Downhole Axial Flux Generator
What is claimed is a downhole tool string component comprising a generator. The generator may comprise a toroidal stator comprising an interior channel formed between inward extending stator poles. A coil of wire is disposed within the interior channel, and a plurality of magnets are rotatably disposed proximate each pole. A downhole tool string component comprises a bore to receive a flow of drilling fluid comprising a central passage and at least one peripheral passage. A compliant member is disposed within the bore and forms an internal diameter of the central passage, and at least one opening. The at least one opening comprises an internal area within the compliant member to divert the flow of drilling fluid into the at least one peripheral passage. The compliant member comprises a compliant property allowing the internal area of the at least one opening to change thus changing the amount of diverted drilling fluid.
1 . A downhole tool string component, comprising:
a bore to receive a flow of drilling fluid comprising a central passage and at least one peripheral passage;
a compliant member disposed within the bore and forming an internal diameter of the central passage; and
at least one opening, comprising an internal area, within the compliant member to divert the flow of drilling fluid into the at least one peripheral passage;
wherein the compliant member comprises a compliant property allowing the internal area of the at least one opening to change thus changing the amount of flow of drilling fluid being diverted.
2 . The downhole tool string component of claim 1 , wherein the at least one peripheral passage directs drilling fluid to a turbine.
3 . The downhole tool string component of claim 2 , wherein the turbine is in communication with an electrical generator.
4 . The downhole tool string component of claim 1 , wherein the at least one peripheral passage directs drilling fluid to the central passage after passing a turbine.
5 . The downhole tool string component of claim 1 , wherein the downhole tool string is in communication with a telemetry system.
6 . The downhole tool string component of claim 1 , wherein the bore comprises a varying internal diameter to alter a pressure in the peripheral passage.
7 . The downhole tool string component of claim 1 , wherein the at least one opening constricts in a direction of the flow of drilling fluid.
8 . The downhole tool string component of claim 1 , wherein the changing of the internal area of the at least one opening is due to a pressure differential between the peripheral and central passage.
9 . The downhole tool string component of claim 1 , wherein the compliant property comprises a modulus of elasticity range of 100 ksi to 90 Msi.
10 . The downhole tool string component of claim 1 , wherein the compliant member may comprise rubber with a metal support, metal, composite, fiberglass, Kevlar carbon fiber, ceramic, boron carbide, alumina, aluminum silicate or combinations thereof.
11 . The downhole tool string component of claim 10 , wherein the composite comprises a matrix material which may comprise epoxy, PEEK, Teflon, plastic, rubber, silicon rubber or combinations thereof.
12 . The downhole tool string component of claim 1 , wherein the at least one opening comprises a helical pattern along the compliant member.
13 . The downhole tool string component of claim 1 , wherein the at least one opening comprises a slit.
14 . The downhole tool string component of claim 13 , wherein the slit comprises a width that fluctuates as the internal area of the at least one opening changes.
15 . The downhole tool string component of claim 14 , wherein the slit comprises opposing sides comprising a pointed side and a notched side to receive the pointed side such that the opposing sides interlock.
16 . The downhole tool string component of claim 1 , wherein the compliant member comprises a single piece.
17 . The downhole tool string component of claim 1 , wherein the compliant member comprises a homogeneous material.
18 . The downhole tool string component of claim 1 , wherein the compliant member comprises a central diameter smaller than an end diameter of the compliant member.
19 . A method of diverting drilling fluid to a turbine, comprising:
providing a bore comprising a central passage and at least one peripheral passage, a compliant member disposed within the bore and forming an internal diameter of the central passage, and at least one opening, comprising an internal area, within the compliant member, wherein the compliant member comprises a compliant property;
passing drilling fluid through the bore;
separating the drilling fluid between the central passage and the at least one peripheral passage by passing a portion of the drilling fluid through the at least one opening and past the turbine; and
flexing the compliant member to alter the internal area of the at least one opening thus varying the amount of flow of drilling fluid being separated.
20 . The method of claim 19 , wherein the flexing is caused by a pressure differential between the central passage and the at least one peripheral passage.