Hybrid Core Progressive Cavity Pump Stator
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Solution Overview
Problem
Progressive cavity pumps face efficiency and lifespan issues due to wear from high temperatures, corrosive, and abrasive fluids, which affect the helically shaped stator and rotor, leading to decreased performance and durability.
Innovation Solution
A progressive cavity pump with a stator featuring a durable, segmented casing made of metallic or corrosion-resistant materials, combined with an elastomeric filler for thermal and abrasion protection, allowing for precise manufacturing and quasi-seamless assembly, and accommodating free rotation of the rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the stator cavity is formed from elastomer material, then the pump can operate with simple structure, but the increased temperatures cause the elastomer to break down over time
Solution Approach 1:
The patent applies composite materials by combining a metallic stator cavity structure with an elastomeric coating layer. The metallic substrate provides structural integrity and thermal resistance, while the elastomeric coating maintains the necessary cavities and provides sealing properties. This composite approach resolves the contradiction by eliminating the temperature breakdown issue of pure elastomer while preserving the functional benefits of elastomeric material.
Solution Approach 2:
The patent changes the material parameter of the stator cavity from pure elastomer to a hybrid metallic-elastomeric composite. This parameter change allows the stator to withstand higher temperatures and more aggressive fluids while maintaining the operational characteristics required for progressive cavity pump function.
2Strength
If metallic rotors are used, then structural strength is improved, but corrosive fluids eat away at metallic rotors
Solution Approach 1:
The patent applies composite materials to the rotor by combining a metallic substrate with an elastomeric coating. The metallic core provides the necessary structural strength for rotor operation, while the elastomeric coating layer protects against corrosion from aggressive fluids. This resolves the contradiction between strength and corrosion resistance.
3Adaptability or versatility
If abrasive materials are pumped, then the pump can handle diverse fluid types, but abrasive materials eat away both metallic and elastomeric materials
Solution Approach 1:
The patent applies beforehand cushioning by implementing a hybrid metallic-e elastomeric construction that provides inherent protection against abrasion before the abrasive materials cause significant wear. The elastomeric components absorb and cushion the impact of abrasive particles, reducing wear on both metallic and elastomeric surfaces and extending pump life when handling abrasive fluids.
Data Source
AI summary
A stator for a progressive cavity pump may include a containment element with an inner surface and a casing. The casing may be arranged within the containment element, be generally isolated from the inner surface of the containment element, and define a stator cavity adapted for receiving a progressive cavity pump rotor and for accommodating substantially free rotation of the progressive cavity pump rotor therein.