Granted Patent B2

US 12,326,170 · App. 18/448,293 · Granted Jun 10, 2025

Inventors: David P. Miess (Magnolia, TX); Gregory Prevost (Spring, TX); Michael V. Williams (Conroe, TX); Edward C. Spatz (Spring, TX); Michael R. Reese (Houston, TX); William W. King (Houston, TX)

Assignee: XR Reserve LLC

F16C17/02F16C33/043F16C2206/04F16C2380/26

Abstract

Claims (38)

1. A bearing assembly, the bearing assembly comprising:

a component having a metal surface, the metal surface comprising a metal containing at least 2 wt. % of a diamond solvent or diamond catalyst based on a total weight of the metal;

a polycrystalline diamond element having a diamond surface;

wherein a contact area of the diamond surface is in sliding contact with the metal surface, and wherein the contact area is less than 80% of a total surface area of the diamond surface.

2. The bearing assembly of claim 1 , wherein the contact area is less than 75% of the total surface area of the diamond surface.

3. The bearing assembly of claim 1 , wherein the contact area is less than 70% of the total surface area of the diamond surface.

4. The bearing assembly of claim 1 , wherein the contact area is less than 60% of the total surface area of the diamond surface.

5. The bearing assembly of claim 1 , wherein the polycrystalline diamond element and the component are positioned to preclude contact between an edge of the diamond surface and the metal surface.

6. The bearing assembly of claim 1 , wherein the contact area of the diamond surface is a circular surface area.

7. The bearing assembly of claim 1 , wherein the contact area of the diamond surface is a linear surface area.

8. The bearing assembly of claim 1 , wherein the diamond solvent or diamond catalyst comprises iron, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, or tantalum.

9. The bearing assembly of claim 1 , wherein the diamond solvent or diamond catalyst comprises iron alloy.

10. The bearing assembly of claim 1 , wherein the metal is softer than a superhard material.

11. The bearing assembly of claim 1 , wherein the bearing assembly is a radial bearing assembly.

12. The bearing assembly of claim 1 , further comprising a rotor, wherein the component is a stator, and wherein the polycrystalline diamond element is coupled with the rotor.

13. The bearing assembly of claim 1 , further comprising a stator, wherein the component is a rotor, and wherein the polycrystalline diamond element is coupled with the stator.

14. A method of providing a bearing, the method comprising:

providing a component having a metal surface, the metal surface comprising a metal containing at least 2 wt. % of a diamond solvent or diamond catalyst based on a total weight of the metal;

providing a polycrystalline diamond element having a diamond surface;

engaging a contact area of the diamond surface with the metal surface, wherein the contact area is less than 80% of a total surface area of the diamond surface, and wherein the engaging includes avoiding contact of an edge of the diamond surface with the metal surface.

15. A system comprising:

a rotor;

a stator;

wherein one of the rotor and the stator comprises a metal surface, the metal surface comprising a metal containing at least 2 wt. % of a diamond solvent or diamond catalyst based on a total weight of the metal;

wherein the other of the rotor and the stator comprises a first plurality of polycrystalline diamond elements, wherein each polycrystalline diamond element of the first plurality of polycrystalline diamond elements has a diamond surface that is in sliding contact with the metal surface.

16. The system of claim 15 , further comprising a first ring, the first ring comprising the first plurality of polycrystalline diamond elements thereon.

17. The system of claim 16 , further comprising a second ring, the second ring comprising a second plurality of polycrystalline diamond elements, wherein each polycrystalline diamond element of the second plurality of polycrystalline diamond elements has a diamond surface that is in sliding contact with the metal surface.

18. The system of claim 17 , wherein the first ring is on a distal portion of the stator, and wherein the second ring is on a proximal portion of the stator.

19. The system of claim 17 , wherein the first and second rings are spaced apart.

20. The system of claim 15 , further comprising a drill string, wherein a proximal end of the stator is connected to the drill string.

21. The system of claim 15 , further comprising a motor housing, wherein a proximal end of the stator is connected to the motor housing.

22. The system of claim 15 , wherein a distal end of the rotor comprises a threaded connection configured for attachment of a drill bit.

23. The system of claim 15 , wherein a distal end of the rotor comprises a drill bit.

24. The system of claim 15 , wherein the rotor comprises the metal surface, and wherein the stator comprises the first plurality of polycrystalline diamond elements.

25. The system of claim 15 , wherein the stator comprises the metal surface, and wherein the rotor comprises the first plurality of polycrystalline diamond elements.

26. The system of claim 15 , wherein the diamond solvent or diamond catalyst comprises iron, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, or tantalum.

27. The system of claim 15 , wherein the diamond solvent or diamond catalyst comprises iron alloy.

28. The system of claim 15 , wherein the metal is softer than a superhard material.

Assignments (2)

Continuity (4)

References Cited (389)