Fiber reinforced sealing element

A sealing element for a rotating control device used in a rotary drilling system, comprising:

• said sealing element molded from a polyurethane base elastomer and fibers mixed into the polyurethane base elastomer;
• said sealing element having an inner surface which forms a bore extending axially through the sealing element;
• a base region;
• a nose region opposite from the base region, wherein the nose region has an inner diameter smaller than the inner diameter of an attachment region;
• at least one region comprising a first concentration of fibers;
• and
• at least one region comprising a second concentration of fibers.

A method for making a sealing element for a rotating control device used in rotary drilling systems, comprising:

• providing a mold for the sealing element for the rotating control device;
• adding fibers at a first concentration to a first liquid elastomer material containing polyurethane;
• placing the first liquid elastomer material having a first concentration of fibers into the mold;
• adding fibers at a second concentration to a second liquid elastomer material containing polyurethane;
• placing the second liquid elastomer material having a second concentration of fibers into the mold;
• heating the fibers and liquid elastomer in the mold;
• forming a sealing element having a bore;
• wherein the sealing element can stretch to receive a wellbore component in a longitudinal insertion through the bore;
• wherein the fibers enhance a property of the sealing element for extending the service life of the sealing element, including at least one of increased resistance to outside pressure, increased resistance to wear, and increased strength;
• and
• wherein the fibers are randomly oriented and uniformly distributed in the sealing element.