Highly wear resistant composite rotary seals with wear layer at inner diameter and/or outer diameter embedded inside or between rubber layers

Abstract

A composite journal seal for use in a roller cone drill bit may include a substantially ring shaped elastomeric body having at least two axial, radial, or canted sealing surfaces, at least one of the at least two axial, radial, or canted sealing surface being a dynamic sealing surface, and at least one reinforcement layer embedded at least 0.005 inches from the at least one dynamic sealing surface.

1 . A composite journal seal for use in a roller cone drill bit, comprising:
 a substantially ring shaped elastomeric body having at least two axial, radial, or canted sealing surfaces, at least one of the at least two axial, radial, or canted sealing surface being a dynamic sealing surface,   at least one reinforcement layer embedded at least 0.005 inches from the at least one dynamic sealing surface.   
     
     
         2 . The composite journal seal of  claim 1 , wherein the at least one reinforcement layer comprises a fabric sheet. 
     
     
         3 . The composite journal seal of  claim 1 , wherein the at least one dynamic sealing surface is formed from a composite wear layer comprising a second elastomeric material in which the reinforcement layer is embedded. 
     
     
         4 . The composite journal seal of  claim 1 , wherein the at least one reinforcement layer is embedded at least 0.010 inches from the at least one dynamic sealing surface. 
     
     
         5 . The composite journal seal of  claim 1 , wherein the at least one reinforcement layer extends circumferentially along at least 50% of the at least one dynamic sealing surface. 
     
     
         6 . A roller cone drill bit, comprising:
 a bit body;   at least one journal extending from a lower portion of the bit body;   a roller cone rotatably mounted on the journal; and   an annular seal positioned between the cone and the journal, the annular seal comprising an elastomeric seal body having:
 a first sealing surface for providing a seal along a dynamic rotary surface formed between the seal body and one of the cone or the journal; 
 a second sealing surface for providing a seal between the seal body and the other of the cone or journal; and 
 a reinforcement layer embedded at least 0.005 inches from first sealing surface or the second sealing surface. 
   
     
     
         7 . The drill bit of  claim 6 , wherein the at least one reinforcement layer comprises a fabric sheet. 
     
     
         8 . The drill bit of  claim 6 , wherein the reinforcement layer is embedded at least 0.005 inches from the first sealing surface. 
     
     
         9 . The drill bit of  claim 8 , wherein the first sealing surface is formed from a composite wear layer comprising a second elastomeric material in which the reinforcement layer is embedded. 
     
     
         10 . The drill bit of  claim 8 , wherein the at least one reinforcement layer is embedded at least 0.010 inches from the first sealing surface. 
     
     
         11 . The drill bit of  claim 9 , wherein the at least one reinforcement layer is embedded at least 0.020 inches from the first sealing surface. 
     
     
         12 . The drill bit of  claim 6 , wherein the first sealing surface is a radial sealing surface along the inner diameter of the annular seal. 
     
     
         13 . The drill bit of  claim 9 , wherein the second elastomeric layer is at least 5 durometer-hardness Shore A greater than the elastomeric seal body. 
     
     
         14 . The drill bit of  claim 9 , wherein the wear layer extends up to 50 percent of the total cross-sectional thickness of the annular seal from the first sealing surface. 
     
     
         15 . The drill bit of  claim 9 , wherein a third elastomeric material forms the second sealing surface. 
     
     
         16 . The drill bit of  claim 15 , wherein the third elastomeric material has a reinforcement layer embedded therein. 
     
     
         17 . The drill bit of  claim 6 , wherein the reinforcement layer is embedded under at least a portion of a containment surface. 
     
     
         18 . The drill bit of  claim 9 , wherein the second elastomeric material comprises at least one of acrylonitrile butadiene, carboxylated acrylonitrile butadiene, hydrogenated acrylonitrile butadiene, carboxylated hydrogenated acrylonitrile butadiene, ethylene propylene, ethylene propylene diene, tetrafluoroethylene and propylene copolymer, fluorocarbon, or perfluoroelastomers, wherein the second elastomeric material is harder than the elastomeric seal body. 
     
     
         19 . The drill bit of  claim 6 , wherein the reinforcement material comprises at least one material harder and/or stronger than the elastomeric seal body selected from the group consisting of an elastomer, plastic, metal, and fabric. 
     
     
         20 . A roller cone drill bit, comprising:
 a bit body;   at least one journal extending from a lower portion of the bit body;   a roller cone rotatably mounted on the journal; and   an annular seal positioned between the cone and the journal, the annular seal comprising an elastomeric seal body having:
 a first sealing surface for providing a seal along a dynamic rotary surface formed between the seal body and one of the cone or the journal; 
 a second sealing surface for providing a seal between the seal body and the other of the cone or journal; and 
 a reinforcement layer embedded within the annular seal along at least 40% of the circumference of the first sealing surface. 
   
     
     
         21 . The drill bit of  claim 20 , wherein the at least one reinforcement layer comprises a fabric sheet. 
     
     
         22 . The drill bit of  claim 20 , wherein the reinforcement layer is embedded at least 0.005 inches from the first sealing surface. 
     
     
         23 . The drill bit of  claim 20 , wherein the first sealing surface is formed from a composite wear layer comprising a second elastomeric material in which the reinforcement layer is embedded. 
     
     
         24 . The drill bit of  claim 23 , wherein the second elastomeric layer is at least 5 durometer-hardness Shore A greater than the elastomeric seal body. 
     
     
         25 . The drill bit of  claim 23 , wherein the wear layer extends up to 50 percent of the total cross-sectional thickness of the annular seal from the first sealing surface.