Elastomer Stator Molding for Screw Drilling Tools
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Solution Overview
Problem
Traditional elastomer materials for screw drilling tools have low high-temperature mechanics performance, insufficient adhesion to metal surfaces, cumbersome molding processes, high energy consumption, and significant pollution, which do not meet the requirements for drilling operations in severe environments.
Innovation Solution
A novel molding method for producing a stator for screw drilling tools using an elastomer material, involving surface treatment, assembly, and a one-shot infusion process with a prepolymer and curing agent, which includes specific steps for mixing, coating, and hierarchical heating to enhance adhesion and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rubber materials are used for screw drilling tools, then the materials have good wear resistance and corrosion resistance, but they have low high-temperature mechanics performance, low tensile strength, low tear strength, insufficient adhesion to metal surfaces, and require cumbersome molding processes with high energy consumption and high pollution
Solution Approach 1:
The patent changes the material parameters by using elastomer materials with specific molecular structures and properties that differ from traditional rubber. The elastomer materials have controlled crosslinking density, molecular weight distribution, and chemical composition to achieve high-temperature resistance, high tensile strength, and high tear strength while enabling simplified molding processes
Solution Approach 2:
The patent uses composite elastomer materials that combine different polymer components, fillers, and additives to achieve superior mechanical properties and adhesion. The composite structure allows optimization of both performance and processability, reducing the need for complex secondary processing steps
2Reliability
If traditional rubber materials are used for screw drilling tools, then the materials can be processed through conventional methods, but the adhesion to metal surfaces is insufficient, especially under fluid percolation conditions
Solution Approach 1:
The patent applies preliminary surface treatment to the metal substrate before molding, including surface roughening, cleaning, and application of coupling agents or primers. This preliminary action enhances the chemical and physical adhesion between the elastomer material and metal surface, ensuring strong bonding under fluid percolation conditions
Solution Approach 2:
The patent introduces intermediary substances such as coupling agents, adhesion promoters, or reactive fillers at the interface between the elastomer material and metal surface. These intermediaries facilitate strong chemical bonding and improve interfacial adhesion strength, particularly under harsh drilling conditions
3Duration of action of stationary object
If traditional rubber materials are used for screw drilling tools, then the materials have acceptable basic properties, but the lifetime is short and drilling cost is high
Solution Approach 1:
The patent optimizes material parameters including crosslinking density, molecular weight, and composition to enhance wear resistance, tear strength, and high-temperature stability. These parameter changes directly extend tool lifetime by improving resistance to degradation mechanisms in drilling environments
Solution Approach 2:
The patent employs a one-shot infusion molding process that segments the production into distinct stages: surface preparation, mold assembly, material infusion, and curing. This segmentation simplifies the overall manufacturing process by eliminating complex multi-step operations while ensuring consistent quality and extended product lifetime
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method improves the mechanical properties of elastomer materials, such as high temperature resistance, tear strength, and peeling strength, while reducing energy consumption and pollution, thus extending the tool's lifetime and meeting stringent drilling environment requirements.
Implementation Method 1
uniformly mixing an adhesive and a diluent, coating the mixture obtained on the inner surface of the dried stator tube
Implementation Method 2
pouring the obtained mixture into the assembled mold obtained in step S3, sealing and curing the poured assembled mold by hierarchical heating
Implementation Method 3
performing a vacuum defoaming under negative pressure on a mixture obtained by uniformly mixing a prepolymer of the elastomer material and a defoaming agent
Data Source
AI summary
A molding method for producing a screw drill stator using an elastomer material includes: S1. sequentially roughening, cleaning and drying an inner surface of the stator tube; mixing an adhesive and a diluent, coating the mixture obtained on the inner surface, and heating it for later use; S2, uniformly coating a mold release agent on a surface of a mandrel mold, and heating or drying it naturally for later use; S3. assembling the processed stator tube and the processed mandrel mold to obtain an assembled mold; S4. performing a vacuum defoaming under negative pressure on a mixture obtained by uniformly mixing a prepolymer of the elastomer material with a defoaming agent; S5. uniformly mixing the defoamed prepolymer of the elastomer material with a curing agent, and pouring the obtained mixture into the assembled mold, sealing and curing the poured assembled mold by hierarchical heating to obtain the stator.