Fiber-loaded rubber compound useful in PDM stators
A rubber compound for use in a stator in a positive displacement motor. The rubber compound includes a fiber reinforcement, wherein fibers in the fiber reinforcement create a grain direction in which “with the grain” is generally orthogonal to “across the grain”. In some embodiments, the rubber compound has a first value for 25% tensile Modulus across the grain and a second value for 25% tensile Modulus with the grain, wherein the first value is at least 10% lower than the second value. In such embodiments, the fiber reinforcement may further include a fiber loading of greater flan 1.0 phr of fibers. In such embodiments, the rubber compound may further have a 25% tensile Modulus of greater than 400 psi across the grain and a 50% tensile Modulus of greater than 700 psi across the grain.
1. A stator, comprising:
a rubber compound formed into a stator;
the rubber compound including a fiber reinforcement, the fiber reinforcement including a plurality of fibers, wherein fibers in the fiber reinforcement create a grain direction in which “with the grain” is generally orthogonal to “across the grain”, wherein the rubber compound has a first value for 25% tensile Modulus “across the grain” and a second value for 25% tensile Modulus “with the grain”, wherein the first value is at least 10% lower than the second value; and
the fiber reinforcement including a fiber loading of greater than 1.0 phr of fibers, and the rubber compound having a 25% tensile Modulus of greater than 400 psi “across the grain” and a 50% tensile Modulus of greater than 700 psi “across the grain”.
2. The stator of claim 1 , in which the fiber reinforcement includes the fiber loading in a range from 1.0 phr of fibers to 20.0 phr of fibers.
3. The stator of claim 1 , in which the fiber reinforcement includes the fiber loading in a range from 1.0 phr of fibers to 6.0 phr of fibers.
4. The stator of claim 1 , in which the fibers have a Modulus of greater than 60 GPa.
5. The stator of claim 1 , in which the fibers have a Modulus in a range of 60 GPa to 110 GPa.
6. The stator of claim 1 , in which the fibers have a Modulus in a range of 60 GPa to 75 GPa.
7. The stator of claim 1 , in which the fiber reinforcement comprises a blend of fibrillated fibers and short chop fibers in a ratio by weight, and in which:
(a) the ratio by weight of fibrillated fibers to short chop fibers in the blend is in a range of 50:1 to 3:1;
(b) the fibrillated fibers have surface areas in a range of 2 m 2 /g to 20 m 2 /g; and
(c) the short chop fibers have lengths in a range of 0.05 mm to 3.0 mm.
8. The stator of claim 7 , in which the ratio by weight of fibrillated fibers to short chop fibers in the blend is in a range of 20:1 to 4:1.
9. The stator of claim 7 , in which the fibrillated fibers have surface areas in a range of 7 m 2 /g to 11 m 2 /g.
10. The stator of claim 7 , in which the short chop fibers have lengths in a range of 0.1 mm to 2.0 mm.
11. The stator of claim 1 , in which the rubber compound is manufactured according to a mixing process in which no masterbatch is used.
12. The stator of claim 1 , in which the rubber compound is manufactured according to a mixing process in which no pre-dispersion agent is added.
13. The stator of claim 1 , in which the rubber compound is manufactured according to a mixing process in which no masterbatch is used and no pre-dispersion agent is added.
14. The stator of claim 1 , in which the fiber reinforcement comprises a blend of at least two fiber types, at least one fiber type in the blend having at least one unique characteristic among other fiber types in the blend wherein said at least one unique characteristic is selected from the group consisting of:
(a) length;
(b) surface area;
(c) chemistry; and
(d) Modulus.
15. A stator, comprising:
a rubber compound formed into a stator;
the rubber compound including a fiber reinforcement, the fiber reinforcement including a plurality of fibers, wherein fibers in the fiber reinforcement create a grain direction in which “with the grain” is generally orthogonal to “across the grain”, wherein the rubber compound has a first value for 25% tensile Modulus “across the grain” and a second value for 25% tensile Modulus “with the grain”, wherein the first value is at least 10% lower than the second value; and
the fiber reinforcement including a fiber loading of greater than 1.5 phr of fibers, and the rubber compound having a 25% tensile Modulus of greater than 400 psi “across the grain” and a 50% tensile Modulus of greater than 700 psi “across the grain”.
16. The stator of claim 15 , in which the fiber reinforcement includes the fiber loading in a range from 1.5 phr of fibers to 10.0 phr of fibers.
17. The stator of claim 15 , in which the fiber reinforcement includes the fiber loading in a range from 1.5 phr of fibers to 6.0 phr of fibers.
18. The stator of claim 15 , in which the fibers have a Modulus of greater than 60 GPa.
19. The stator of claim 15 , in which the fibers have a Modulus in a range of 60 GPa to 110 GPa.
20. The stator of claim 15 , in which the fibers have a Modulus in a range of 60 GPa to 75 GPa.
21. The stator of claim 15 , in which the fiber reinforcement comprises a blend of fibrillated fibers and short chop fibers in a ratio by weight, and in which:
(a) the ratio by weight of fibrillated fibers to short chop fibers in the blend is in a range of 50:1 to 3:1;
(b) the fibrillated fibers have surface areas in a range of 2 m 2 /g to 20 m 2 /g; and
(c) the short chop fibers have lengths in a range of 0.05 mm to 3.0 mm.
22. The stator of claim 21 , in which the ratio by weight of fibrillated fibers to short chop fibers in the blend is in a range of 20:1 to 4:1.
23. The stator of claim 21 , in which the fibrillated fibers have surface areas in a range of 7 m 2 /g to 11 m 2 /g.
24. The stator of claim 21 , in which the short chop fibers have lengths in a range of 0.1 mm to 2.0 mm.
25. The stator of claim 15 , in which the rubber compound is manufactured according to a mixing process in which no masterbatch is used.
26. The stator of claim 15 , in which the rubber compound is manufactured according to a mixing process in which no pre-dispersion agent is added.
27. The stator of claim 15 , in which the rubber compound is manufactured according to a mixing process in which no masterbatch is used and no pre-dispersion agent is added.
28. The stator of claim 15 , in which the fiber reinforcement comprises a blend of at least two fiber types, at least one fiber type in the blend having at least one unique characteristic among other fiber types in the blend wherein said at least one unique characteristic is selected from the group consisting of:
(a) length;
(b) surface area;
(c) chemistry; and
(d) Modulus.
29. A stator, comprising:
a rubber compound formed into a stator;
the rubber compound including a fiber reinforcement, the fiber reinforcement including a plurality of fibers, wherein fibers in the fiber reinforcement create a grain direction in which “with the grain” is generally orthogonal to “across the grain”, wherein the rubber compound has a first value for 25% tensile Modulus “across the grain” and a second value for 25% tensile Modulus “with the grain”, wherein the first value is at least 10% lower than the second value; and
the fiber reinforcement including a fiber loading of greater than 2.0 phr of fibers, and the rubber compound having a 25% tensile Modulus of greater than 400 psi “across the grain” and a 50% tensile Modulus of greater than 700 psi “across the grain”.
30. The stator of claim 29 , in which the fiber reinforcement includes the fiber loading in a range from 2.0 phr of fibers to 5.0 phr of fibers.
31. The stator of claim 29 , in which the fiber reinforcement includes the fiber loading in a range from 2.0 phr of fibers to 4.0 phr of fibers.
32. The stator f claim 29 , in which the fibers have a Modulus of greater than 60 GPa.
33. The stator of claim 29 , in which the fibers have a Modulus in a range of 60 GPa to 110 GPa.
34. The stator of claim 29 , in which the fibers have a Modulus in a range of 60 GPa to 75 GPa.
35. The stator of claim 29 , in which the fiber reinforcement comprises a blend of fibrillated fibers and short chop fibers in a ratio by weight, and in which:
(a) the ratio by weight of fibrillated fibers to short chop fibers in the blend is in a range of 50:1 to 3:1;
(b) the fibrillated fibers have surface areas in a range of 2 m 2 /g to 20 m 2 /g; and
(c) the short chop fibers have lengths in a range of 0.05 mm to 3.0 mm.
36. The stator of claim 35 , in which the ratio by weight of fibrillated fibers to short chop fibers in the blend is in a range of 20:1 to 4:1.
37. The stator of claim 35 , in which the fibrillated fibers have surface areas in a range of 7 m 2 /g to 11 m 2 /g.
38. The stator of claim 35 , in which the short chop fibers have lengths in a range of 0.1 mm to 2.0 mm.
39. The stator of claim 29 , in which the rubber compound is manufactured according to a mixing process in which no masterbatch is used.
40. The stator of claim 29 , in which the rubber compound is manufactured according to a mixing process in which no pre-dispersion agent is added.
41. The stator of claim 29 , in which the rubber compound is manufactured according a mixing process in which no masterbatch is used and no pre-dispersion agent is added.
42. The stator of claim 29 , in which the fiber reinforcement comprises a blend of at least two fiber types, at least one fiber type in the blend having at least one unique characteristic among other fiber types in the blend wherein said at least one unique characteristic is selected from the group consisting of:
(a) length;
(b) surface area;
(c) chemistry; and
(d) Modulus.
43. A stator, comprising:
a rubber compound formed into a stator;
the rubber compound including a fiber reinforcement, the fiber reinforcement including a plurality of fibers, wherein fibers in the fiber reinforcement create a grain direction in which “with the grain” is generally orthogonal to “across the grain”, wherein the rubber compound has a first value for 25% tensile Modulus “across the grain” and a second value for 25% tensile Modulus “with the grain”, wherein the first value is at least 10% lower than the second value; and
the fiber reinforcement including a fiber loading of greater than 2.5 phr of fibers, and the rubber compound having a 25% tensile Modulus of greater than 400 psi “across the grain” and a 50% tensile Modulus of greater than 700 psi “across the grain”.
44. The stator of claim 43 , in which the fiber reinforcement includes the fiber loading in a range from 2.5 phr of fibers to 10.0 phr of fibers.
45. The stator of claim 43 , in which the fiber reinforcement includes the fiber loading in a range from 2.5 phr of fibers to 6.0 phr of fibers.
46. The stator of claim 43 , in which the fibers have a Modulus of greater than 60 GPa.
47. The stator of claim 43 , in which the fibers have a Modulus in a range of 60 GPa to 110 GPa.
48. The stator of claim 43 , in which the fibers have a Modulus in a range of 60 GPa to 75 GPa.
49. The stator of claim 43 , in which the fiber reinforcement comprises a blend of fibrillated fibers and short chop fibers in a ratio by weight, and in which:
(a) the ratio by weight of fibrillated fibers to short chop fibers in the blend is in a range of 50:1 to 3:1;
(b) the fibrillated fibers have surface areas in a range of 2 m 2 /g to 20 m 2 /g; and
(c) the short chop fibers have lengths in a range of 0.05 mm to 3.0 mm.
50. The stator of claim 49 , in which the ratio by weight of fibrillated fibers to short chop fibers in the blend is in a range of 20:1 to 4:1.
51. The stator of claim 49 , in which the fibrillated fibers have surface areas in a range of 7 m 2 /g to 11 m 2 /g.
52. The stator of claim 49 , in which the short chop fibers have lengths in a range of 0.1 mm to 2.0 mm.
53. The stator of claim 43 , in which the rubber compound is manufactured according to a mixing process in which no masterbatch is used.
54. The stator of claim 43 , in which the rubber compound is manufactured according to a mixing process in which no pre-dispersion agent is added.
55. The stator of claim 43 , in which the rubber compound is manufactured according to a mixing process in which no masterbatch is used and no pre-dispersion agent is added.
56. The stator of claim 43 , in which the fiber reinforcement comprises a blend of at least two fiber types, at least one fiber type in the blend having at least one unique characteristic among other fiber types in the blend wherein said at least one unique characteristic is selected from the group consisting of:
(a) length;
(b) surface area;
(c) chemistry; and
(d) Modulus.