Drill coupler for mitigating torsional vibration

A method of manufacturing a coupler for connecting a first drill string component to a second drill string component, the coupler comprising a housing, a base, and an intermediate component disposed between, the method comprising the steps of:

• forming the housing and the base, wherein:
• the housing comprises a first threaded connecting portion at a first end for connecting to a first drill string component;
• the base comprises a second threaded connecting portion at a second end for connecting to a second drill string component;
• and
• the first end and the second end are at opposite ends of the coupler;
• inserting the base at least partially into the housing and securing to one another;
• and
• forming the intermediate component by injecting or pouring a settable compound into a space between the housing and the base, wherein:
• the intermediate component is made from a resiliently deformable material, wherein the coupler is configured for rotation about a longitudinal axis of the coupler during use;
• the intermediate component is configured for allowing limited relative rotation between the housing and the base about the longitudinal axis;
• the intermediate component deforms as the housing and the base rotate relative to one another about the longitudinal axis and returns to an original shape as the housing and the base return to their respective original positions;
• the base and the housing are secured to one another using a locking ring that is removably coupled with the base and that constrains axial movement between the base and the housing;
• and
• the locking ring has a maximum outer diameter that is smaller than a maximum outer diameter of the housing and a maximum outer diameter of the base.

A method of manufacturing a coupler for connecting a first drill string component to a second drill string component, the coupler comprising a housing, a base, and an intermediate component disposed between, the method comprising the steps of:

• forming the housing, the base, and the intermediate component, wherein:
• the housing comprises a first threaded connecting portion at a first end for connecting to a first drill string component;
• and
• the base comprises a second threaded connecting portion at a second end for connecting to a second drill string component;
• inserting the base at least partially into the housing with the intermediate component disposed between, wherein the intermediate component is made from a resiliently deformable material;
• and
• securing the base and the housing to one another using a locking ring that is removably coupled with the base and that constrains axial movement between the base and the housing and such that the first end and the second end are at opposite sides of the coupler, wherein:
• the locking ring has a maximum outer diameter that is smaller than a maximum outer diameter of the housing and a maximum outer diameter of the base;
• the coupler is configured for rotation about a longitudinal axis of the coupler during use;
• the intermediate component is configured for allowing limited relative rotation between the housing and the base about the longitudinal axis;
• and
• the intermediate component deforms as the housing and the base rotate relative to one another about the longitudinal axis and returns to an original shape as the housing and the base return to their respective original positions.