Segmented Superhard Tilting Pads to Limit Bearing Fluid Leakage
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Solution Overview
Problem
Current superhard bearing materials, such as polycrystalline diamond compacts (PDCs), face limitations in size and production due to high-pressure/high-temperature (HPHT) processing constraints, making it challenging to produce large, high-quality PDCs for applications requiring larger tilting pads in mechanical systems like subterranean drilling and turbines.
Innovation Solution
The use of multiple superhard bearing segments, each with a superhard table bonded to a substrate, assembled to form a larger superhard bearing surface, allowing for the creation of larger tilting pads that exceed the size limitations of individual PDCs, with seams between segments minimizing fluid leakage and enhancing wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple superhard bearing segments are assembled to form larger tilting pads, then the size of tilting pads can exceed HPHT production limitations, but seams between segments may cause fluid leakage
Solution Approach 1:
The bearing surface is divided into multiple superhard bearing segments that are assembled together to form larger tilting pads, allowing the bearing elements to exceed the size limitations of individual HPHT-produced PDCs while maintaining the superhard properties throughout the bearing surface
Solution Approach 2:
A sealant material is introduced as an intermediary substance applied to the seams between adjacent superhard bearing segments to prevent fluid leakage, thereby eliminating the reliability issue associated with segmented construction while preserving the ability to create large bearing surfaces
2Ease of manufacture
If PDC bearing elements are brazed directly into preformed recesses, then assembly is simplified, but the size and quality of PDCs are constrained by HPHT processing limitations
Solution Approach 1:
Instead of requiring single large PDCs that exceed HPHT production capabilities, the bearing surface is segmented into multiple smaller PDC segments that can be individually produced within HPHT limitations and then assembled together to form the complete bearing element
Solution Approach 2:
The superhard bearing segments are pre-formed to precise dimensions and configurations before assembly, allowing for quality control and proper fit within the bearing assembly, ensuring that the preliminary manufacturing steps produce components that will function correctly when assembled
Data Source
AI summary
Tilting pad bearing assemblies and apparatuses are disclosed herein. The disclosed tilting pad bearing assemblies and apparatuses may be employed in downhole motors of a subterranean drilling system or other mechanical systems. In an embodiment, a bearing assembly or apparatus includes a support ring and a plurality of tilting pads. Each tilting pad is tilted and/or tiltably secured relative to the support ring. In some embodiments, one or more of the tilting pads include a plurality of superhard bearing segments assembled to form a superhard bearing surface. One or more seams may be positioned between adjacent superhard bearing segments of the superhard bearing segments. In other embodiments, one or more of the tilting pads may include at least one or only one superhard bearing segment, such as a polycrystalline diamond bearing segment.