Reinforced Directional Drilling Power Section Composite
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Solution Overview
Problem
Directional drilling mud motors face mechanical failure due to severe operating conditions, often resulting in unnoticed structural breakdowns in the power section, which degrades non-metallic materials used in their components.
Innovation Solution
A reinforced directional drilling assembly is developed by applying strengthening materials to resilient layers, forming a reinforced polymer composite, and integrating signal-indicating materials for status detection, using materials like fibers, epoxy, and conductive polymers to enhance durability and data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-metallic materials (composite materials, elastomers) are used in mud motor components, then ease of manufacture and corrosion resistance are improved, but strength and reliability under severe operating conditions deteriorate
Solution Approach 1:
The patent applies composite materials by combining elastomeric resilient material with non-metallic reinforcement materials (such as fibrous or sheet-like materials) to create a multi-layer composite structure. This composite construction provides both the corrosion resistance and ease of manufacture advantages of non-metallic materials while significantly improving strength and reliability under severe operating conditions through the reinforcing elements.
2Object-affected harmful factors
If non-metallic materials are used in mud motor components, then corrosion resistance is improved, but reliability under severe operating conditions deteriorates
Solution Approach 1:
The patent uses composite materials combining elastomeric materials with non-metallic reinforcement materials to maintain corrosion resistance while improving reliability. The reinforcement layer embedded within the elastomeric material prevents structural breakdown under severe operating conditions, allowing the component to withstand harsh environments without failing.
3Ease of operation
If resilient materials are used in mud motor components, then ease of operation is improved, but strength and durability deteriorate
Solution Approach 1:
The patent applies composite materials where elastomeric resilient material provides ease of operation through flexibility and cushioning, while embedded non-metallic reinforcement materials (fibrous or sheet-like) provide durability and resistance to structural breakdown. This multi-layer composite structure simultaneously achieves both ease of operation and long service life under severe conditions.
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 solution increases the longevity and reliability of the power section, reduces drilling costs, and enables real-time monitoring of the drilling assembly's status, allowing for timely intervention and data collection.
Implementation Method 1
The at least one polymer may be solidified on the portion of the at least one resilient layer by using chemical additives
Implementation Method 2
The at least one polymer may be solidified on the portion of the at least one resilient layer by applying ultraviolet radiation
Implementation Method 3
The at least one polymer may be solidified on the portion of the at least one resilient layer by applying electron beams
Implementation Method 4
The at least one polymer may be solidified on the portion of the at least one resilient layer by heating
Implementation Method 5
The at least one polymer may be solidified on the portion of the at least one resilient layer by exposing to part of the microwave spectrum, exposing to the full microwave spectrum
Implementation Method 6
The at least one polymer may be solidified on the portion of the at least one resilient layer by steam curing
Implementation Method 7
The at least one polymer may be solidified on the portion of the at least one resilient layer by curing/solidification, and/or cooling
Data Source
AI summary
Reinforced directional drilling assemblies and methods of forming reinforced directional drilling assemblies are provided. Strengthening materials may be incorporated into a resilient layer and/or a polymer-based composite material within a directional drilling assembly to improve the durability and performance of a power section within the directional drilling assembly. Inclusion of strengthening materials within a directional drilling assembly may provide a method to detect the status of a power section and send a signal from downhole upon detecting status of the power section. Inclusion of strengthening materials also may provide a method to collect data about operating conditions, including pressure, temperature, torque, RPM, stress level, shock, vibration, downhole weight on bit, and/or equivalent circulating density to send to the surface or to MWD/LWD systems. The strengthening materials may collect data by themselves or in conjunction with a sensor.