Progressive Cavity Motor Stator Adhesion via Surface Treatment
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Solution Overview
Problem
Mud motors in downhole drilling operations often fail due to insufficient adhesion or bonding between materials, leading to mechanical failures under severe operating conditions.
Innovation Solution
A method of manufacturing a progressive cavity motor or pump that involves treating the inner surface of a cylindrical shell with an adhesive treatment layer, injecting elastomeric material between the shell and a stator mold, curing, and forming an elastomeric material layer with a stator profile, which is then adhered to the shell and housed within a stator housing with a metal-to-metal bonding agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional manufacturing methods are used without adhesive treatment, then the manufacturing process is simpler, but the adhesion and bonding strength between elastomeric material and cylindrical shell is insufficient
Solution Approach 1:
The inner surface of the cylindrical shell is treated with an adhesive treatment layer before the elastomeric material is injected and cured. This preliminary action prepares the surface to enhance adhesion, resolving the contradiction by adding a simple preparatory step that significantly improves bonding strength without complicating the overall manufacturing process
2Reliability
If the elastomeric material is directly placed in the cylindrical shell without adhesive treatment, then the manufacturing process is faster, but the bonding strength between components is insufficient under severe operating conditions
Solution Approach 1:
The adhesive treatment layer is applied to the cylindrical shell inner surface before injecting the elastomeric material. This preliminary preparation ensures strong bonding that maintains reliability under severe operating conditions, while the treatment process is integrated into the manufacturing flow to minimize impact on productivity
3Strength
If no adhesive treatment layer is applied to the cylindrical shell, then the manufacturing steps are fewer, but the bonding between the elastomeric material and shell is insufficient
Solution Approach 1:
The surface properties of the cylindrical shell are modified by applying an adhesive treatment layer, which changes the surface parameters to enhance bonding capability. This parameter change approach allows the shell surface to better bond with the elastomeric material while maintaining ease of manufacture through a straightforward coating or treatment process
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
Enhances the adhesion and bonding strength between the elastomeric material and the cylindrical shell, improving the durability and reliability of the motor assembly in harsh oilfield environments.
Implementation Method 1
treating an inner surface of a cylindrical shell to facilitate adhering an elastomeric material to the cylindrical shell, thereby forming an adhesive treatment layer on the inner surface of the cylindrical shell
Implementation Method 2
disposing an adhesive material comprising a metal-to-metal bonding agent within the stator housing, thereby forming an adhesive layer within the stator housing, and adhering the cartridge within the stator housing
Data Source
AI summary
A stator and a method of manufacturing at least a portion of a progressive cavity motor or pump include disposing a cylindrical shell within a cylindrical housing, disposing a stator mold within the cylindrical shell, disposing an elastomeric material between the stator mold and the cylindrical shell, removing the stator mold from within the elastomeric material, thereby forming an elastomeric material layer having a stator profile within the cylindrical shell, and removing the cylindrical shell from within the cylindrical housing, thereby forming a cartridge having the elastomeric material layer disposed within the cylindrical shell.