Reinforced directional drilling assemblies and methods of forming same

Abstract

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.

1 . A method of forming a reinforced drilling assembly, the method comprising:
 applying to a component of the assembly at least one strengthening material to a resilient layer to form a reinforced resilient layer;   forming a polymer-based composite material having at least one strengthening material; and   adhering the reinforced resilient layer to the polymer-based composite material.   
     
     
         2 . The method of  claim 1 , wherein the resilient layer is formed through one of the following processes:
 extrusion, coextrusion to form a tube with multi-layers, coextrusion to form a tube with multi-sections, winding, injection molding, compression molding, transfer molding, and shaping over a mandrel.   
     
     
         3 . The method of  claim 1 , wherein adhering further comprises:
 inserting at least one strengthening material between the reinforced resilient layer and the polymer-based composite material; and   filling a cavity through casting.   
     
     
         4 . The method of  claim 1 , wherein adhering further comprises:
 inserting at least one strengthening material between the reinforced resilient layer and the polymer-based composite material; and   filling a cavity through injection.   
     
     
         5 . The method of  claim 1 , wherein forming a polymer-based composite material comprises:
 mixing the polymer-based composite material with the at least one strengthening material.   
     
     
         6 . The method of  claim 1 , wherein the at least one strengthening material is selected from the group comprising:
 fibers, cord, carbon, glass, polymeric fibers, Kevlar, nylon, short or long fibers, microfibers, nano fibers, fabrics, sheets, mesh filaments, woven reinforcing cloths, three-dimensional structural fibers, wires, conductive polymers, bi-filament materials, multi-filament materials, and fiber optic materials.   
     
     
         7 . The method of  claim 1 , wherein the polymer-based composite material is selected from the group comprising:
 epoxies, metal-filled epoxies, inorganic-filled epoxies, polymer fiber-filled epoxies, polyimides, polyether ether ketones, polyketones, phenolic resins, and polyphenylene sulfides.