Bearing assemblies, apparatuses, and motor assemblies using the same

Abstract

Bearing assemblies, apparatuses, and motor assemblies using the same are disclosed. In an embodiment, a bearing assembly may include a plurality of superhard bearing elements distributed circumferentially about an axis. Each of the superhard bearing elements may include a bearing surface. At least one of the plurality of superhard bearing elements may include at least one texture feature that may be formed in a lateral surface thereof. The bearing assembly may also include a support ring that carries the superhard bearing elements.

What is claimed is: 
     
         1 . A method for manufacturing a bearing assembly, the method comprising:
 forming a superhard bearing element that includes a superhard table bonded to a substrate, the superhard table defining a bearing surface and at least a portion of a lateral surface;   forming at least one texture feature in the lateral surface of the superhard bearing element, at least a portion of the at least one texture feature is formed in the superhard table; and   securing the superhard bearing element to a support ring.   
     
     
         2 . The method of  claim 1 , wherein the at least one texture feature is formed in the lateral surface of the at least one superhard bearing element before the at least one superhard bearing element is secured to the support ring. 
     
     
         3 . The method of  claim 1 , wherein forming the at least one texture feature includes at least one of laser-cutting or electro-discharge machining the at least one texture feature in the lateral surface. 
     
     
         4 . The method of  claim 1 , wherein forming the at least one texture feature in the bearing surface includes computer numerical control machining the at least one texture feature in the lateral surface. 
     
     
         5 . The method of claim of  claim 1 , wherein the at least one texture feature is effective to increase a surface area of the at least one of the plurality of superhard bearing elements in contact with fluid during operation. 
     
     
         6 . The method of  claim 1 , wherein the superhard table includes polycrystalline diamond. 
     
     
         7 . The method of  claim 1 , wherein the texture feature includes one or more grooves. 
     
     
         8 . The method of  claim 7 , where the texture feature follows a path substantially extending between the bearing surface of the at least one of superhard bearing elements and a bottom surface of the at least one of the plurality of superhard bearing elements. 
     
     
         9 . The bearing assembly of  claim 8 , wherein the path includes at least one of a generally curved path, a generally linear path, a generally semi-cylindrical path, or a generally helical curved path. 
     
     
         10 . The method of  claim 7 , wherein the one or more groves include two or more intersecting grooves. 
     
     
         11 . The bearing assembly of  claim 1 , wherein the at least one texture feature includes dimples, recesses, protrusions, or grooves. 
     
     
         12 . A method for manufacturing a bearing apparatus, the method comprising:
 forming a first bearing assembly including:
 forming a superhard bearing element that includes a superhard table bonded to a substrate, the superhard table defining a bearing surface and at least a portion of a lateral surface; 
 forming at least one texture feature in the lateral surface of the superhard bearing element, at least a portion of the at least one texture feature is formed in the superhard table; and 
 securing the superhard bearing element to a support ring; 
   forming a second bearing assembly including:
 securing to a plurality of second bearing elements to a second support ring, each of the plurality of second bearing elements including a second bearing surface; and 
   positioning the first bearing assembly and the second bearing assembly relative to each other such that the bearing surfaces of the first bearing assembly generally oppose the second bearing surfaces of the second bearing assembly.   
     
     
         13 . The method of  claim 12 , wherein the at least one texture feature is effective to increase a surface area of the at least one of the plurality of superhard bearing elements in contact with fluid during operation. 
     
     
         14 . The method of  claim 12 , wherein the first bearing assembly is configured as a rotor, and the second bearing assembly is configured as a stator. 
     
     
         15 . The method of  claim 12 , wherein at least one of the second plurality of superhard bearing elements includes at least one texture feature. 
     
     
         16 . The method of  claim 12 , wherein positioning the first bearing assembly and the second bearing assembly relative to each other forms a thrust-bearing apparatus or a radial bearing apparatus. 
     
     
         17 . A method of operating a bearing apparatus, the method comprising:
 rotating a first bearing assembly and a second bearing assembly relative to each other; and   directing flow of lubrication fluid over and/or around one or more superhard bearing elements of the first bearing assembly by influencing flow of lubrication fluid with at least one texture feature formed in the one or more superhard bearing elements, wherein the at least one texture feature is effective to increase a surface area of the one or more superhard bearing elements in contact with the lubrication fluid.   
     
     
         18 . The method of  claim 17 , wherein the at least one texture feature is formed in a lateral surface of the one or more superhard bearing elements. 
     
     
         19 . The method of  claim 17 , wherein the one or more superhard bearing elements include a superhard table bonded to a cemented carbide substrate, and the at least a portion of the at least one texture feature is formed in the superhard table. 
     
     
         20 . The method of  claim 17 , wherein the texture feature includes one or more grooves, and at least some of the one or more grooves include edge features configured to influence the lubrication fluid.