Diamond bearing with cooling/lubrication channels

Abstract

A thrust bearing comprises at least one diamond bearing segment, wherein the segment has a front surface and a back surface. A plurality of bearing pads extend a predetermined distance from the front surface, each of the plurality of bearing pads has a load surface substantially parallel to the front surface. The plurality of bearing pads act cooperatively to provide a load bearing surface area. The bearing pads are shaped and arranged in a predetermined pattern to enhance the load carrying surface area, and the predetermined pattern creates a plurality of flow micro-channels between the bearing pads. In another aspect, a thrust bearing comprises a diamond bearing surface, and a predetermined pattern of cavities formed in the diamond bearing surface for providing a fluid reservoir for lubricating and cooling the load surface.

What is claimed is:  
     
         1 . A diamond thrust bearing, comprising: 
 a. at least one diamond bearing segment, said segment having a front surface and a back surface; and    b. a plurality of bearing pads extending a predetermined distance from said front surface, each of said plurality of bearing pads having a load surface substantially parallel to said front surface, said plurality of bearing pads acting cooperatively to provide a load bearing surface area, said bearing pads shaped and arranged in a predetermined pattern to enhance the load carrying surface area, said predetermined pattern creating a plurality of flow micro-channels between said bearing pads.    
     
     
         2 . The thrust bearing of  claim 1 , wherein the plurality of bearing pads are integral with the bearing segment.  
     
     
         3 . The thrust bearing of  claim 1 , wherein the plurality of bearing pads comprise shaped diamond inserts mounted in said front surface.  
     
     
         4 . The thrust bearing of  claim 1 , further comprising at least one flow macro-channel providing fluid to cool and lubricate said bearing pads.  
     
     
         5 . The thrust bearing of  claim 1 , further comprising a second predetermined pattern formed on said back surface of said at least one diamond bearing segment for enhancing attachment to a support ring.  
     
     
         6 . The thrust bearing of  claim 1 , wherein the plurality of bearing pads are formed into said bearing segment by a pressing operation.  
     
     
         7 . The thrust bearing of  claim 1 , wherein the plurality of bearing pads are formed into said bearing segment by at least one of (i) electric discharge machining and (ii) laser ablation operation.  
     
     
         8 . The thrust bearing of  claim 1 , wherein the flow channels are formed to have a predetermined shape to reduce stresses at an intersection of said bearing element and said front surface.  
     
     
         9 . The thrust bearing of  claim 1 , wherein at least one edge of said load surfaces is shaped to enhance hydrodynamic lubrication of said load surface.  
     
     
         10 . The thrust bearing of  claim 1 , wherein each of the plurality of bearing pads has at least one cavity formed in said load surface of said bearing pad for providing a fluid reservoir for lubricating said load surface.  
     
     
         11 . The thrust bearing of  claim 4 , wherein the at least one macro-flow channel is located proximate at least one of (i) the front surface of said bearing segment and (ii) the back surface of said bearing segment.  
     
     
         12 . A diamond thrust bearing, comprising: 
 a. a diamond bearing surface; and    b. a predetermined pattern of cavities formed in said diamond bearing surface for providing a fluid reservoir for lubricating said load surface.    
     
     
         13 . A method of increasing the load capacity of a diamond bearing, comprising: 
 a. providing at least one diamond bearing segment having a front surface and a back surface; and    b. disposing a plurality of bearing pads having a predetermined shape in a predetermined pattern in the front surface of said at least one diamond bearing segment, said predetermined shape and said predetermined pattern substantially increasing a load bearing surface area of said diamond bearing, said predetermined shape and said predetermined pattern creating a plurality of flow micro-channels between said bearing pads for cooling said diamond bearing.    
     
     
         14 . The method of  claim 13 , wherein the step of disposing a plurality of bearing pads having a predetermined shape in a predetermined pattern in the front surface of said at least one diamond bearing segment includes forming said plurality of bearing pads as an integral part of said at least one diamond bearing segment.  
     
     
         15 . The method of  claim 13 , wherein the step of disposing a plurality of bearing pads having a predetermined shape in a predetermined pattern in the front surface of said at least one diamond bearing segment includes disposing shaped diamond inserts in said front surface.  
     
     
         16 . The method of  claim 13 , further comprising forming a second predetermined pattern on the back surface of said diamond bearing segment for attachment to a support ring.  
     
     
         17 . The method of  claim 13 , further comprising disposing at least one flow macro-channel proximate at least one of (i) the front surface of said diamond bearing segment and (ii) the back surface of said diamond bearing segment.  
     
     
         18 . The method of  claim 13 , further comprising forming at least one cavity in a load surface of each of said plurality of bearing pads for providing a fluid reservoir.  
     
     
         19 . The method of  claim 13 , further comprising shaping at least one edge of a load surface of each of said plurality of bearing pads to enhance hydrodynamic lubrication of said load surface.