary core including a material selected from the group consisting of metal, carbon or ceramic material; said primary core constitutes about 30%-90% by volume of said coated particle; said primary core has an average particle diameter of at least 0.1 microns; said reactive binder having a coating thickness of at least 0.01 microns; said coating thickness of said reactive binder less than said average particle diameter of said primary core; said primary core including a material selected from the group consisting of metal, ceramic and carbon, said metal used in said primary core includes aluminum, tungsten, silicon, boron, tantalum, iron, magnesium, silver, nickel, molybdenum, hafnium, niobium, cobalt, zirconium, stainless steel, copper, and/or titanium, said ceramic used in said primary core includes KClO 4 , AgNO 3 , and/or Bi 2 O 3 , said carbon used in said primary core includes graphite, carbonyl iron powder, iron-coated carbon fiber, nickel-coated carbon fiber, and/or milled graphite fiber; reactive binder includes one or more materials selected from the group consisting of silicon, silver, zinc, magnesium, aluminum, iron, graphite, titanium, zirconium, tantalum, hafnium, tungsten, molybdenum, chrome, boron, manganese, silicon, germanium, aluminum-iron, magnesium-iron, magnesium-carbon, aluminum-carbon, nickel-aluminum, titanium-boron, calcium, sodium, carbonyl iron, and lithium. 
     
     
         33 . A dissolvable device that is at least partially formed from said reactive matrix composite as defined in  claim 32 , said dissolvable device is in the form of a proppant, frac ball, valve, plug, ball, or sleeve; said reactive matrix composite having a dissolution rate of about 0.1-5 mm/hour in a brine solution, said reactive matrix composite having a strength that is greater than 8000 psig, said dissolvable device is in the form of a proppant, frac ball, valve, plug, ball, or sleeve. 
     
     
         34 . The reactive matrix composite as defined in  claim 32 , wherein said reactive matrix composite having a dissolution rate of about 0.1-5 mm/hour in a brine solution, said reactive matrix composite having a strength that is greater than 8000 psig, said dissolvable device is in the form of a proppant, frac ball, valve, plug, ball, or sleeve. 
     
     
         35 . The reactive matrix composite as defined in  claim 32 , wherein said plurality of coated particles are sintered together. 
     
     
         36 . The reactive matrix composite as defined in  claim 32 , wherein said coating thickness of said reactive binder is less than 50% of a particle diameter of said primary core, said primary core unit has an average particle diameter of about 0.1-500 microns. 
     
     
         37 . The reactive matrix composite as defined in  claim 32 , wherein said coating thickness of said reactive binder is 0.01 microns to 50 microns. 
     
     
         38 . The reactive matrix composite as defined in  claim 32 , wherein said primary core primarily includes one or more materials selected from the group consisting of magnesium, tungsten, titanium, silicon, boron, hafnium, tantalum, niobium, molybdenum and zirconium. 
     
     
         39 . The reactive matrix composite as defined in  claim 32 , wherein each of said porous preformed particles has 10-50% open porosity. 
     
     
         40 . The reactive matrix composite as defined in  claim 32 , wherein said reactive binder includes one or more materials selected from the group consisting of zinc, magnesium, aluminum, carbonyl iron, titanium, magnesium-iron, magnesium-carbon, titanium-boron, and boron. 
     
     
         41 . The reactive matrix composite as defined in  claim 32 , wherein said reactive binder includes a composite of a reactive material and an oxidizer, said reactive material including one or more materials from the group consisting of magnesium, zirconium, tantalum, titanium, hafnium, calcium, tungsten, molybdenum, chrome, manganese, silicon, germanium and aluminum, said oxidizer including one or more materials from the group consisting of fluorinated polymer and chlorinated polymer, bismuth oxide, potassium perchlorate, potassium nitrate silver nitrate, iron oxide, tungsten oxide, molybdenum oxide, boron, aluminum, and silicon. 
     
     
         42 . The reactive matrix composite as defined in  claim 32 , wherein said reactive binder includes a composite of a fuel, an oxidizer, and a reactive polymeric material. 
     
     
         43 . The reactive matrix composite as defined in  claim 42 , wherein said reactive polymeric material includes aluminum-potassium perchlorate-polyvinylidene difluoride. 
     
     
         44 . The reactive matrix composite as defined in  claim 32 , wherein said reactive matric composite further includes a catalyst addition, said catalyst includes one or more materials selected from the group consisting of solid additives such as sulfur, phosphorous, tin, lead, bismuth, iron aluminide, metal salts, and oxides or intermetallic compounds having low melting points below 500° C. 
     
     
         45 . The reactive matrix composite as defined in  claim 32 , wherein said reactive matric composite further includes a secondary coating, said secondary coating formed of a different material from said reactive binder and said primary core, said secondary coating positioned between said primary core and said reactive binder or on an outer surface of said reactive binder. 
     
     
         46 . The reactive matrix composite as defined in  claim 32 , wherein said reactive binder includes two materials selected from the group consisting of zinc, aluminum, magnesium, iron-aluminum, nickel-aluminum, titanium-boron, zirconium, tantalum, titanium, hafnium, calcium, tungsten, molybdenum, chrome, manganese, silicon, and germanium. 
     
     
         47 . The reactive matrix composite as defined in  claim 32 , wherein said reactive binder includes an oxidizer, said oxidizer including one or more materials from the group consisting of fluorinated polymer and chlorinated polymer, bismuth oxide, potassium perchlorate, potassium nitrate, silver nitrate, iron oxide, tungsten oxide, molybdenum oxide, boron, aluminum, and silicon. 
     
     
         48 . The reactive matrix composite as defined in  claim 32 , wherein said reactive binder includes a reactive polymeric material, said reactive polymeric material includes polyvinylidene difluoride.