Hybrid core progressive cavity pump

1. A stator for a progressive cavity pump, comprising:

a containment element with an inner surface; and

a casing arranged within the containment element, generally isolated from the inner surface of the containment element, and defining a stator cavity adapted for receiving a progressive cavity pump rotor and for accommodating substantially free rotation of the progressive cavity pump rotor therein, wherein, the casing comprises a plurality of segments each having an end component arranged on an end thereof that is configured to limit the orientation in which adjacent segments are assembled to orientations that provide a functionally seamless stator cavity.

2. The stator of claim 1 , wherein the stator cavity has a substantially constant cross-sectional shape with a continually changing orientation.

3. The stator of claim 1 , wherein the end component comprises at east one of a male end component and a female end component.

4. The stator of claim 1 , wherein the end component comprises a longitudinal length and the substantially constant cross-sectional shape and the continually changing orientation thereof is maintained along the longitudinal length and through the end component.

5. The stator of claim 1 , wherein the casing is supported in general isolation from the containment element by support structures.

6. The stator of claim 1 , further comprising support structures extending from an outer surface of the casing and configured for supporting the casing within the containment element.

7. The stator of claim 1 , further comprising filler arranged between the casing and the inner surface of the containment element.

8. The stator of claim 7 , wherein the casing comprises a metallic material and the filler comprises an elastomer material.

9. A progressive cavity pump, comprising:

a drive system;

a progressive cavity pump rotor flexibly coupled to the drive system and rotationally, operable by the drive system; and

a stator comprising:

a containment element with an inner surface; and

a casing arranged within the containment element, generally isolated from the inner surface of the containment element, and defining a stator cavity adapted for receiving the progressive cavity pump rotor and for accommodating substantially free rotation of the progressive cavity pump rotor therein, wherein, the casing comprises a plurality of segments each having an end component arranged on an end thereof that is configured to limit the orientation in which adjacent segments are assembled to orientations that provide a functionally seamless stator cavity.

10. The pump of claim 9 , wherein the stator cavity has a substantially constant cross-sectional shape with a continually changing orientation.

11. The stator of claim 9 , wherein the end component comprises a longitudinal length and the substantially constant cross-sectional shape and the continually changing orientation thereof is maintained along the longitudinal length and through the end component.

12. A method of manufacturing a progressive cavity pump stator, comprising:

printing a casing defining a stator cavity adapted for receiving a progressive cavity pump rotor and for accommodating substantially free rotation of the progressive cavity pump rotor therein, wherein printing further comprises printing an end component with the casing that is configured to limit the orientation in which adjacent segments are assembled to orientations that provide a functionally seamless stator cavity; and

arranging the casing within a containment element.

13. The method of claim 12 , wherein printing the casing comprises printing a plurality of segments of the casing and assembling the plurality of segments end to end to form the casing.

14. The method of claim 8 , wherein printing the casing further comprises printing support structures adapted for supporting the casing within the containment element.

15. The method of claim 12 , further comprising placing filler material between the casing and the containment element.