Structural expandable materials

Abstract

A composite particle that incorporates a material and is designed to undergo a reaction and/or mechanical or chemical change with the environment to increase in volume. The composite particle can be combined with a constraining matrix to create an expandable particle upon reaction. These particles can be used in stimulating wells, including oil and gas reservoirs.

1 - 33 . (canceled) 
     
     
         34 . A method of treating a subterranean formation comprising:
 a. providing A) a proppant; said proppant comprising an expandable composite material; said expandable composite material having a compressive strength after expansion of at least 2,000 psig; said expandable composite material configured to undergo a volumetric expansion of at least 2%; said expandable composite material formed of an expandable material and a polymer material; said polymer material forming i) a matrix or binder with said expandable material, ii) a coating about said expandable material, or combinations thereof; said polymer material selected from the group consisting of polyurea, epoxy, silane, carbosilane, silicone, polyarylate, polyimide, polyester, polyether, polyamine, polyamide, polyacetal, polyvinyl, polyureathane, epoxy, polysiloxane, polycarbosilane, polysilane, nylon, and polysulfone; said expandable composite material including I) one or more materials selected from the group consisting of calcium, lithium, CaO, Li 2 O, Na 2 O, iron, aluminum, silicon, magnesium, K 2 O and zinc, II) a compressed shape memory material, or combinations thereof; said polymer composition including a polymer selected from the group consisting of polyester, polyether, polyamine, polyamide, polyacetal, polyvinyl, polyureathane, epoxy, polysiloxane, polycarbosilane, polysilane, polysulfone, and nylon; and/or B) a force delivery device; said force delivery device includes a retaining structure, an expandable composite material at least partially positioned in said retaining structure, and a protective layer at least partially covering an opening in said retaining structure; said retaining structure formed of a different materials from said expandable composite material; said expandable composite material having a compressive strength after expansion of at least 2,000 psig; said expandable composite material configured to undergo a volumetric expansion of at least 2%; said expandable composite material formed of an expandable material and a polymer material; said polymer material forming i) a matrix or binder with said expandable material, ii) a coating about said expandable material, or combinations thereof; said polymer material selected from the group consisting of polyurea, epoxy, silane, carbosilane, silicone, polyarylate, polyimide, polyester, polyether, polyamine, polyamide, polyacetal, polyvinyl, polyureathane, epoxy, polysiloxane, polycarbosilane, polysilane, nylon, and polysulfone; said expandable composite material including I) one or more materials selected from the group consisting of calcium, lithium, CaO, Li 2 O, Na 2 O, iron, aluminum, silicon, magnesium, K 2 O and zinc, II) a compressed shape memory material, or combinations thereof; said protective layer at least partially formed of a polymer composition; said polymer composition including a polymer selected from the group consisting of polyester, polyether, polyamine, polyamide, polyacetal, polyvinyl, polyureathane, epoxy, polysiloxane, polycarbosilane, polysilane, polysulfone, and nylon; and,   b. introducing said proppant and/or said force delivery device into said subterranean formation.   
     
     
         35 . The method as defined in  claim 34 , further including the step of exposing said proppant and/or said force delivery device to a fluid environment to cause said expandable composite material to expand and thereby cause said proppant and/or at least a portion of said force delivery device to expand in said subterranean formation. 
     
     
         36 . The method as defined in  claim 35 , wherein said step of exposing results in said mechanical or chemical change to said expandable material, said mechanical or chemical change to said expandable material at least partially resulting from said reaction to said expandable material selected from the group consisting of a hydrolization reaction, a carbonation reaction, and an oxidation reaction. 
     
     
         37 . The method as defined in  claim 34 , wherein said expandable composite material comprises 10-80% by volume of said expandable material. 
     
     
         38 . The method as defined in  claim 34 , wherein said protective layer has a thickness of 0.1 µm to 1 mm. 
     
     
         39 . The method as defined in  claim 34 , wherein said expandable composite material includes one or more materials selected from the group consisting of flakes, fibers, powders, and nanopowders. 
     
     
         40 . The method as defined in  claim 39 , wherein said expandable composite material includes iron micro-powder. 
     
     
         41 . The method as defined in  claim 34 , wherein said polymer material includes polysulfone, nylon, and/or epoxy. 
     
     
         42 . The method as defined in  claim 34 , wherein said expandable material includes CaO. 
     
     
         43 . The method as defined in  claim 34 , wherein said expandable composite material includes a catalyst formulated to accelerate expansion of said expandable composite material. 
     
     
         44 . The method as defined in  claim 34 , wherein said expandable composite material includes strengthening fillers, diluting fillers, or combinations thereof, said strengthening fillers, diluting fillers, or combinations thereof including one or more materials selected from the group consisting of fumed silica, silica, glass fibers, carbon fibers, carbon nanotubes, and other finely divided inorganic material. 
     
     
         44 . The method as defined in  claim 34 , wherein said force delivery device is a sealing device, a fluidic device, expandable device, or fluid actuated telescoping device. 
     
     
         45 . The method as defined in  claim 34 , wherein said expandable composite material retains a permeability at least 300 millidarcys after expanding with clamping forces of 1000-7000 psig. 
     
     
         46 . The method as defined in  claim 34 , wherein said expandable composite material includes a catalyst formulated to accelerate said reaction. 
     
     
         47 . The method as defined in  claim 46 , wherein said catalyst includes one or more materials selected from the group consisting of AlCl 3  and a galvanically-active material.