Thermoset nanocomposite particles, processing for thier production, and their use in oil and natural gas drilling applications

A method for producing a polymeric nanocomposite particle, exhibiting at least one of enhanced resistance to deformation under load, enhanced retention of resistance at elevated temperature, and enhanced retention of resistance in acidic, basic, or hydrocarbon environments, comprising:

• preparing an organic phase comprising a reactive mixture dispersed within an organic liquid medium, containing at least one of an initiator;
• a dispersant;
• and at least one of a monomer, an oligomer or combinations thereof, said monomer and oligomer being capable of creating crosslinks between polymer chains, and from 0.001 to 60 volume percent of nanofiller particles possessing a length that is less than 0.5 microns in at least one principal axis direction;
• said nanofiller particles comprising at least one of fine particulate material, fibrous material, discoidal material, or a combination of such materials, said nanofiller particles being selected from the group consisting of natural nanoclays, synthetic nanoclays or mixtures thereof;
• wherein said nanofiller particles are substantially dispersed within the liquid medium;
• mixing said organic phase with an aqueous phase to form a polymeric nanocomposite particle precursor composition;
• subjecting the nanocomposite particle precursor composition to suspension polymerizing conditions;
• and
• forming the polymeric nanocomposite particle, whereby said nanofiller particles are dispersed throughout said polymeric nanocomposite particle and wherein said polymeric nanocomposite particle has about neutral buoyancy relative to water.