Methods utilizing a bearing assembly having enhanced selected support for nonuniform loads
View Patent ↗Embodiments of the invention are directed to bearing assemblies configured to effectively carry nonuniform loads, bearing apparatuses including such bearing assemblies, and methods of operating such bearing assemblies and apparatuses. In an embodiment, under some operational conditions, one or more portions of the bearing assemblies and bearing apparatus may be preferentially loaded, such as to carry preferentially higher loads (e.g., radial and/or axial loads) than other portion(s) of the bearing assemblies and bearing apparatus.
1. A method of operating a bearing apparatus, the method comprising:
providing a first bearing assembly having one or more first superhard bearing surfaces;
engaging a second bearing assembly with the first bearing assembly, the second bearing assembly including:
one or more second superhard bearing elements each of which includes a second superhard bearing surface, all of the second superhard bearing surface of each of the one or more second superhard bearing elements collectively defining a reinforced portion; and
one or more third superhard bearing elements each of which includes a third superhard bearing surface, all of the third superhard bearing surface of each of the one or more third superhard bearing elements collectively defining an unreinforced portion, the reinforced portion having a higher bearing surface density than the unreinforced portion;
wherein at least one of:
a surface area of the second superhard bearing surface of each of the one or more second superhard bearing elements is greater than a surface area of the third superhard surface of any of the one or more third superhard bearing elements;
the one or more second superhard bearing elements include a plurality of second superhard bearing elements that contact adjacent ones of the plurality of second superhard bearing elements and the one or more third superhard bearing elements include a plurality of third superhard bearing elements that are spaced from adjacent ones of the plurality of third superhard bearing elements; or
the one or more second superhard bearing elements include a plurality of second superhard bearing elements and the one or more third superhard bearing elements include a plurality of third superhard bearing elements, and wherein a gap between adjacent ones of the plurality of second superhard bearing elements is less than a gap between adjacent ones of the plurality of third superhard bearing elements; and
supporting a first portion of a total load by the reinforced portion and a second portion of the total load by the unreinforced portion.
2. The method of claim 1 , wherein the first portion has a first percentage per degree load, the second portion has a second percentage per degree load, and the first percentage is greater than the second percentage.
3. The method of claim 1 , wherein the first percentage is greater than about 0.3% per degree.
4. The method of claim 1 , wherein the first percentage is less than about 9% per degree.
5. The method of claim 1 , wherein each of the first and second bearing assemblies includes a thrust-bearing assembly.
6. The method of claim 1 , wherein each of the first and second bearing assemblies includes a radial bearing assembly.
7. A method of operating a bearing apparatus, the method comprising:
providing a first bearing assembly having one or more first superhard bearing surfaces;
engaging a second bearing assembly with the first bearing assembly, the second bearing assembly including:
a plurality of second superhard bearing elements distributed about an axis, each of the plurality of second superhard bearing elements having a second superhard material including a second superhard bearing surface;
a reinforced portion that has a span angle defined by two reference lines intersecting at the axis, wherein a reinforced superhard bearing surface area is defined by each second superhard bearing surface entirely within the span angle and any portion of any other second superhard bearing surface partially within the span angle; and
an unreinforced portion defined by a vertical angle of the span angle, wherein an unreinforced portion superhard bearing surface area is defined by each second superhard bearing surface entirely within the vertical angle and any portion of any other second superhard bearing surface partially within the vertical angle;
wherein the reinforced superhard bearing surface area is at least 8% greater than the unreinforced superhard bearing surface area; and
supporting a first portion of a total load by the reinforced portion and a second portion of the total load by the unreinforced portion.
8. The method of claim 7 , wherein the first portion has a first percentage per degree load, the second portion has a second percentage per degree load, and the first percentage is greater than the second percentage.
9. The method of claim 7 , wherein the first percentage is greater than about 0.3% per degree.
10. The method of claim 7 , wherein the first percentage is less than about 9% per degree.
11. The method of claim 7 , wherein each of the first and second bearing assemblies includes a thrust-bearing assembly.
12. The method of claim 7 , wherein each of the first and second bearing assemblies includes a radial bearing assembly.
13. The method of claim 7 , wherein each of the plurality of second superhard bearing elements includes a superhard table including the second superhard material, the superhard table bonded to a substrate.
14. The method of claim 13 , wherein the superhard tables of the plurality of second superhard bearing elements in the reinforced portion exhibit at least one of a greater thickness or thermal stability than the superhard tables of the plurality of second superhard bearing elements in the unreinforced portion.
15. The method of claim 7 , wherein the span angle is between 5° and 72°.
16. The method of claim 7 , wherein the reinforced superhard bearing surface area includes a substantially uninterrupted superhard bearing surface.
17. The method of claim 7 , wherein:
the plurality of second superhard bearing elements collectively define a total bearing surface; and
the reinforced superhard bearing surface area defines at least 80% of the total bearing surface.
18. The method of claim 7 , wherein the reinforced superhard bearing surface area is at least 15% greater than the first unreinforced superhard bearing surface area.
19. The method of claim 7 , wherein the reinforced superhard bearing surface area is at least 35% greater than the first unreinforced superhard bearing surface area.
20. A method of operating a bearing apparatus; the bearing apparatus included in a system having a shaft operably coupled to the bearing apparatus; the bearing apparatus including a first bearing assembly and a second bearing assembly; the method comprising:
rotating the shaft to cause engagement of the second bearing assembly with the first bearing assembly, the second bearing assembly including:
a plurality of polycrystalline diamond bearing elements distributed about an axis, each of the plurality of polycrystalline diamond bearing elements having a polycrystalline diamond material including a polycrystalline diamond bearing surface;
a reinforced portion that has a span angle defined by two reference lines intersecting at the axis, wherein a reinforced polycrystalline diamond bearing surface area is defined by each polycrystalline diamond bearing surface entirely within the span angle and any portion of any other polycrystalline diamond bearing surface partially within the first span angle; and
an unreinforced portion defined by a vertical angle of the span angle, wherein an unreinforced portion polycrystalline diamond bearing surface area is defined by each polycrystalline diamond bearing surface entirely within the vertical angle and any portion of any other polycrystalline diamond bearing surface partially within the vertical angle;
wherein the reinforced polycrystalline diamond bearing surface area is at least 8% greater than the unreinforced polycrystalline diamond bearing surface area; and
supporting a first portion of a total load by the reinforced portion and a second portion of the total load by the unreinforced portion.