US 12,129,352 B2
Syntactic foams with enhanced resistance to swelling and corrosion
Shashwat Shukla, Singapore (SG); and Arpana Singh, Singapore (SG)
Assigned to Halliburton Energy Services, Inc., Houston, TX (US)
Filed by Halliburton Energy Services, Inc., Houston, TX (US)
Filed on Nov. 30, 2021, as Appl. No. 17/537,942.
Prior Publication US 2023/0167263 A1, Jun. 1, 2023
Int. Cl. C08J 9/32 (2006.01); C08K 3/04 (2006.01); C08K 3/34 (2006.01); C08K 7/24 (2006.01); E21B 47/017 (2012.01)
CPC C08J 9/32 (2013.01) [C08K 3/041 (2017.05); C08K 3/042 (2017.05); C08K 3/346 (2013.01); C08K 7/24 (2013.01); E21B 47/017 (2020.05); C08J 2300/00 (2013.01); C08K 2201/003 (2013.01); C08K 2201/005 (2013.01); C08K 2201/011 (2013.01)] 10 Claims
 
1. A syntactic foam for use in a flowable downhole tool, the syntactic foam comprising:
a matrix material comprising a polymer material selected from the group consisting of polyurethane, polyamide, epoxy resin, phenolic resin, cyanate ester, polyester, vinyl ester, polyethylene, polypropylene, polystyrene, nylon, high density polyethylene, and any combination thereof and further comprising a plurality of at least one of carbon nanotubes, graphene-based materials, or nano-clay; and
a plurality of microspheres embedded within the matrix material, wherein the plurality of microspheres comprises a metallic glass material having an amorphous structure for resisting stress-corrosion cracking in a downhole environment and comprises at least one of zirconium, cobalt, and aluminum, or at least one silver, niobium, titanium, beryllium, nickel, copper, chromium, or yttrium, the microspheres are hollow microspheres and each of the hollow microspheres have an inner diameter and an outer diameter, wherein the ratio of the inner diameter to the outer diameter is at least 0.85 and the outer diameter is between about 1 micron and about 300 microns.