This is a continuation-in-part application of prior, co-pending U.S. patent application Serial No. 08/000,989, by the same inventors, filed 01/06/93, and incorporated herein by reference.

SPECIFICATION BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to mud or suitable liquid motor systems. More particularly, the present invention relates to an improved system for a mud motor which incorporates fluid bearings within the system, and eliminates leakage of fluid within the system through a unique sealing assembly.

2. General Background of the Invention

The utilization of a mud driven motor for rotating a drill or other specialty bit in the process of drilling oil or workover wells is well known. The system would normally include a rotor assembly housed within an exterior stator, with the rotor coupled to the upper end of a drive shaft, several upper and lower output shafts engaged to a drill bit. Mud is run through the stator/rotor assembly, which causes the rotor to rotate, which in turn provides rotation to the drill bit. The mud is recycled to the surface, where, after undergoing treatment is recirculated though the mud motor system downhole.

Of course, when drive or output shafts are housed within an exterior casing or stator assembly, the rotation of the shafts generate friction and wear. To prevent this detrimental effect, the internal spaces between the shaft and its housing are usually provided with a lubricating fluid, which is effectively sealed within the space so that the wear of the shaft is reduced by the lubricant. Or, a certain amount of mud is allowed to "leak" through the

bearings. Of course, the lubricating fluid must be maintained within a sealed area, since it cannot mix with the mud driving the motor (if it is the scaled bearing design of motor) . However, oftentimes, during the drilling process utilizing a mud motor system, the thrust produced on the formation results in a certain amount of vibration and other movement of the shafts within the motor casings. This side-to-side movement of the shafts creates an instantaneous and minute gap between the sealing members around the shaft and the shaft seal diameter. The result is usually the seepage of the lubricating oil out of the system, and movement of the oil into the mud system, or worse yet, loss of sufficient oil due to leakage, that the shaft is rotating within its housing with no or little lubrication which could result in excessive wear or seizure of the motor.

A second problem encountered in the mud motor systems utilized today is the amount of damage (short life) that these systems undergo due to insufficient thrust bearing assemblies in the systems. The common metal-to-metal or metal-to-rubber bearing systems result in a great amount of wear during drilling, and lend to the leakage problem heretofore discussed. When, of course, the bearings wear, they must be changed, or the result could be loss of the entire system. This is time-consuming and expensive.

There have been several patents noted in applicant's prior art statement provided herewith which address the general subject matter of mud motor systems, but fail to correct the problems as cited. SUMMARY OF THE INVENTION

The system of the present invention solves the problems in the art in a simple and straightforward manner. What is provided is an improved mud (or liquid) motor system for drilling or workover down hole which includes an upper rotor portion housed within a stator body connectedly

engaged to a drill or workover string. The stator assembly receives a flow of drilling fluid through the drill or workover string, and flow of fluid through a continuous bore of a certain profile within the stator, imparts rotation to the rotor. The lower end of the rotor is engaged to a drive shaft, which is in turn connected to upper and lower output shafts. Rotation of the rotor likewise imparts rotation to the drive and output shafts. There is provided a drill or specialty bit secured to the lower end of the lower output shaft which, when rotation is in effect, drills into the "formation" or performs some specialty function.

There is further provided a sealing section within the system which defines a plurality of seals to seal against leaking of lubricating fluid within the output shaft sections. These seals incorporate a flexible member within the seal body to allow the seal to move in unison with the side-to-side movement of the drive shafts, to prevent gaps between the seal and the output shaft bodies. Further there is provided fluid bearings within the assembly which incorporate a quantity of fluid to bear against the lower output shaft, so that the shaft contacts the fluid bearing when the shaft is forced upward (or down depending on the type of operation and fluid bearing design incorporated in the assembly) .

It should be kept in mind that this bit and assembly is used generally to drill small bores using coiled tubing, cleaning wells, to under ream, and for special surface drilling, and therefore is rather small in diameter for such tasks.

An additional embodiment provides a means incorporated into the assembly for serving as a device for allowing the assembly to include a jarring action of the bit as the bit cuts into the rock or the like material. Therefore, it is a principal object of the present invention to provide a liquid motor drilling system which

utilizes a spring (or equivalent) supported fluid seal so that lateral movement of the components in the system do not allow leakage between the seals and the component bodies. It is a further principal object of the present invention to provide an improved liquid motor system for drilling or workover which provides fluid bearings within the system to allow output shafts to bear axial thrust to reduce metal-to-metal or metal-to-rubber contact when force is placed on the output shafts.

It is a further object of the present invention to provide a mud motor system which incorporates a novel system of fluid seals and fluid bearings to eliminate leaking of fluid in the system, and to help sustain the components from unnecessary wear due to less metal-to-metal or metal-to-rubber contact.

It is a further object of the present invention to provide a mud motor system which incorporates a mechanism for enabling the bit to impact the rock or like material in a jarring action during the drilling process. BRIEF DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:

FIGURE 1 illustrates a partial view of the upper portion of the mud motor assembly (the rotor and stator) attached to a top sub downhole; FIGURE 2 illustrates a partial view of the lower portion of the rotor rotatably secured to the drive shaft in the mud motor assembly;

FIGURE 3 illustrates a partial view of the lower end of the drive shaft secured to the upper output shaft in the mud motor assembly;

FIGURE 4 illustrates that portion of the upper output

shaft in the bearing body housing the packing retainer, upper seal assembly, upper bearing and fluid bearings;

FIGURE 5 illustrates that portion of the lower output shaft housing the lower bearing and the lower seal assembly;

FIGURE 6 illustrates the drill bit section of the mud motor assembly;

FIGURES 7 and 8 illustrate a four lobe stator and a three lobe rotor utilized in the preferred embodiment of the present invention;

FIGURES 9 through 11 illustrate cross section views of the spring-assisted seal assemblies utilized in the preferred embodiment of the present invention;

FIGURES 12 and 13 illustrate the sealing function of the sealing assemblies utilized in the preferred embodiment of the present invention;

FIGURES 14 and 15 illustrate isolated cross section views of the flexing movement of the sealing members utilized in the preferred embodiment of the system of the present invention;

FIGURES 16 through 18 illustrate the principal and additional embodiments of the fluid bearings utilized in the system of the present invention, respectively. FIGURE 19 illustrates an additional embodiment of the sealing assembly in the system of the present invention;

FIGURE 20 illustrates yet an additional embodiment of the sealing assembly in the system of the present invention; and FIGURE 21 illustrates an additional embodiment of the present invention wherein a jarring mechanism has been provided between the lower seal body and the bit;

FIGURES 22 and 23 illustrate the embodiment of the present invention seen in FIGURE 21 wherein the jarring mechanism has been provided between the stationary bearing and the lower output shaft;

FIGURES 24 through 26 illustrate in isolated view the construction and the operation of the jarring mechanism of the embodiment of the system illustrated in FIGURES 21 through 23.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGURES 1 through 18 illustrate the preferred embodiment of the complete mud motor assembly of the present invention. More particularly, FIGURES 1 through 6 illustrate cross section views of the general overall components of the present invention, which will be initially discussed. As seen in FIGURES 1 through 6, which if taken together, would comprise an overall view of the invention, mud motor assembly 10 is connected at its upper end 12 to a top sub 14, which is cylindrically shaped, and includes internal threads 16 for threadably engaging the upper end 12 of mud motor assembly 10. Top sub 14 would include a bore 18 through its body for allowing fluid (designated by arrow 19) to flow from the rig floor in the direction of arrow 20. The sub 14 would be threaded to the uppermost exterior component, the stator 22, which would serve as a housing for the rotor 24, as will be explained further, and is generally referred to as the motor portion of the system. Further, internally, the rotor 24 would be connectedly engaged to a drive shaft 26, with the drive shaft 26 housed within a drive shaft body 27, which externally is threadably engaged to the stator 22 via threads 29. The lower end of the drive shaft 26 is connected to an upper output shaft 28 which is in turn connected to a lower output shaft 30, which is then threaded to the drill bit 32. Externally, the upper and lower output shafts 28, 30 are housed within a bearing body 34 connected at its upper end 35 to the drive shaft body 27 and at its lower end to a seal body 37 which seals around the lower end of the lower output shaft 30 extending out of the seal body 37. Contained within and straddling the upper

and lower output shafts 28, 30 is the sealing section 36, which is defined as that area positioned between an upper seal assembly 38 and a lower seal assembly 40, wherein the critical functions of the new assembly 10 function. Although these, in general, make up the major components of the assembly 10, the detailed components will be discussed, together with the novel construction and functions.

For an understanding of the rotor 24, and its function, reference should be made to FIGURES 7 and 8 which illustrate cross-section views of a three lobed rotor 24 and a four lobe stator 22. As seen in the figures, the rotor 24 extends throughout the length of stator 22, where there is provided a continuous rubber housing 42 between the stator 22 and the metal rotor 24. Metal rotor 24 comprises a series of lobes 44 and valleys 46, between each lobe 44, with lobes 44 spiraling down the length of the rotor 24 through the stator 22, which of course results in spiral valleys 46. As fluid 19 is pumped through the spiral stator valleys, the rotor 24 is forced to rotate, which ultimately imparts rotation to the drill bit 32, as will be discussed further. Since the fluid 19 flowing through the stator causes the rotation of the internal mechanisms to occur, this section is referred to as the motor section of the assembly. It should be noted that the particular design of the rotor 24 is critical since the construction of the lobes 44 and valleys 46 determine the torque which is required to operate the system at its optimum level. These optimal parameters will be discussed further.

Turning now to FIGURE 2, there is illustrated the lower end 50 of the rotor 24 connectedly engaged to the upper end 52 of drive shaft 26. As seen in the figure, the upper end 52 of shaft 26 is secured through a flat pin section 53 engaged in a slot 53a in the lower end 50 of rotor 24. This connection at 50 firmly secures the rotor 24 to the drive shaft 26, although the drive shaft 26 would tend to bend during the operation of the motor. At this

connection point between the rotor 24 and shaft 26, the fluid which flows down through the valleys 46 of rotor 24, will exit the rotor 24 in the general area labeled as 57, and will flow in the annular space 59 between the shaft 26 and the outer drive shaft body 27, which houses the drive shaft 26. Generally, the drive shaft 26, because of its length and diameter, will have the ability to flex during rotation, as the fluid flows around it and down the assembly, after exiting the rotor 24. Reference is now made to FIGURE 3 which illustrates the lower end 58 of drive shaft 26 keyed or connectedly engaged to an upper portion 60 of the upper output shaft 28, in a similar manner as described earlier in the connection between the drive shaft 26 and rotor 24. The connection, however, between the lower end 58 of drive shaft 26 and the upper end 60 of output shaft 28 defines a fluid flow bore 62 for allowing the fluid 19 which is flowing in the annular space 59 between drive shaft body 27 and drive shaft 26 to enter into a bore 62 within the upper output shaft 28, and to continue its flow down to the drill bit 32. The fluid 19 will exit from bit 32 and assist in washing the cuttings from the bit during drilling.

FIGURE 4 illustrates upper output shaft 28 as it would be threadably engaged to the lower output shaft 30. It should be noted that these two shafts 28 and 30 constitute shafts which are supported by bearing assemblies and fluid sealing means. Further, at this point the surfaces of shafts 28 and 30 are highly polished to accommodate the fluid seals, so that the fluid which drives the assembly 10, as previously discussed, will not get by the seals, but will enter the bore 64 of the output shaft 30 to continue to the bit.

When discussing the next feature of the present invention, reference should be made to FIGURES 4 and 5 together. In these figures there is illustrated the primary sealing means of the present invention which is quite

unique. This sealing means serves to capture a heavy oil within the sealing section, and to isolate it from the surrounding parts of the tool which accomplishes several critical functions that will be discussed. However, first a discussion will be had concerning the means by which the sealing section accomplishes its sealing function.

It is important to keep in mind, as previously discussed, that when the rotor 24 is rotated by the passage of the fluid 19, the rotor 24 tends to vibrate side to side, which, in turn causes the drive shaft to vibrate, together with the upper output shaft 28. This vibration would tend to lead to fluid leakage of the drive fluid 19 into the fluid seal section 36 of the assembly, or fluid leaking from the fluid seal section 36, as previously defined, to the outside. As seen in FIGURE 4, there is positioned along the outer wall of the upper output shaft 28, a packing means 66, which comprises a packing retainer 68 filling the annular space 59 between the wall of the shaft 28 and the outer bearing body 34, which defines the outer wall of this portion of the assembly. Normally, the packing retainer 68 would be a sufficient seal. However, due to the vibration previously discussed there are positioned a series of spring loaded seal means 72, defining individual sealing members. Each of the seal means 72 are more clearly illustrated in FIGURES 9 through 11. As seen in those figures and in FIGURE 4, in overall view, the seal means 72 would comprise two seal members 74 and 76. Member 74 would further comprise a flexible body 78, including a body portion 80 and a pair of flexing arms 82, 84, extending from the body portion 80. For purposes of construction, it should be noted in the FIGURES that arm 82 is substantially thinner than arm 84. The reason for this is that arm 82, being thinner, is able to respond more quickly to side to side shifts of the output shafts 28 and 30 during drilling. There is further provided a first metal spring member 86, housed within or on the body 78,

and curved so that the ends 85 of the spring member 86 extends into each arm 82, 84. With this configuration, the arms, although flexible, when flexed, would instantaneously return to their normal position when released, due to the presence of the metal spring 86. There may also be provided a second spring 88 to provide greater flexion and return when the arms 82, 84 are flexed. Second sealing member 74 will be discussed further.

It should be noted that in addition to the unique spring configuration of the body portion 80, is the arrangement of the sealing members to form the continuous seal along the sealing surface. As seen in FIGURE 4, there is illustrated a first plurality of sealing members, at least four as illustrated in the figure, positioned along a first sealing surface 90 between the packing retainer 68 and the wall of the upper output shaft 28, thus sealing the sealing section 36 from drive fluid 19 flowing into the section. However, there is further illustrated again four sealing members positioned between the inner surface of the bearing body 34, which houses the upper output shaft 28 and the packing retainer 68. These particular seals would have a double sealing action, first sealing the heavy bearing oil contained within sealing section 36 from flowing out of the section, and also sealing off from the fluid 19 entering the sealing section 36.

Turning now to the sealing members in greater detail, reference is made to FIGURES 12 and 13. In these figures, there is illustrated detail views of the sealing members 74, 76 as seen in FIGURE 4. As illustrated, first member 74 would engage a flat surface 70 of packing retainer 68, and the legs 82, 84 of the body portion 80 would extend upward, sealing against the wall of the packing retainer 68 and the wall of either the output shaft 30 or the wall of the packing retainer 68. In either case, the spring member or members 86 housed within or on body 80, and extending into legs 82, 84, would maintain sufficient force on the legs,

so that the legs 82, 84 would form a continuous seal between the surfaces, and would prevent fluid flow thereby. However, as illustrated, the sealing in this area does not depend on a single sealing member 74, but includes a plurality of members positioned to form a continuous interlocking sealing means.

As seen in FIGURES 12 and 13, there is illustrated a second sealing member 76, shown in phantom view, would be shaped essentially as the first member 74 previously described. However, its lowermost end would comprise a male member 94 extending from the body 80, and would be sealing engaged into the space 96 formed between the legs 82, 84 of body portion 80. As seen in the figures, this defines a continuous seal between the body portions 80, between the surfaces. Although only two body members 74, 76 are illustrated, it is foreseen that these interlocking sealing members could be positioned in any number, with each interlocking the one before it and behind it to define the continuous seal. To further illustrate the sealing ability of members 74, 76, reference is made to FIGURES 14 and 15, which illustrate a sealing member, 74, housed within a groove 75 of output shaft 30, with one of the arms 84 of member 74 making contact with the wall of seal body 37. Referring to both FIGURES 14 and 15 simultaneously, 15 illustrates a motion of the shaft 30 vibrating inward toward the wall of body 37, so that the arm 82 of member 74 is flexed inwardly, and as soon as a vibrating motion moves the shaft body away from body 37, the arm 82 flexes back into the position as seen in FIGURE 14. It is this ability to flex and return to its original position instantaneously is what effects a continuous seal within the space 85 between the wall of the shaft 30 and the seal body 37.

As was stated earlier, it is important to note that the presence of the springs 86 within each sealing body 80 is critical in eliminating leakage of fluid by the sealing

bodies during operation of the tool. Because of the flexion of the springs 86 within each body, as the upper output shaft would tend to wobble or vibrate within the bearing body 34, and would tend to create a gap between the upper output shaft 28 and the packing retainer 68,or the packing retainer 68 and the bearing body 34, the springs prevent this. Should the shaft 28 wobble or vibrate, the springs 74, 76 within the legs 82, 84 will have the legs flex outward and inward to follow the movement of the shaft, thus eliminating any gaps which would normally occur as a result of the vibration. This, of course, as stated earlier, would be true for preventing the drive fluid 19 seeping into the tool, or the bearing oil 92 from seeping out of the seal section 36 of the tool. Although this discussion has concentrated on the sealing through the upper sealing assembly 38 as seen in FIGURE 4, reference should be made to FIGURE 5 wherein the same sealing means are utilized to seal the lower seal assembly 40 in the tool. The problem which is confronted in this portion of the tool, is to prevent the flow of fluids around the total assembly to seep into the lower drive area during drilling. As seen and discussed previously, the lower end of the upper output shaft 28 is attached to a lower output shaft 30, which in turn attaches to the bit 32. The lower output shaft 36 is housed within a seal body 37 at its lower end, so that fluid does not flow into the tool. The seal body 37 is threadably secured to the bearing body 34 and therefore, the only leakage possible is between the inner wall of the seal body 37 and the outer wall of the lower output shaft 30. This, again would normally occur as the bit vibrates during the drilling process.

Because of this potential for leakage there would be provided a lower sealing means 100 comprising a plurality of sealing members 74, 76 positioned between the lower output shaft 30 and the seal body 37 as illustrated in FIGURE 5. As further noted in FIGURE 5, the arrangement of

the sealing members 74, 76 is unique in that a plurality of upper and lower sealing members 74, 76 are arranged back to back, to withstand the pressure from both sides within the system. As further illustrated, the lower sealing members 74, 76 rest upon a shoulder 79 within the wall of seal body 37, and the upper members 74, 76 are maintained in place via a metal ring 81 formed within the wall of the seal body 37. These members 74, 76 would be constructed identical to the members previously discussed, and again would flex along with the movement of the shaft 30, thus effecting a continuous, non-interrupted seal. Of course in both the upper and lower seal assemblies, there would be provided static seals in the form of 0-rings 102 which would assist in the sealing function. Turning now to another critical feature of the present invention, reference is made to FIGURES 4, 5 and FIGURES 14 through 16. As seen in FIGURE 4, positioned directly below the upper seal assembly 38, and the packing retainer 68, there is placed an upper journal bearing 104, which is press fitted into the annular space between the outer bearing body 34 and the upper output shaft 28.

In addition, as seen in FIGURE 5, there is a second journal bearing 106, press fitted between the wall of the bearing body 34 and the wall of the lower output shaft 30. It is held in place by a thrust plate 108 at its lower end. The journal bearings 104 and 106 serve to create the precise alignment of the output shafts 28, 30 and to take out the wobble during drilling.

In discussing this portion of the assembly, it is crucial to understand that in such mud motor systems, it is critical that the friction caused by the rotation of the output shafts 28, 30 in the housings is reduced as much a possible, so that torque on the bit is at its maximum potential. As thrust is applied on the bit 32 upward or downward, the bit tends to move upward or downward. For example, reference is made to FIGURE 6 where there is

illustrated bit 32 connected to the lower end of lower output shaft 30, which is housed on its lower end within seal body 37 . As illustrated, there is a portion 31 of the shaft 30 exposed so that should force be applied on the bit, the shaft 30 will be free to move upward or downward before the bit 32 makes contact with the seal body 37.

So that the friction is minimized during this operation, there is provided a fluid bearing means 110 positioned between the upper seal assembly 38 and the lower seal assembly 40, that means defined in general by the area designated by the numeral 112 in FIGURES 4 and 5. This fluid bearing means 112 would comprise generally a heavy oil or fluid sealed within the annular space 114 between the wall of the output shafts 28, 30 and the wall of the bearing body 37, between the upper and lower seal assemblies 38, 40 respectively. Critical to this means is the space defined between the upper end of lower output shaft 30, and upper journal bearing 104. This space 114 is filled with heavy oil trapped within that space by the sealing members 74, 76 previously discussed. Therefore, as force is placed upward on the drill bit 32, for example during drilling, the output shaft 30 tends to move the bit 32 toward the lower end 39 of the seal body 37. (See FIGURE 6) When this occurs, the upper end of the lower output shaft 30 compresses the oil in space 114, which then provides a fluid bearing surface 120 against the upper end 31 of the output shaft 30, which would be virtually frictionless, since there is no contact between the shaft 30 and the upper journal bearing 104. In essence, the fluid bearing is formed by the difference in the annular areas at seal surfaces 90 and the outside diameter of output shaft 28. In the event the oil within space 114 is lost, the upper end of shaft 30 would simply contact the lower end of upper journal bearing 104 and ride on that surface as a thrust bearing until the oil could be reinstated in the space. In this particular design, the

fluid bearing 112 will function as such when the bit is being forced upward during, for example, drilling.

Although this design would not accommodate a fluid bearing 112 when the bit 32 is being pulled, an embodiment of the tool could be designed to accommodate a fluid bearing 112, of the type described, for the shaft 30 to encounter a fluid bearing 112 in the event the shaft 30 is pulled down by the bit 32. Reference is also made to space 125, which is defined as the space between upper face 121 of the lower journal bearing 106 and the shoulder 122 on the wall of the lower output shaft 30. If one were to position the upper journal bearing 104 in the position of the lower journal bearing 106, and decrease the diameter of the shaft 30, accordingly, a space would be created which would be similar to the space 114 presently accommodating the fluid bearing. Therefore, to pull upward, which would, in effect tend to pull lower output shaft 30 down, the fluid within space 114 would be compressed between journal bearing 106 and shoulder 122, and thus would serve as a fluid bearing surface against the downward movement of shaft 30, as it would bear against shoulder 122 of shaft 30. In general, the concept is to provide a means for allowing the lower output shaft 30, when pulled down or forced upward, to encounter a fluid, rather than solid material, and thus ride on a fluid surface, to greatly reduce friction. Of course, as stated earlier, if the fluid bearing fails, there is a mechanical bearing to back it up and not suffer loss of or destruction of the assembly.

FIGURE 16 illustrates the upper sealing assembly 38 utilized in the principal embodiment of the present invention, while FIGURES 17 and 18 illustrate alternate embodiments of the sealing assembly of the present invention. Reference is made in all three figures to that area of the sealing means between the bearing body 34 and the output shaft 30. In FIGURE 16 there is illustrated the single acting compressive load fluid chamber 114, wherein

the fluid 119 is held sealed in place via sealing members 74 on either end of the fluid chamber. In the alternate embodiment as illustrated in FIGURE 17, the fluid chamber has been dissected into two separate chambers 123, 124 with seals 74 on each end of each chamber, and seals on the outside diameter of 30 to effect a double acting load mechanism to resist compression and tension loads. As illustrated in FIGURE 18, there again is illustrated the single acting tension load mechanism. This design is aimed at resisting the opening force on the motor due to pulling up, with the larger chamber portion 134 serving as the primary fluid bearing, and the hydrostatic forces resisting any compressive loads which may occur.

FIGURE 19 further illustrates an additional embodiment system of the present invention relative to the manner in which the sealing assembly undertakes a seal between the upper and lower output shafts 28, 30 and the wall of the bearing body 34. In this particular embodiment, there is provided a modified output shaft 128 would include a first upper annular flange portion 129 positioned within the sealing section 36 of the system, which would house the bearing oil 92 in that annular space 59 between the shaft 128, the wall of bearing body 34, and positioned above the upper journal bearing 104. The FIGURE also illustrates a modified lower output shaft 130 which would likewise include a second lower annular flange portion 131 positioned below the lower journal bearing 106 so that the sealing section 36 would be included between the upper and lower flanges 129, 131. As illustrated, each of the upper and lower annular flanges 129, 131 would extend and be housed within an upper and lower seal assemblies 135, 137. Each sealing assembly would further include a sealing body 130 positioned around the inner body wall of the body 34, with seal body 130 including a vertical body portion 132 and a pair of spaced apart horizontal flange portions 134, 134A, to define a

space 139 therebetween. The flange portions 134, 134A could be secured together via bolting or the like to define the complete seal body 130. The flange portions 134, 134A would extend into the annular space 59 between the shaft 128 and the body 34 so that the flange portions 129, 131 of shaft 128 and 130 would each be housed within space 139 defined by flanges 134, 134A of body 130. Each flange 134, 134A would further include one or more continuous channels 138 housing a plurality of seal members 74 which would be constructed as was described earlier in the patent. Seal members 74 would form a flexible continuous seal between each flange 129 and the upper face of flange 134, and the lower face of flange 134A of body 130.

The seal body 130 itself of seal assemblies 135, 137 would be engaged along the inner wall of housing 34, and would have the ability to slide upward and downward in the direction of arrows 142 as indicated in the FIGURES. Sealing assemblies 135, 137 would be maintained in the sealing engagement around the inner face of bearing body 34 via a pair of o-rings 141, 143. In this manner each of the sealing assemblies 135, 137 would travel upward and downward with the movement of the modified upper and lower output shafts 128, 130 to maintain the seal between the assemblies and the shafts. Further, as illustrated, the assemblies 135, 137 would further provide a thrust bearing 140 within the channels housing the spring loaded seals 74 to effect a complete seal, to avoid the oil flowing beyond the upper and lower assemblies out, or to prevent the mud within the system from entering the sealed area 36. In this particular embodiment, it is foreseen that this "horizontal sealing" between the flange 129 and sealing assemblies 135, 137 would at all times seal due to the force of the rotating shaft 128 irregardless of whether rotating shaft 128 would wobble side to side or not. Even during wobbling of the shaft as seen in the FIGURES, the seal between the seal assemblies 135, 137 and the

horizontal flanges 129, 131 of output shafts 128, 130 respectively, is maintained at all times in view of the fact that there is no vertical movement of the shafts during wobble, only side to side or horizontal movement which would not effect the sealing between the seals 74 and the shafts 128, 130. In this manner, the bearing oil 92 would be at all times maintained within the sealing section 36, between the upper and lower seal assemblies 135, 137, to maintain the oil 92 within the section, and to prevent mud from leaking in from above the upper assembly 135 or from below the lower assembly 137. The assemblies ability to maintain an oil reservoir between the assemblies would define the liquid thrust bearing portion of the system in this particular embodiment, as was discussed earlier. Yet another embodiment, as seen in FIGURE 20, would be very similar to the embodiment as illustrated in FIGURE 19 and discussed earlier, and would carry out the same sealing function in the similar fashion; therefore, there will be no discussion of the functioning principles, as these were discussed in relation to FIGURE 19. The principal difference in this embodiment is the positioning of the journal bearings 104, 106. This embodiment would incorporate the upper and lower journal bearings 104, 106 into each sealing assembly 135, 137 as illustrated. Therefore, the journal bearings 104, 106 would be press fitted into an annular space between the wall of the sealing assembly 135, 137 and the wall of the output shafts 128, 130. In this manner, the sealing assemblies 135, 137 define single sealing components with the spring-loaded seals 74 and the journal bearings 104, 106 incorporated into the sealing assemblies as a single component.

Another embodiment of the present invention addresses the need to provide for axial movement of the drill bit during drilling. Axial movement of the bit, i.e., moving up and down, is not used in other downhole motors. In the drilling assembly as discussed in the previous embodiment,

there is incorporated a thrust bearing assembly which does not allow the up and down motion, but such motion is allowed in this embodiment for several reasons. For example, if the rotor 24 and the stator 22 have grit between their common interference areas around the circumference of the rotor, due to dirty fluid coming in, the rubber lining of the stator may bond slightly to the surface of the rotor. At that point the motor needs to start or restart if it is in a downhole application, by shearing this bond surface. As was discussed earlier, the rotation of the rotor turns all of the inner assembly which of course also turns the bit. Therefore, if axial slack, or up and down motion, is allowed in the assembly, when the pumps are activated, the pressure drop across the rotor will force it downward, which can shear the bond or clean the grit out from between the rotor and the stator. If this is unsuccessful, pressing on the end of the output shaft, such as by setting the motor on bottom and putting weight on it from above, will slide the rotor upward into the stator further. Either one of these two methods will usually free or reduce the bond and the motor will start. This has been called a kick start feature. The axial thrust bearing, including a gap, filled with oil, or unfilled, allows for a certain amount of axial slack. An 1/8 to 1/4 inch space has proven to be sufficient to break the bond between the rotor and stator rubber lining or clean the trash therebetween.

There are drills, called vibra drills or vibrating type drills, that vibrate rapidly up and down as they rotate, and they are typically used to drill into masonry or concrete. The vibration helps break up the material while the drill rotates to excavate or remove chips as the hole is dug. The two motions of rotating the bit, together with axial vibration of the bit, have been quite beneficial for drilling in concrete. The motor is quite often used to remove scale and deposits from the side of the walls of

tubing and also to drill out cement that is left in the well from plugging or bridging applications. It would be somewhat advantageous to have a motor that would both rotate the bit and also vibrate up and down to achieve these results.

FIGURES 21 through 26 illustrate the embodiment of the present invention allowing for axial movement of the bit during drilling, by the numeral 200. In the previous embodiments, the mud motor assembly 10 addressed imparting rotation to the drill bit 32 during the drilling process through the use of components in the system. However, in the present embodiment illustrated in FIGURES 21 through 26, the system incorporates a means for providing a vertically directed jarring assembly 200 for imparting vertical impact to the formation which is being drilled in addition to the rotational torque imparted to the drill bit 32. This means enables the bit to more effectively cut into the formation, particularly when the formation is rock or the like, and provides for more efficient drilling. In order to effectively describe the embodiment reference will be first made to FIGURE 21, where the jarring means 200, creating the axial movement of the assembly, is positioned between the drill bit 32 and the seal body 37, as described in the earlier embodiment. Further, the detail construction of the assembly is illustrated in FIGURES 24 through 26. FIGURES 22 and 23 illustrate the assembly 200 positioned at alternate sites in the entire drilling assembly 10. Turning now to FIGURE 21, there is illustrated the seal body 37 and the drill bit 32. As seen in the earlier embodiment in FIGURE 6, there was a space 31 between the seal body 37 and bit 32. In this new embodiment, the space 31 is occupied by the jarring means 200, which comprises a first lower ramp ring 202, and an upper stationary ramp ring 204. Each of the rings 202, 204, are of equal diameter, with the diameter of the seal body 37. Each ring comprises a continuous outer wall 206,

and the lower ring 202 has a flat under face 208, which engages to the rotating drill bit 32, and thus rotates with bit 32. Upper ring 204 likewise comprises an outer wall 206, and has a flat upper face 210 which engages the lower end of seal body 37, thus remaining stationary during the drilling process.

Turning now to the means by which rings 202, 204 impart jarring action reference is made to FIGURES 24 through 26. As illustrated in the figures. Each of the surfaces 212 of each ramp ring 202, 204 engage against one another during the operation of this embodiment of the drilling assembly. As illustrated, the surface 212 actually comprises a spiral surface 214, which originates at point 216, as illustrated, and gradually spirals upward to terminate at point 218, some 360 degrees along surface 212. The termination point 218, is at a level 220, somewhat higher than origination point 216, and thus results in a vertical wall 222 defined between the origination and termination points 216, 218, respectively. When the two ramp rings 202, 204, are matingly engaged, as illustrated in FIGURES 24 and 25, the spiral surfaces 214 of each ring 202, 204, are positioned so that each of the ramps are inclining in the opposite direction, as illustrated. Thus, as seen in FIGURE 25, the two rings 202, 204, are engaged, with each vertical wall 222 positioned adjacent one another, to form the configuration of the rings 202, 204. However, as the lower ring 204 is rotated, and the upper ring 202 remains stationary, the result is seen in FIGURE 24, where the rings' respective ramps are engaged at their highest level 220, and when the rotation of lower ring 204 is complete, the vertical walls slide by one another, and the rings fall in to the position as seen in FIGURE 25. This rotation of the moveable ring 204, as defined by the rotation of bit 32, occurs again and again, and each time a revolution of the lower ring 204 is completed, the rings fall in to place, thus providing the

axial movement, and creating the "jarring" action against the drill bit, which provides for greater biting of the bit into the surrounding formation, and increases the effectiveness of the drilling process. It should be noted that the positioning of each ring 202, 204 between the bit 32 and the ring seal 37, is a position which allows access to the debris, etc. surrounding the assembly in the formation. Therefore, it is foreseen that in this embodiment, because of its susceptibility to corrosion from the outside, that the rings would have to be replaced quite often.

This concept of the upper and lower jarring rings can be applied between other components of the assembly 10. For example, reference is made to FIGURE 22 where rings 202, 204 have been positioned in the oil filled chamber preferably on the face 31 as seen in FIGURE 5, which is the upper surface of the lower output shaft 30. This positioning would be used in a compression type drilling which would be the most common application. During the drilling process, when the assembly is set on bottom with the jarring means 200 in place, with the rings 202, 204 in the oil chamber, the assembly would move upward and bring the two rings 202, 204 together. As the motor starts and rotates, the rotation makes the moveable ring 202 slide up against the stationary ring 204, and when the rings reach their vertical faces 212, the top of their peak, i.e., the falling off spot on the rings, then the motor would then be free to close downward. So, the effect is the operator of the motor would start the motor up and then would set it on bottom and put weight on it and at that point the motor, as it rotates, would go up and down the ramp surfaces created by rings 202, 204, or lift itself up and then when it fell off of the ramps it would fall down due to having the weight above it. Therefore, it would bang downward a certain number of times per revolution depending on the design of the ring 202, 204. The net result is the

downward impact simultaneously with bit rotating, thus producing a more efficient drilling application in difficult formations.

FIGURE 23 illustrates the application of the rings 202, 204 in drilling upward, such as under reaming and pulling upward. As seen, the rings 202, 204 would be positioned on face 122 in FIGURE 5, which is positioned on the shoulder on the lower output shaft 30, and face 121, which is the upper end of the bearing that is in the housing of the bearing body shown in FIGURE 5. Therefore, when pulled upward, the rotation of the motor would also cause the same banging in the same manner as was described earlier.

The following table lists the part numbers and part descriptions as used herein and in the drawings attached hereto.

GLOSSARY OF TERMS: mud motor assembly 10 upper end 12 top sub 14 threads 16 bore 18 fluid (arrows 19) arrow 20 stator 22 metal rotor 24 drive shaft 26 drive shaft body 27 upper output shaft 28 threads 29 lower output shaft 30 shaft portion 31 drill bit 32 bearing body 34 upper end 35 sealing section 36

10

15

20

25

30

35

10

15

20

25

30

35

Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.

What is claimed as invention is:

A:20091001.PCT/cgc