# US 8,783,099 B2 · Downhole sensors impregnated with hydrophobic material, tools including same, and related methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,783,099 B2 - Document ID: US8783099B2 - Status: Granted - Kind: B2 - Application number: 13/175,528 - Filed: 2011-07-01 - Published: 2013-01-03 - Granted: 2014-07-22 - Earliest claimed: 2011-07-01 - Assignees: Baker Hughes Incorporated - Applicants: David H. Lilly; Holger C. Stibbe - Inventors: David H. Lilly; Holger C. Stibbe - Web page: https://patentgrep.com/patent/US8783099B2 ## CPC - E21B 47/017: Protecting measuring instruments - Y10T 29/49982: Coating - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A downhole tool includes a sensor having a sensitive component, a polymer that at least partially covers the sensitive component, and a hydrophobic material impregnated within the polymer and/or the sensitive component of the sensor. Methods of forming the downhole tool include covering a portion of the sensor with a polymer and impregnating a hydrophobic material within the polymer and/or the sensitive component of the sensor. ## Claims ### Claim 1 A downhole tool, comprising: a sensor, the sensor comprising: a sensitive component; a polymer at least partially covering an outward-facing surface of the sensitive component; and a hydrophobic fluid impregnated within at least one of the polymer and the sensitive component. ### Claim 2 (depends on 1) The downhole tool of claim 1, wherein the hydrophobic fluid is substantially evenly dispersed throughout the at least one of the polymer and the sensitive component. ### Claim 3 (depends on 1) The downhole tool of claim 1, wherein the hydrophobic fluid comprises polydimethylsiloxane. ### Claim 4 (depends on 1) The downhole tool of claim 1, wherein the hydrophobic fluid comprises at least one of a silicone-based oil, a non-polar silicone material, and a fluorocarbon. ### Claim 5 (depends on 1) The downhole tool of claim 1, wherein the sensor is configured to detect a signal in an environment at a pressure of at least 30 kpsi and at a temperature of at least 175 degrees Celsius. ### Claim 6 (depends on 1) The downhole tool of claim 1, wherein the sensor comprises an acoustic sensor. ### Claim 7 (depends on 6) The downhole tool of claim 6, wherein the sensitive component comprises a piezoelectric ceramic transducer. ### Claim 8 (depends on 1) The downhole tool of claim 1, wherein the polymer comprises a thermoplastic material. ### Claim 9 (depends on 8) The downhole tool of claim 8, wherein the thermoplastic material comprises polyetheretherketone. ### Claim 10 (depends on 1) The downhole tool of claim 1, wherein the sensor is supported within a tool segment. ### Claim 11 (depends on 10) The downhole tool of claim 10, wherein the tool segment is configured for attachment to at least one of a drill string and a wireline. ### Claim 12 (depends on 1) The downhole tool of claim 1, further comprising: at least one active device comprising the sensor. ### Claim 13 (depends on 12) The downhole tool of claim 12, further comprising an earth-boring tool. ### Claim 14 (depends on 13) The downhole tool of claim 13, wherein the earth-boring tool comprises a drill bit. ### Claim 15 (depends on 1) The downhole tool of claim 1, wherein: the sensor is an acoustic sensor; and the sensitive component is a piezoelectric transducer, the piezoelectric transducer impregnated with the hydrophobic fluid. ### Claim 16 (depends on 15) The downhole tool of claim 15, wherein the acoustic sensor is configured to detect a signal in a downhole environment at, at least, 30 kpsi and at, at least, 175 degrees Celsius. ### Claim 17 (depends on 15) The downhole tool of claim 15, wherein the hydrophobic fluid is impregnated within both the piezoelectric transducer and the polymer. ### Claim 18 A method of forming a downhole tool, the method comprising: forming a sensor having a sensitive component; at least partially covering an outward-facing surface of the sensitive component with a polymer; and impregnating at least one of the polymer and the sensitive component with a hydrophobic fluid. ### Claim 19 (depends on 18) The method of claim 18, wherein at least partially covering an outward-facing surface of the sensitive component with a polymer precedes impregnating at least one of the polymer and the sensitive component with the hydrophobic material fluid. ### Claim 20 (depends on 18) The method of claim 18, wherein at least partially covering an outward-facing surface of the sensitive component with a polymer comprises at least partially covering the outward-facing surface of the sensitive component with polyetheretherketone. ### Claim 21 (depends on 18) The method of claim 18, wherein at least partially covering an outward-facing surface of the sensitive component with a polymer comprises encapsulating the sensor with a thermoplastic material. ### Claim 22 (depends on 18) The method of claim 18, wherein impregnating at least one of the polymer and the sensitive component with a hydrophobic fluid comprises impregnating a thermoplastic material with at least one of a silicone-based oil, a non-polar silicone material, and a fluorocarbon. ### Claim 23 (depends on 22) The method of claim 22, wherein impregnating a thermoplastic material with at least one of a silicone-based oil, a non-polar silicone material, and a fluorocarbon comprises impregnating the thermoplastic material with the silicone-based oil in a high-pressure and high-temperature environment.