Abstract: A Moineau style stator includes a helical cavity component having reinforced helical lobes. The lobes are reinforced with a three-dimensional network of physically bonded aggregate particles. The network of bonded aggregate provides a porous skeletal-like structural reinforcement. Pore volume between the bonded aggregate particles may optionally be partially or substantially filled with an elastomer. An elastomer liner is typically deployed on an inner surface of the helical lobes to promote a rotational interference fit with a rotor.

Abstract: A Moineau style stator includes a helical reinforcement component that provides an internal helical cavity. A resilient liner is deployed on an inner surface of the helical reinforcement component. The helical reinforcement component includes a solder or braze material and is typically metallurgically bonded to an inner wall of a stator tube. In exemplary embodiments, the helical reinforcement component includes a composite mixture of solder and aggregate. Exemplary embodiments of this invention address the heat build up and subsequent elastomer breakdown in the lobes of prior arts stators by providing a helical reinforcement component. Solder reinforced stators tend to be less expensive to fabricate than reinforced stators of the prior art.

Abstract: A progressing cavity stator and a method for fabricating such a stator are disclosed. Exemplary embodiments of the progressing cavity stator include a plurality of rigid longitudinal stator sections concatenated end-to-end in a stator tube. The stator sections are rotationally aligned so that each of the internal lobes extends in a substantially continuous helix from one end of the stator to the other. The stator further includes an elastomer liner deployed on an inner surface of the concatenated stator sections. Exemplary embodiments of this invention include a comparatively rigid stator having high torque output and are relatively simple and inexpensive to manufacture as compared to prior art rigid stators.

Abstract: A hydrostatic mechanical seal assembly includes a locally deployed pump for pressurizing a lubricant fluid between the opposing faces of a mating ring and a sealing ring. In one exemplary embodiment, such pressurization may be achieved via a device that converts the rotational motion of a drive shaft into fluid pressure. The locally deployed pump is intended to advantageously provide a stable positive pressure on the sealing interface between the mating and sealing rings, which may provide improved sealing characteristics, especially in demanding downhole environments.

Abstract: A hydrostatic mechanical seal assembly includes a locally deployed pump for pressurizing a lubricant fluid between the opposing faces of a mating ring and a sealing ring. In one exemplary embodiment, such pressurization may be achieved via a device that converts the rotational motion of a drive shaft into fluid pressure. The locally deployed pump is intended to advantageously provide a stable positive pressure on the sealing interface between the mating and sealing rings, which may provide improved sealing characteristics, especially in demanding downhole environments.

Abstract: A Moineau stator for a downhole drilling motor and a method for fabricating the stator are disclosed. The stator includes an internal helical cavity component fabricated from an improved elastomeric material formulated to provide both high resilience and good processability. For example, in one exemplary embodiment the elastomer material includes rheological parameters ML in a range from about 1.0 to about 4.0 lb·in and MH in a range from about 75 to about 110 lb·in according to ASTM D2084 at 380 degrees F. Stators in accordance with this invention may exhibit improved efficiency (and may thus provide improved torque output) as compared with conventional stators without substantially increasing manufacturing costs.

Abstract: A progressing cavity stator and a method for fabricating such a stator are disclosed. Exemplary embodiments of the progressing cavity stator include a plurality of rigid longitudinal stator sections concatenated end-to-end in a stator tube. The stator sections are rotationally aligned so that each of the internal lobes extends in a substantially continuous helix from one end of the stator to the other. The stator further includes an elastomer liner deployed on an inner surface of the concatenated stator sections. Exemplary embodiments of this invention include a comparatively rigid stator having high torque output and are relatively simple and inexpensive to manufacture as compared to prior art rigid stators.

Abstract: A progressing cavity stator and a method for fabricating such a stator are disclosed. Exemplary embodiments of the progressing cavity stator include a plurality of rigid longitudinal stator sections concatenated end-to-end in a stator tube. The stator sections are rotationally aligned so that each of the internal lobes extends in a substantially continuous helix from one end of the stator to the other. The stator further includes an elastomer liner deployed on an inner surface of the concatenated stator sections. Exemplary embodiments of this invention include a comparatively rigid stator having high torque output and are relatively simple and inexpensive to manufacture as compared to prior art rigid stators.

Abstract: The inventive stator includes a helical cavity component made from a material chosen to reinforce an elastomer liner deployed thereon. The contouring of the elastomer liner is asymmetrical, such that the elastomer liner is relatively thick on the loaded side of a lobe as compared to its thickness on the unloaded side of the lobe.

Abstract: A progressing cavity stator and a method for fabricating such a stator are disclosed. The progressing cavity stator includes first and second elastomer layers fabricated from corresponding first and second elastomer materials. The first and second elastomer materials are selected to have at least one distinct material property. Exemplary embodiments of this invention may reduce tradeoffs associated with elastomer material selection and may further address the heat build up and subsequent elastomer breakdown in the lobes of prior art stators.

Abstract: A progressing cavity stator is provided. The progressing cavity stator includes a fiber reinforced composite component providing an internal helical cavity having at least one helical groove and an elastomeric liner disposed on an internal surface of the fiber reinforced composite component. In various exemplary embodiments, the fiber reinforced composite component includes a plurality of fibers disposed in a matrix material, the plurality of fibers being disposed such that distinct portions thereof follow correspondingly distinct directions. Exemplary embodiments of this invention may advantageously exhibit a prolonged service life in downhole applications as compared to conventional progressing cavity stators. A replaceable progressing cavity insert for a stator is also provided. Methods for fabricating progressing cavity stators and progressing cavity inserts are also provided.

Abstract: The inventive stator includes a helical cavity component made from a material chosen to reinforce an elastomer liner deployed thereon. The contouring of the elastomer liner is asymmetrical, such that the elastomer liner is relatively thick on the loaded side of a lobe as compared to its thickness on the unloaded side of the lobe.