US Patent 11649690 Solid state lost circulation material

Provided is a solid-state lost circulation apparatus that may comprise a drillable tube with one or more fluid ports, an expandable layer, and an isolation layer. Upon introduction of the expandable layer to an activation agent through one or more fluid ports, the expandable layer may activate, expand, and harden into a hardened and expanded expandable layer, while rupturing the isolation layer. Further provided is a lost circulation assembly system that may include a drill pipe and a solid-state lost circulation apparatus. Further provided is a method of mitigating a lost circulation zone with a lost circulation assembly system. Further provided is a solid plug that may be positioned in a wellbore and may include a hardened and expanded expandable layer and a drillable tube. Further provided is a remnant of a solid plug that may form a fluid-tight seal across a face of a lost circulation zone.