Fiber Reinforced Elastomeric Stator

Abstract

Embodiments disclosed herein relate to a composition useful for forming stator or a portion thereof. The composition may include: a curable elastomer; a fiber fibrous compound; a fiber dispersion compound; and optionally carbon black.

What is claimed: 
     
         1 . (canceled) 
     
     
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         10 . (canceled) 
     
     
         11 . The composition of  claim 19 , wherein the curable elastomer comprises at least one of NBR and HNBR and has a Mooney Viscosity (ML(1+4) at 121° C.) in the range from about 20 to about 120. 
     
     
         12 . The composition of  claim 19 , wherein the composition comprises:
 from about 75 to about 99 wt. % curable elastomer;   from about 1.25 to about 1.75 phr aramid fiber;   from about 0.5 to about 15 phr amorphous silicon dioxide; and   from about 10 to about 100 phr carbon black.   
     
     
         13 . A method of forming a stator or a portion thereof, comprising:
 admixing a curable elastomer, a fiber, and a fiber dispersion compound to form a curable composition;   disposing the curable composition in a mold; and   curing the curable composition to form a stator liner or portion thereof having randomly dispersed fiber.   
     
     
         14 . The method of  claim 13 , wherein the admixing comprises mixing the curable elastomer with a predispersion comprising the fiber and the fiber dispersion compound. 
     
     
         15 . (canceled) 
     
     
         16 . A drilling motor, comprising:
 a stator, the stator having a stator liner with at least one elastomeric layer formed at least partially from a composition including a curable elastomer, a fiber, and a fiber dispersion compound; and   a rotor, the rotor being configured to rotate eccentrically when a drilling fluid is passed through the motor;   wherein the composition includes from about 0.5 to about 1.8 phr fiber, where phr is defined as parts per hundred parts curable elastomer, and the fiber dispersion compound is selected from the group consisting of a solid fiber dispersion compound, a liquid fiber dispersion compound, or mixtures thereof.   
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . A composition useful for forming a fiber reinforced elastomeric component useful in oilfield products, such as a seal or a stator liner, the composition comprising:
 a curable elastomer;   a fiber, wherein the composition comprises from about 0.5 to about 1.8 phr fiber, where phr is defined as parts per hundred parts curable elastomer; and   a fiber dispersion compound selected from the group consisting of a solid fiber dispersion compound, a liquid fiber dispersion compound, or mixtures thereof.   
     
     
         20 . The composition of  claim 19 , wherein the fiber dispersion compound comprises a solid fiber dispersion compound comprising a nanometer or micrometer sized spherical structure. 
     
     
         21 . The composition of  claim 19 , wherein the solid fiber dispersion compound comprises at least one of amorphous silicon dioxide, an alumina silicate, a silica aluminate, a magnesium silicate, coal dust, and silicon dioxide powder. 
     
     
         22 . The composition of  claim 19 , wherein the solid fiber dispersion compound comprises amorphous silicon dioxide having an average particle size in the range from about 30 nm to about 300 nm and a surface area in the range from about 10 m 2 /g to about 30 m 2 /g. 
     
     
         23 . The composition of  claim 19 , wherein the liquid fiber dispersion compound comprises at least one of a liquid polymer, a processing aid, a wax, and a plasticizer. 
     
     
         24 . The composition of  claim 19 , wherein the composition comprises from about 1 to about 1.8 phr fiber. 
     
     
         25 . The composition of  claim 19 , wherein the composition comprises from about 1.25 to about 1.75 phr fiber. 
     
     
         26 . The composition of  claim 19 , wherein the fiber comprises at least one of carbon fibers, boron fibers, ceramic fibers, glass fibers, thermoplastic fibers, natural fiber, metallic fibers, and synthetic fibers. 
     
     
         27 . The composition of  claim 19 , wherein the fiber comprises an aramid fiber. 
     
     
         28 . The composition of  claim 19 , wherein the curable elastomer comprises at least one of NBR, HNBR, FKM, FEPM, and FFKM. 
     
     
         29 . The composition of  claim 19 , further comprising carbon black. 
     
     
         30 . (canceled) 
     
     
         31 . (canceled) 
     
     
         32 . (canceled) 
     
     
         33 . The drilling motor of  claim 16 , wherein the composition further includes carbon black. 
     
     
         34 . The drilling motor of  claim 16 , wherein the fiber dispersion compound includes amorphous silicon dioxide. 
     
     
         35 . The method of  claim 13 , wherein carbon black is also admixed to form the curable composition. 
     
     
         36 . The method of  claim 13 , wherein the fiber dispersion compound includes amorphous silicon dioxide.