Tilting superhard bearing elements in bearing assemblies, apparatuses, and motor assemblies using the same
View Patent ↗Embodiments relate to tilting superhard bearing element bearing assemblies and apparatuses. The disclosed assemblies/apparatuses may be employed in downhole motors of a subterranean drilling system or other mechanical systems. In an embodiment, a bearing assembly may include a support ring and a plurality of superhard bearing elements each of which is tilted and/or tiltably secured relative to the support ring and distributed circumferentially about an axis. Each of the superhard bearing elements includes a bearing surface and a base portion. The base portion of the at least one of the superhard bearing elements may include a tilting feature configured to allow the at least one of the superhard bearing elements to be tiltable about a tilt axis. The bearing assembly includes retaining features that secure the superhard bearing elements to the support ring.
1. A bearing assembly, comprising:
a support ring;
a plurality of superhard bearing elements each of which is tilted and/or tiltably secured relative to the support ring and distributed circumferentially about an axis, at least one of the superhard bearing elements includes a bearing surface and a base portion including a tilting feature having a rocker pivot comprising a convex portion configured to allow the at least one of the superhard bearing elements to be tiltable about a tilt axis, the base portion of the at least one of the superhard bearing elements further including two substantially planar portions between which the convex portion is disposed, wherein the convex portion has a width of about 5 percent to 50 percent of a width of the base portion; and
a plurality of retaining features that secure the superhard bearing elements to the support ring such that the superhard bearing elements are tilted and/or tiltably secured to the support ring.
2. The bearing assembly of claim 1 wherein the support ring includes a plurality of recesses that receive the superhard bearing elements.
3. The bearing assembly of claim 2 wherein at least one of the recesses includes a base surface having a concave portion.
4. The bearing assembly of claim 1 wherein at least one of the superhard bearing elements is tiltable from about 0.5 degrees to 20 degrees relative to the tilt axis.
5. The bearing assembly of claim 1 wherein at least one of the superhard bearing elements is tiltable in two or more directions.
6. The bearing assembly of claim 1 wherein the tilting feature comprises a rotatable connection between the support ring and at least one of the superhard bearing elements.
7. The bearing assembly of claim 1 wherein at least one of the retaining features comprises:
a base recess extending at least partially through the base portion of the at least one of the superhard bearing elements; and
an elongated retaining member, wherein at least a portion of the elongated retaining member is positioned in the base recess to tiltably secure the at least one of the superhard bearing elements to the support ring.
8. The bearing assembly of claim 7 wherein the base portion comprises a metallic portion attached to a substrate of the at least one of the superhard bearing elements.
9. The bearing assembly of claim 1 wherein at least one of the retaining features comprises:
one or more grooves formed in a lateral surface of the at least one of the superhard bearing elements; and
a plurality of retaining members attached to the support ring, each of two of the retaining members including a head portion positioned between the at least one of the superhard bearing elements and an adjacent one of the superhard bearing elements, wherein at least a portion of the head portion of each of the two of the retaining members is received within the one or more grooves to tiltably secure the at least one of the superhard bearing elements to the support ring.
10. The bearing assembly of claim 1 wherein the axis is a thrust axis, and the support ring and the tilting bearing elements define a thrust-bearing assembly; or wherein the axis is a rotation axis, and the support ring and the tilting bearing elements define a radial bearing assembly.
11. A bearing apparatus, comprising:
a stator including:
a first support ring;
a first plurality of superhard bearing elements each of which is tilted and/or tiltably secured relative to the support ring and distributed circumferentially about an axis, at least one of the first plurality of superhard bearing elements including a bearing surface and a base portion, wherein the base portion includes a tilting feature having a rocker pivot comprising a convex portion configured to allow the at least one of the first plurality of superhard bearing elements to be tiltable about a first tilt axis, the base portion further including two substantially planar portions between which the convex portion is disposed, the convex portion having a width of about 5 percent to 50 percent of a width of the base portion; and
a plurality of retaining features that secure the first plurality of superhard bearing elements to the first support ring; and
a rotor including
a second plurality of superhard bearing elements generally opposed the first plurality of superhard bearing elements of the first bearing assembly; and
a second support ring that carries the second plurality of superhard bearing elements.
12. The bearing apparatus of claim 11 wherein at least one of the second plurality of superhard bearing elements includes a bearing surface and a base portion, wherein the base portion includes a tilting feature configured to allow the at least one of the second plurality of superhard bearing elements to be tiltable about a second tilt axis.
13. The bearing apparatus of claim 11 wherein the first support ring includes a plurality of recesses that receive the first plurality of superhard bearing elements.
14. The bearing apparatus of claim 13 wherein at least one of the recesses includes a base surface having a concave portion.
15. The bearing apparatus of claim 11 wherein at least one of the first plurality of superhard bearing elements is tiltable from about 0.5 degrees to 20 degrees relative to the tilt axis.
16. The bearing apparatus of claim 11 wherein at least one of the first plurality of superhard bearing elements is tiltable in two or more directions.
17. The bearing apparatus of claim 11 wherein the tilting feature comprises a rotatable connection between the first support ring and the at least one of the first plurality of superhard bearing elements.
18. The bearing apparatus of claim 11 wherein at least one of the retaining features comprises:
a base recess extending at least partially through the base portion of the at least one of the first plurality of superhard bearing elements; and
an elongated retaining member, wherein at least a portion of the elongated retaining member is positioned in the base recess to tiltably secure the at least one of the first plurality of superhard bearing elements to the first support ring.
19. The bearing apparatus of claim 18 wherein the base portion comprises a metallic portion attached to a substrate of the at least one of the first plurality of superhard bearing elements.
20. The bearing apparatus of claim 11 wherein at least one of the retaining features comprises:
one or more grooves formed in a lateral surface of the at least one of the first plurality of superhard bearing elements; and
a plurality of retaining members attached to the first support ring, each of two of the retaining members including a head portion positioned between the at least one of the first plurality of superhard bearing elements and an adjacent one of the first plurality of superhard bearing elements, wherein at least a portion of the head portion of each of the two of the retaining members is received within the one or more grooves to tiltably secure the at least one of the first plurality of superhard bearing elements to the first support ring.
21. The bearing apparatus of claim 11 wherein the axis is a thrust axis;
or wherein the axis is a rotation axis.
22. A bearing assembly, comprising:
a support ring;
a plurality of superhard bearing elements each of which is tilted and/or tiltably secured relative to the support ring and distributed circumferentially about an axis, at least one of the superhard bearing elements including a bearing surface and a base portion having a tilting feature configured to allow the at least one of the superhard bearing elements to be tiltable about a tilt axis, wherein the at least one of the superhard bearing elements includes one or more grooves formed in a lateral surface thereof; and
a plurality of retaining members attached to the support ring, each of two of the retaining members including a head portion positioned between the at least one of the superhard bearing elements and an adjacent one of the superhard bearing elements, at least a portion of the head portion of each of the two of the retaining members is received within the one or more grooves to tiltably secure the at least one of the superhard bearing elements to the support ring.
23. The bearing assembly of claim 22 wherein the support ring includes a plurality of recesses that receive the superhard bearing elements.
24. The bearing assembly of claim 23 wherein at least one of the recesses includes a base surface having a concave portion.
25. The bearing assembly of claim 22 wherein at least one of the superhard bearing elements is tiltable from about 0.5 degrees to 20 degrees relative to the tilt axis.
26. The bearing assembly of claim 22 wherein at least one of the superhard bearing elements is tiltable in two or more directions.