# US 2019/0169953 A1 · Molded degradable downhole tool elements > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0169953 A1 - Document ID: US20190169953A1 - Status: Published application - Kind: A1 - Application number: 16/211,847 - Filed: 2018-12-06 - Published: 2019-06-06 - Earliest claimed: 2017-12-06 - Assignees: Magnum Oil Tools International, Ltd. - Applicants: Magnum Oil Tools International, Ltd. - Inventors: W. Lynn Frazier - Web page: https://patentgrep.com/patent/US20190169953A1 ## CPC - E21B 33/1208: {characterised by the construction of the sealing or packing means (E21B33/1277 takes precedence)} - B29C 45/14311: {using means for bonding the coating to the articles (B29C45/14795 takes precedence)} - B29C 45/14795: {Porous or permeable material, e.g. foam} - B29C 2045/14327: {anchoring by forcing the material to pass through a hole in the article} - B29K 2067/046: {PLA, i.e. polylactic acid or polylactide} - B29K 2705/02: Aluminium - E21B 2200/08: Down-hole devices using materials which decompose under well-bore conditions - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS - 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract A two-part structural element for a downhole tool is disclosed, and methods of making the same. The two parts are a moldable plastic second part and a first part being an insert for placement in a mold, typically before a thermoset or thermoplastic second part is poured or otherwise placed in the mold. One or both of the two parts may be degradable in a downhole fluid. ## Claims ### Claim 1 A structural element for a downhole tool, comprising: a first part and a second part; the first part comprising a metal capable of degrading in an aqueous downhole fluid and capable of being placed in a mold with the second part, the first part disposed within the structural element such that when the tool is used in an aqueous downhole fluid at least some of the first part is at an outer surface of the structural element, and in contact with the aqueous downhole fluid, and at least some of the first part is not at the outer surface of the structural element; the second part comprising a moldable material capable of degrading in the aqueous downhole fluid; the second part disposed within the structural element such that when the tool is used in the aqueous downhole fluid at least some of the second part is not at the outer surface of the structural element; and the structural element capable of degradation more quickly in the aqueous downhole fluid than a similar structural element comprised solely of the second part will degrade. ### Claim 2 (depends on 1) The structural element of claim 1, wherein the first part comprises an at least partly open cell metallic skeleton. ### Claim 3 (depends on 2) The structural element of claim 2, wherein the at least partly open cell skeleton is non-rigid. ### Claim 4 (depends on 2) The structural element of claim 2, wherein the at least partly open cell skeleton is rigid. ### Claim 5 (depends on 4) The structural element of claim 4, wherein the rigid, at least partly open cell skeleton is die compressed knitted wire magnesium alloy or aluminum alloy. ### Claim 6 (depends on 4) The structural element of claim 4, wherein the rigid, open cell skeleton is foam metal. ### Claim 7 (depends on 2) The structural element of claim 2, wherein the at least partly open cell skeleton is made of metal wire. ### Claim 8 (depends on 7) The structural element of claim 7, wherein the wire is aluminum alloy or magnesium alloy. ### Claim 9 (depends on 7) The structural element of claim 7, wherein the average diameter or average shortest dimension of the wire is between 2 and 250 mil. ### Claim 10 (depends on 7) The structural element of claim 7, wherein the wire is an ordered wire mesh. ### Claim 11 (depends on 7) The structural element of claim 7, wherein the wire is woven wire mesh. ### Claim 12 (depends on 7) The structural element of claim 7, wherein the wire is knitted wire mesh. ### Claim 13 (depends on 12) The structural element of claim 12, wherein the knitted wire mesh is capable of being die compressed. ### Claim 14 (depends on 1) The structural element of claim 1, wherein the second part is a polymer acid degradable in the aqueous downhole fluid. ### Claim 15 (depends on 1) The structural element of claim 1, wherein the first part is comprised of multiple metal particles. ### Claim 16 (depends on 15) The structural element of claim 15, wherein the metal particles are granular metal or metal shavings. ### Claim 17 (depends on 1) The structural element of claim 1, wherein the first part comprises a rigid, solid insert. ### Claim 18 (depends on 1) The structural element of claim 1, wherein the first part comprises randomly arranged metal fibers. ### Claim 19 (depends on 1) The structural element of claim 1, wherein the first part comprises long, ordered fibers. ### Claim 20 A method of making a structural element for a downhole tool, the method comprising the steps of: providing a mold having a mold cavity; partly filing the cavity with a first material comprising an insert; filing the mold cavity with an uncured or unset second material, the second material comprising a material in a plastic or fluid state, the second material at least partly encapsulating the first material; allowing the second material to cure or set to a solid form; and removing the form from the mold cavity; wherein at least one of the first or second material is degradable in a downhole fluid. ### Claim 21 (depends on 20) The method of claim 20, further including the step of machining the form. ### Claim 22 (depends on 20) The method of claim 20, wherein the mold of the providing step includes internal projections. ### Claim 23 (depends on 20) The method of claim 20, wherein the partly filing step and the filling step are accomplished simultaneously with a slurry comprising a mixture of the first material and the second material filling the mold cavity. ### Claim 24 (depends on 20) The method of claim 20, wherein the insert of the partly filing step is a rigid body with open cells. ### Claim 25 (depends on 20) The method of claim 20, wherein the insert of the partly filing step is a skeleton with open cells. ### Claim 26 (depends on 25) The method of claim 25, further including prior to the partly filing step, the step of preforming the skeleton into a skeleton configuration. ### Claim 27 (depends on 26) The method of claim 26, wherein the skeleton configuration is tabular. ### Claim 28 (depends on 26) The method of claim 26, wherein the skeleton configuration is cylindrical. ### Claim 29 (depends on 26) The method of claim 26, wherein the preforming step includes compressing the skeleton. ### Claim 30 (depends on 25) The method of claim 25, wherein the skeleton is capable of degrading in a downhole fluid. ### Claim 31 (depends on 25) The method of claim 25, wherein the skeleton is comprised of ordered, open cells. ### Claim 32 (depends on 25) The method of claim 25, wherein the skeleton is comprised of irregular, open cells. ### Claim 33 (depends on 20) The method of claim 20, wherein the insert of the partly filing step is comprised of multiple loose particles. ### Claim 34 (depends on 20) The method of claim 20, wherein the insert of the partly filing step is comprised of foam metal. ### Claim 35 (depends on 20) The method of claim 20, wherein the insert of the partly filing step is comprised of long fibers. ### Claim 36 (depends on 20) The method of claim 20, wherein the second material cures or sets to form an elastomer. ### Claim 37 (depends on 20) The method of claim 20, wherein the insert is comprised of aluminum or magnesium wire or shavings. ### Claim 38 (depends on 37) The method of claim 37, wherein the wire or shavings are die pressed before the partly filling step. ### Claim 39 (depends on 20) The method of claim 20, wherein the filling step includes the step of compressing. ### Claim 40 (depends on 20) The method of claim 20, wherein the filling step includes the step of pouring the second material. ### Claim 41 (depends on 20) The method of claim 20, wherein the filling step includes the step of injecting the second material. ### Claim 42 A structural element for a settable downhole tool, the structural element comprising: a first part comprising a metal capable of degradation in an aqueous downhole fluid and configured to fit into a mold; and a second part comprising a moldable material. ### Claim 43 (depends on 42) The structural element of claim 42, wherein the settable downhole tool will release from a well's casing more quickly than if the structural element were comprised solely of the second part. ### Claim 44 (depends on 42) The structural elements of claim 42, wherein the settable downhole tool will be more millable after two hours in aqueous downhole fluid than if the structural element was comprised solely of the second part. ### Claim 45 A structural element for a settable downhole tool, comprising: a first part comprising a metal degradable in an aqueous downhole fluid and capable of being used in an injection mold with a second part comprising a thermoset or thermoplastic material, the first part comprising a skeleton and disposed within the structural element so when the tool is used in an aqueous downhole fluid at least some outer portions of the first part are at the outer surface of the structural element, are in contact with the aqueous downhole fluid, and at least some inner portions of the first part are not in contact with the aqueous fluid; and a second part comprising an injection moldable material. ### Claim 46 (depends on 45) The structural element of claim 45, wherein the first part comprises an at least partly open cell metallic skeleton. ### Claim 47 (depends on 46) The structural element of claim 46, wherein the at least partly open cell skeleton is non-rigid. ### Claim 48 (depends on 46) The structural element of claim 46, wherein the at least partly open cell skeleton is rigid. ### Claim 49 (depends on 46) The structural element of claim 46, wherein the rigid, at least partly open cell skeleton is die compressed knitted wire magnesium alloy or aluminum alloy. ### Claim 50 (depends on 46) The structural element of claim 46, wherein the rigid, open cell skeleton is foam metal. ### Claim 51 (depends on 46) The structural element of claim 46, wherein the at least partly open cell skeleton is made of metal wire. ### Claim 52 (depends on 51) The structural element of claim 51, wherein the wire is aluminum alloy or magnesium alloy. ### Claim 53 (depends on 51) The structural element of claim 51, wherein the average diameter or average shortest dimension of the wire is between 2 and 250 mil. ### Claim 54 (depends on 51) The structural element of claim 51, wherein the wire is an ordered wire mesh. ### Claim 55 (depends on 51) The structural element of claim 51, wherein the wire is woven wire mesh. ### Claim 56 (depends on 51) The structural element of claim 51, wherein the wire is knitted wire mesh. ### Claim 57 (depends on 56) The structural element of claim 56, wherein the knitted wire mesh is capable of being die compressed. ### Claim 58 (depends on 45) The structural element of claim 45, wherein the second part is a polymer acid. ### Claim 59 (depends on 58) The structural element of claim 58, wherein the second part is degradable in an aqueous downhole fluid. ### Claim 60 (depends on 45) The structural element of claim 45, wherein the first part is granular metal or shavings. ### Claim 61 (depends on 60) The structural element of claim 60, wherein the granular metal or shavings are comprised of a magnesium alloy. ### Claim 62 (depends on 45) The structural element of claim 45, wherein the first part comprises a rigid, solid insert. ### Claim 63 (depends on 45) The structural element of claim 45, wherein the first part comprises randomly arranged metal fibers. ### Claim 64 (depends on 63) The structural element of claim 63, wherein the metal fibers are die pressed. ### Claim 65 A structural element for a downhole tool, comprising: a first part and a second part; the first part comprising a metal degradable in an aqueous downhole fluid and capable of being used in an injection mold with the second part, the first part comprising a skeleton and disposed within the structural element so when the tool is used in an aqueous downhole fluid at least some outer portions of the first part are at the outer surface of the structural element, are in contact with the aqueous downhole fluid, and at least some inner portions of the first part are not in contact with the aqueous fluid; the second part comprising an injection moldable material degradable in an aqueous downhole fluid; the second part disposed within the structural element so when the tool is used in an aqueous downhole fluid at least some inner portions of the first part are not in contact with the aqueous downhole fluid; the first part degrades more quickly in aqueous downhole fluid than the second part, and degradation of the first part increases the surface area of the second part in contact with the aqueous downhole fluid; and the structural element degrades more quickly in the aqueous downhole fluid than a similar structural element comprised solely of the second part injection moldable material will degrade.