Nano particle reinforced polymer element for stator and rotor assembly

Abstract

A nano particle reinforced polymer element of a stator and rotor assembly for a power section of a positive displacement fluid motor or a progressive cavity pump. Nano-sized particles are blended with an uncured polymer to improve the physical and chemical properties of the polymer. The use of nano-sized particles reduces the quantity of reinforcement material required to manufacture the polymer for the stator and rotor assembly and lowers the viscosity of the uncured polymer to improve manufacturing characteristics. The use of chemically functionalized nano particles improves the chemical and physical characteristics of the polymer.

1 . A stator and rotor assembly comprising:
 a stator having an inner surface;   an inner core disposed within the inner surface of the stator and defining a cavity, the inner core comprising a polymer material having a plurality of nano particles integrated therein; and   a rotor disposed within the cavity, operable to rotate within the inner core.   
   
   
       2 . The stator and rotor assembly as recited in  claim 1 , wherein the stator further comprises a substantially cylindrical inner surface. 
   
   
       3 . The stator and rotor assembly as recited in  claim 1 , wherein the rotor further comprises a spiral rotor. 
   
   
       4 . The stator and rotor assembly as recited in  claim 1 , wherein the rotor further comprises a helical rotor. 
   
   
       5 . The stator and rotor assembly as recited in  claim 1 , wherein the stator and rotor assembly is part of a positive displacement fluid motor. 
   
   
       6 . The stator and rotor assembly as recited in  claim 1 , wherein the stator and rotor assembly is part of a progressive cavity pump. 
   
   
       7 . The stator and rotor assembly as recited in  claim 1 , wherein the polymer material is selected from an elastomer, a thermoset and a thermoplastic. 
   
   
       8 . The stator and rotor assembly as recited in  claim 1 , wherein the polymer material further comprises an elastomer selected from the group consisting of nitrile, carboxylated acrylonitrile butadiene, hydrogenated acrylonitrile butadiene, carboxylated hydrogenated acrylonitrile butadiene, hydrogenated carboxylated acrylonitrile butadiene, tetrafluoroethylene and propylene, perfluoroelastomers, ethylene propylene, ethylene propylene diene, polychloroprene rubber, natural rubber, polyether eurethane and styrene butadiene rubber. 
   
   
       9 . The stator and rotor assembly as recited in  claim 1 , wherein the polymer material further comprises a thermoplastic selected from the group consisting of polyphenylene sulfides, polyetherketone-ketones, polyetheretherketones, polyetherketones and polytetrafluorethylenes. 
   
   
       10 . The stator and rotor assembly as recited in  claim 1 , wherein the nano particles further comprise nano clays. 
   
   
       11 . The stator and rotor assembly as recited in  claim 1 , wherein the nano particles further comprise carbon nano fibers. 
   
   
       12 . The stator and rotor assembly as recited in  claim 1 , wherein the nano particles are selected from the group consisting of single wall carbon nano tubes, multi-wall carbon nano tubes and carbon nano tube arrays. 
   
   
       13 . The stator and rotor assembly as recited in  claim 1 , wherein the nano particles are selected from the group consisting of polysilane resins, polycarbosilane resins, polysilsesquioxane resins and polyhedral oligomeric silsesquioxane resins. 
   
   
       14 . The stator and rotor assembly as recited in  claim 1 , wherein the nano particles are in the range from approximately 0.1 nanometers to approximately 500 nanometers, at the least dimension. 
   
   
       15 . The stator and rotor assembly as recited in  claim 1 , wherein the nano particles are in the range from approximately 0.5 nanometers to approximately 100 nanometers, at the least dimension. 
   
   
       16 . The stator and rotor assembly as recited in  claim 1 , wherein the nano particles are chemically functionalized. 
   
   
       17 . A stator and rotor assembly comprising:
 a stator having an inner surface;   an inner core disposed within the inner surface of the stator and defining a cavity, the inner core comprising a polymer host material having a plurality of nano structures integrated therein, the nano structures selected from the group consisting of polysilane resins, polycarbosilane resins, polysilsesquioxane resins, polyhedral oligomeric silsesquioxane resins, monomers, polymers and copolymers of any of these resins, carbon nanotubes and any of the preceding nano structures that are chemically functionalized; and a rotor disposed within the cavity, operable to rotate within the inner core.   
   
   
       18 . The stator and rotor assembly as recited in  claim 17 , wherein the stator further comprises a substantially cylindrical inner surface. 
   
   
       19 . The stator and rotor assembly as recited in  claim 17 , wherein the rotor further comprises a spiral rotor. 
   
   
       20 . The stator and rotor assembly as recited in  claim 17 , wherein the rotor further comprises a helical rotor. 
   
   
       21 . The stator and rotor assembly as recited in  claim 17 , wherein the stator and rotor assembly is part of a positive displacement fluid motor. 
   
   
       22 . The stator and rotor assembly as recited in  claim 17 , wherein the stator and rotor assembly is part of a progressive cavity pump. 
   
   
       23 . The stator and rotor assembly as recited in  claim 17 , wherein the polymer material is selected from an elastomer, a thermoset and a thermoplastic. 
   
   
       24 . The stator and rotor assembly as recited in  claim 17 , wherein the polymer material further comprises an elastomer selected from the group consisting of nitrile, carboxylated acrylonitrile butadiene, hydrogenated acrylonitrile butadiene, carboxylated hydrogenated acrylonitrile butadiene, hydrogenated carboxylated acrylonitrile butadiene, tetrafluoroethylene and propylene, perfluoroelastomers, ethylene propylene, ethylene propylene diene, polychloroprene rubber, natural rubber, polyether eurethane and styrene butadiene rubber. 
   
   
       25 . A stator and rotor assembly comprising:
 a stator having an inner surface;   an inner core disposed within the inner surface of the stator and defining a cavity, the inner core comprising an elastomer host material and chemically functionalized carbon nanotubes; and   a rotor disposed within the cavity, operable to rotate within the inner core.   
   
   
       26 . The downhole tool system as recited in  claim 25  wherein the elastomer host material further comprises a copolymer of acrylonitrile and butadiene. 
   
   
       27 . The downhole tool system as recited in  claim 25  wherein the elastomer host material is selected from the group consisting of acrylonitrile butadiene, carboxylated acrylonitrile butadiene, hydrogenated acrylonitrile butadiene, highly saturated nitrile, carboxylated hydrogenated acrylonitrile butadiene, hydrogenated carboxylated acrylonitrile butadiene, ethylene propylene, ethylene propylene diene, tetrafluoroethylene and propylene, fluorocarbon and perfluorocarbon. 
   
   
       28 . The downhole tool system as recited in  claim 25  wherein the elastomer host material and the nanomaterial have interfacial interactions. 
   
   
       29 . The downhole tool system as recited in  claim 25  wherein the nanomaterial structurally complements the elastomer host material. 
   
   
       30 . The downhole tool system as recited in  claim 25  wherein the nanomaterial chemically complements the elastomer host material. 
   
   
       31 . The downhole tool system as recited in  claim 25  wherein the nanomaterial structurally and chemically complements the elastomer host material. 
   
   
       32 . The stator and rotor assembly as recited in  claim 25  wherein the stator and rotor assembly is part of a positive displacement fluid motor. 
   
   
       33 . The stator and rotor assembly as recited in  claim 25  wherein the stator and rotor assembly is part of a progressive cavity pump. 
   
   
       34 . A stator and rotor assembly comprising:
 a stator having an inner surface and defining a cavity;   a rotor disposed within the cavity, operable to rotate within the cavity; and   a polymer layer disposed exteriorly on the rotor, the polymer layer having a plurality of nano particles integrated therein.   
   
   
       35 . The stator and rotor assembly as recited in  claim 34 , wherein the stator and rotor assembly is part of a positive displacement fluid motor. 
   
   
       36 . The stator and rotor assembly as recited in  claim 34 , wherein the stator and rotor assembly is part of a progressive cavity pump. 
   
   
       37 . The stator and rotor assembly as recited in  claim 34 , wherein the polymer layer is formed from a material selected from an elastomer, a thermoset and a thermoplastic. 
   
   
       38 . The stator and rotor assembly as recited in  claim 34 , wherein the polymer layer is formed from an elastomer selected from the group consisting of nitrile, carboxylated acrylonitrile butadiene, hydrogenated acrylonitrile butadiene, carboxylated hydrogenated acrylonitrile butadiene, hydrogenated carboxylated acrylonitrile butadiene, tetrafluoroethylene and propylene, perfluoroelastomers, ethylene propylene, ethylene propylene diene, polychloroprene rubber, natural rubber, polyether eurethane and styrene butadiene rubber. 
   
   
       39 . The stator and rotor assembly as recited in  claim 34 , wherein the polymer layer is formed from a thermoplastic selected from the group consisting of polyphenylene sulfides, polyetherketone-ketones, polyetheretherketones, polyetherketones and polytetrafluorethylenes. 
   
   
       40 . The stator and rotor assembly as recited in  claim 34 , wherein the nano particles further comprise carbon nano fibers. 
   
   
       41 . The stator and rotor assembly as recited in  claim 34 , wherein the nano particles are selected from the group consisting of single wall carbon nano tubes, multi-wall carbon nano tubes and carbon nano tube arrays. 
   
   
       42 . The stator and rotor assembly as recited in  claim 34 , wherein the nano particles are selected from the group consisting of polysilane resins, polycarbosilane resins, polysilsesquioxane resins and polyhedral oligomeric silsesquioxane resins. 
   
   
       43 . The stator and rotor assembly as recited in  claim 34 , wherein the nano particles are chemically functionalized. 
   
   
       44 . A stator and rotor assembly comprising:
 a stator having an inner surface and defining a cavity;   a rotor disposed within the cavity, operable to rotate within the cavity; and   a polymer layer disposed exteriorly on the rotor, the polymer layer having a plurality of nano particles integrated therein, the nano particles selected from the group consisting of polysilane resins, polycarbosilane resins, polysilsesquioxane resins, polyhedral oligomeric silsesquioxane resins, monomers, polymers and copolymers of any of these resins, carbon nanotubes and any of the preceding nano structures that are chemically functionalized.   
   
   
       45 . A stator and rotor assembly comprising:
 a stator having an inner surface and defining a cavity;   a rotor disposed within the cavity, operable to rotate within the cavity; and   a elastomer layer disposed exteriorly on the rotor, the elastomer layer having a plurality of chemically functionalized carbon nanotubes integrated therein.   
   
   
       46 . A stator and rotor assembly comprising:
 a stator having an inner surface with a polymer layer disposed thereon defining a cavity; and   a rotor disposed within the cavity and operable to rotate within the cavity, the rotor having a polymer layer disposed exteriorly thereon;   wherein the polymer layer of the stator and the polymer layer of the rotor each have a plurality of nano particles integrated therein.   
   
   
       47 . The stator and rotor assembly as recited in  claim 46 , wherein the stator and rotor assembly is part of a positive displacement fluid motor. 
   
   
       48 . The stator and rotor assembly as recited in  claim 46 , wherein the stator and rotor assembly is part of a progressive cavity pump. 
   
   
       49 . The stator and rotor assembly as recited in  claim 46 , wherein the polymer layer is formed from a material selected from an elastomer, a thermoset and a thermoplastic. 
   
   
       50 . The stator and rotor assembly as recited in  claim 46 , wherein the polymer layer is formed from an elastomer selected from the group consisting of nitrile, carboxylated acrylonitrile butadiene, hydrogenated acrylonitrile butadiene, carboxylated hydrogenated acrylonitrile butadiene, hydrogenated carboxylated acrylonitrile butadiene, tetrafluoroethylene and propylene, perfluoroelastomers, ethylene propylene, ethylene propylene diene, polychloroprene rubber, natural rubber, polyether eurethane and styrene butadiene rubber. 
   
   
       51 . The stator and rotor assembly as recited in  claim 46 , wherein the polymer layer is formed from a thermoplastic selected from the group consisting of polyphenylene sulfides, polyetherketone-ketones, polyetheretherketones, polyetherketones and polytetrafluorethylenes. 
   
   
       52 . The stator and rotor assembly as recited in  claim 46 , wherein the nano particles further comprise carbon nano fibers. 
   
   
       53 . The stator and rotor assembly as recited in  claim 46 , wherein the nano particles are selected from the group consisting of single wall carbon nano tubes, multi-wall carbon nano tubes and carbon nano tube arrays. 
   
   
       54 . The stator and rotor assembly as recited in  claim 46 , wherein the nano particles are selected from the group consisting of polysilane resins, polycarbosilane resins, polysilsesquioxane resins and polyhedral oligomeric silsesquioxane resins. 
   
   
       55 . The stator and rotor assembly as recited in  claim 46 , wherein the nano particles are chemically functionalized. 
   
   
       56 . A stator and rotor assembly comprising:
 a stator having an inner surface with a polymer layer disposed thereon defining a cavity; and   a rotor disposed within the cavity and operable to rotate within the cavity, the rotor having a polymer layer disposed exteriorly thereon;   wherein the polymer layer of the stator and the polymer layer of the rotor each have a plurality of nano particles integrated therein, the nano particles selected from the group consisting of polysilane resins, polycarbosilane resins, polysilsesquioxane resins, polyhedral oligomeric silsesquioxane resins, monomers, polymers and copolymers of any of these resins, carbon nanotubes and any of the preceding nano structures that are chemically functionalized.   
   
   
       57 . A stator and rotor assembly comprising:
 a stator having an inner surface with a polymer layer disposed thereon defining a cavity; and   a rotor disposed within the cavity and operable to rotate within the cavity, the rotor having a polymer layer disposed exteriorly thereon;   wherein the polymer layer of the stator and the polymer layer of the rotor each have a plurality of chemically functionalized carbon nanotubes integrated therein.