Submersible well pump with improved diaphragm

Abstract

A composite diaphragm for a hydraulically driven diaphragm pump that incorporates both non-rigid and semi-rigid materials to obtain the benefits of both, wherein the non-rigid materials provide desired resistance to flex fatigue, and wherein the semi-rigid materials provide desired shape characteristics to thereby increase pumping capacity of a hydraulically driven positive displacement diaphragm pump.

1 . A diaphragm for use in a hydraulically driven diaphragm pump, said diaphragm comprising: 
 at least one non-rigid and at least one semi-rigid material used to construct the diaphragm; and    a port for transferring a working fluid into and out of the diaphragm.    
   
   
       2 . The diaphragm as defined in  claim 1  wherein the at least one semi-rigid material is further comprised of a semi-rigid diaphragm forming an outer layer of the diaphragm.  
   
   
       3 . The diaphragm as defined in  claim 2  wherein the at least one non-rigid material is further comprised of a non-rigid diaphragm forming an inner layer of the diaphragm.  
   
   
       4 . The diaphragm as defined in  claim 3  wherein the diaphragm is further comprised of an adhesive disposed between the non-rigid diaphragm and the semi-rigid diaphragm.  
   
   
       5 . The diaphragm as defined in  claim 1  wherein the diaphragm is further comprised of: 
 the at least one non-rigid material forming an inner layer of the diaphragm;    the at least one semi-rigid material forming a discontinuous outer layer of the diaphragm; and    an adhesive disposed between the at least one non-rigid inner layer and the at least one semi-rigid material discontinuous outer layer.    
   
   
       6 . The diaphragm as defined in  claim 5  wherein the at least one discontinuous semi-rigid layer is disposed symmetrically about the non-rigid inner layer of the diaphragm.  
   
   
       7 . The diaphragm as defined in  claim 1  wherein the at least one semi-rigid material is further comprised of a thicker or multiple layers of the at least one non-rigid material to thereby add stiffness.  
   
   
       8 . The diaphragm as defined in  claim 7  wherein the thicker or multiple layers of the at least one non-rigid material is disposed discontinuously about the diaphragm.  
   
   
       9 . The diaphragm as defined in  claim 1  wherein the at least one semi-rigid material is further comprised of a pre-formed layer of the least one non-rigid material to thereby add stiffness.  
   
   
       10 . The diaphragm as defined in  claim 1  wherein the diaphragm is further comprised of: 
 the at least one semi-rigid material disposed in a center of the pumping chamber, the semi-rigid material forming a column of at least three spokes; and    the at least one non-rigid material disposed as an outer layer around the semi-rigid material, wherein the at least one non-rigid material forms at least three channel between the at least one non-rigid material and the semi-rigid material when the at least one non-rigid material is collapsed.    
   
   
       11 . A hydraulically driven diaphragm pump comprising: 
 a) at least one pumping chamber;    b) a diaphragm comprised of non-rigid and semi-rigid materials, wherein the diaphragm is disposed within the at least one pumping chamber;    c) a port for transferring a working fluid into and out of the diaphragm;    d) a diaphragm pump power and control system for controlling movement of the working fluid; and    e) a valve block including at least two check valves for controlling movement of a pumped fluid outside the diaphragm.    
   
   
       12 . The hydraulically driven diaphragm pump as defined in  claim 11  wherein the semi-rigid material is further comprised of a semi-rigid diaphragm forming an outer layer of the diaphragm.  
   
   
       13 . The hydraulically driven diaphragm pump as defined in  claim 12  wherein the non-rigid material is further comprised of a non-rigid diaphragm forming an inner layer of the diaphragm.  
   
   
       14 . The hydraulically driven diaphragm pump as defined in  claim 13  wherein the diaphragm is further comprised of an adhesive disposed between the non-rigid diaphragm and the semi-rigid diaphragm.  
   
   
       15 . The diaphragm as defined in  claim 11  wherein the diaphragm is further comprised of: 
 the at least one non-rigid material forming an inner layer of the diaphragm;    the at least one semi-rigid material forming a discontinuous outer layer of the diaphragm; and    an adhesive disposed between the at least one non-rigid inner layer and the at least one semi-rigid material discontinuous outer layer.    
   
   
       16 . The diaphragm as defined in  claim 15  wherein the at least one discontinuous semi-rigid layer is disposed symmetrically about the non-rigid inner layer of the diaphragm.  
   
   
       17 . The diaphragm as defined in  claim 11  wherein the at least one semi-rigid material is further comprised of a thick layer of the at least one non-rigid material to thereby add stiffness.  
   
   
       18 . The diaphragm as defined in  claim 17  wherein the thick layer of the at least one non-rigid material is disposed discontinuously about the diaphragm.  
   
   
       19 . The diaphragm as defined in  claim 11  wherein the at least one semi-rigid material is further comprised of a pre-formed layer of the least one non-rigid material to thereby add stiffness.  
   
   
       20 . The diaphragm as defined in  claim 11  wherein the at least one semi-rigid material is selected from the group of semi-rigid materials comprised of Polyvinylidene Fluoride (PVDF), TPFE, thermoplastics, highly cross-linked nitrile, polyolefins, polyethylene, polypropylene, and Fluoropolymers.  
   
   
       21 . The diaphragm as defined in  claim 11  wherein the at least one non-rigid material is selected from the group of non-rigid materials comprised of elastomeric materials including rubber, thermoset rubber, nitrile, highly saturated nitrile, EPDM, Polyurathane, natural rubber, SBR, and Flororubber.  
   
   
       22 . A method for providing a diaphragm for use in a hydraulically driven diaphragm pump that has improved downhole life and greater pump capacity, said method comprising the steps of: 
 a) providing at least one non-rigid and at least one semi-rigid material;    b) forming a wall of the diaphragm using the at least one non-rigid material and the at least one semi-rigid material, wherein the at least one non-rigid material increases flex fatigue life, and wherein the at least one semi-rigid material provides improved shape control and diffusion resistance; and    c) providing a port in one end of the diaphragm for transferring a working fluid into and out of the diaphragm.    
   
   
       23 . The method as defined in  claim 22  wherein the method further comprises the step of using the at least one semi-rigid material to form an outer layer of the diaphragm to thereby control an overall shape of the diaphragm.  
   
   
       24 . The method as defined in  claim 23  wherein the method further comprises the step of using the at least one non-rigid material to form an inner layer of the diaphragm to thereby provide increased flex fatigue resistance.  
   
   
       25 . The method as defined in  claim 24  wherein the method further comprises the step of disposing an adhesive between the non-rigid diaphragm and the semi-rigid diaphragm.  
   
   
       26 . The method as defined in  claim 22  wherein the method is further comprised of the steps of: 
 a) forming an inner layer of the diaphragm using the at least one non-rigid material;    b) forming a discontinuous outer layer of the diaphragm using the at least one semi-rigid material; and    c) disposing an adhesive between the at least one non-rigid inner layer and the at least one semi-rigid material discontinuous outer layer, wherein the discontinuous outer layer defines a collapsed shape of the diaphragm.    
   
   
       27 . The method as defined in  claim 26  wherein the method is further comprised of the step of symmetrically disposing the at least one discontinuous semi-rigid layer around the non-rigid inner layer of the diaphragm, to thereby form a symmetrical shape when the diaphragm is collapsed.  
   
   
       28 . The method as defined in  claim 22  wherein the method is further comprised of the step of providing a thicker layer of the at least one non-rigid material to function as a semi-rigid material, to thereby add stiffness to the diaphragm without adding a different semi-rigid material.  
   
   
       29 . The method as defined in  claim 28  wherein the method is further comprised of the step of discontinuously disposing the at least one non-rigid material about the diaphragm in order to obtain a non-symmetrical cross-section for the collapsed diaphragm.  
   
   
       30 . The method as defined in  claim 22  wherein the method is further comprised of the steps of: 
 a) disposing the at least one semi-rigid material in a center of the pumping chamber, wherein the semi-rigid material forms a column of three spokes; and    b) disposing the at least one non-rigid material as an outer layer around the semi-rigid material, wherein the at least one non-rigid material forms at least three channels between the at least one non-rigid material and the semi-rigid material when the at least one non-rigid material is collapsed.