Patents by Inventor Timothy N. Sexton
Timothy N. Sexton has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 9765819Abstract: 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. The bearing assembly may also include a support ring structure having a support ring that carries the superhard bearing elements. The support ring structure may include at least one erosion resistant region exhibiting a higher erosion resistance than another region of the support ring.Type: GrantFiled: September 16, 2015Date of Patent: September 19, 2017Assignee: US SYNTHETIC CORPORATIONInventor: Timothy N. Sexton
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Patent number: 9759264Abstract: Durability-enhanced 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 includes a bearing surface. The bearing assembly may further include a support ring structure that carries the plurality of superhard bearing elements. The support ring structure may have a first portion that exhibits a first yield strength and a second portion that exhibits a second yield strength. The first yield strength of the first portion may be greater than the second yield strength of the second portion.Type: GrantFiled: July 16, 2014Date of Patent: September 12, 2017Assignee: US SYNTHETIC CORPORATIONInventor: Timothy N. Sexton
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Publication number: 20170254358Abstract: Embodiments of the invention relate to tilting pad bearing assemblies and apparatuses. 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.Type: ApplicationFiled: May 19, 2017Publication date: September 7, 2017Inventors: Craig H. Cooley, Timothy N. Sexton
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Patent number: 9726222Abstract: Embodiments of the invention are directed to bearing assemblies configured to effectively provide heat dissipation for bearing elements, bearing apparatuses including such bearing assemblies, and methods of operating such bearing assemblies and apparatuses. In an embodiment, a bearing assembly includes a plurality of superhard bearing elements distributed about an axis. Each superhard bearing element of the plurality of superhard bearing elements has a superhard table including a superhard surface. The bearing assembly includes a support ring structure coupled to the plurality of superhard bearing elements. One or more of the superhard bearing elements includes a superhard table, which may improve heat transfer from such superhard bearing elements.Type: GrantFiled: May 4, 2015Date of Patent: August 8, 2017Assignee: U.S. Synthetic CorporationInventors: Jair Jahaziel Gonzalez, Timothy N. Sexton
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Patent number: 9702400Abstract: Embodiments of the invention relate to tilting pad bearing assemblies and apparatuses. 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.Type: GrantFiled: August 20, 2014Date of Patent: July 11, 2017Assignee: US SYNTHETIC CORPORATIONInventors: Craig H. Cooley, Timothy N. Sexton
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Publication number: 20170146060Abstract: In an embodiment, a bearing assembly may include a support ring to which one or more superhard bearing elements may be mounted. The support ring may include one or more relief features configured to reduce residual stresses in the superhard bearing elements that are induced by brazing the superhard bearing elements to the support ring, operational loads, other processes, or combinations of the foregoing. Reducing the residual stresses in the superhard bearing elements may help prevent damage to the superhard bearing elements. The bearing assembly may be used in subterranean drilling systems and/or other types of systems.Type: ApplicationFiled: February 8, 2017Publication date: May 25, 2017Inventors: Craig H. Cooley, Timothy N. Sexton
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Publication number: 20170097044Abstract: Bearing apparatuses including contacting bearing surfaces comprising superhard materials are disclosed. In one embodiment, the present invention relates to bearings including polycrystalline diamond inserts or compacts defining a plurality of surfaces that move relative to one another and contact one another. For example, apparatuses may include radial bearings, or other bearings including arcuate bearing surfaces that more in relation to one another, without limitation. In one embodiment, a superhard bearing element may comprise a superhard table (e.g., polycrystalline diamond) forming an arcuate bearing surface. Further, such a superhard bearing element may comprise a chamfer formed about at least a portion of a periphery of the arcuate bearing surface. Bearing apparatuses including such bearing elements and various mechanical systems are disclosed.Type: ApplicationFiled: December 22, 2016Publication date: April 6, 2017Applicant: US Synthetic CorporationInventors: Craig H. Cooley, Timothy N. Sexton
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Patent number: 9611885Abstract: Embodiments to bearing apparatuses for placement into a borehole containing a drilling fluid in which the apparatus is configured for transferring heat to the drilling fluid from a lubricating fluid substantially sealed within the apparatus. The apparatus includes a substantially sealed housing, first and second bearing assemblies disposed about a rotatable shaft extending through the housing, where the bearing assemblies are within the substantially sealed housing. Each bearing assembly includes superhard bearing elements. One bearing assembly is fixed relative to the shaft so as to rotate therewith, while another bearing assembly is fixed relative to the housing. In an embodiment, a lubricating fluid for lubricating the superhard bearing elements may circulate from within a circulation cavity of the housing or shaft between the superhard bearing elements, and be recirculated back into the circulation cavity. In other embodiments, the lubricating fluid may not be recirculated.Type: GrantFiled: February 26, 2013Date of Patent: April 4, 2017Assignee: US SYNTHETIC CORPORATIONInventors: Craig H Cooley, Timothy N Sexton
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Patent number: 9599155Abstract: In an embodiment, a bearing assembly may include a support ring to which one or more superhard bearing elements may be mounted. The support ring may include one or more relief features configured to reduce residual stresses in the superhard bearing elements that are induced by brazing the superhard bearing elements to the support ring, operational loads, other processes, or combinations of the foregoing. Reducing the residual stresses in the superhard bearing elements may help prevent damage to the superhard bearing elements. The bearing assembly may be used in subterranean drilling systems and/or other types of systems.Type: GrantFiled: March 31, 2015Date of Patent: March 21, 2017Assignee: US SYNTHETIC CORPORATIONInventors: Craig H. Cooley, Timothy N. Sexton
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Patent number: 9573213Abstract: Apparatuses and methods are provided for manufacturing bearing assemblies. In accordance with one embodiment, a fixture is provided for use in brazing bearing elements to a bearing ring. The fixture comprises a substantially annular body and at least one or more force-applying mechanism associated with the annular body. The force applying mechanisms include a push rod disposed within a channel that is formed in the annular body, the push rod being displaceable within the channel. A biasing member is configured to bias the push rod in a radial direction relative to the annular body. In one embodiment, a plurality of force-applying mechanisms are circumferentially spaced about the substantially annular body. In one embodiment, the push rods extend radially inwardly from a peripheral surface of the body, while in another embodiment the push rods extend radially outwardly from peripheral surface of the body.Type: GrantFiled: November 16, 2015Date of Patent: February 21, 2017Assignee: US Synthetic CorporationInventors: Timothy N. Sexton, John Corradini
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Patent number: 9562561Abstract: Bearing apparatuses including contacting bearing surfaces comprising superhard materials are disclosed. In one embodiment, the present invention relates to bearings including polycrystalline diamond inserts or compacts defining a plurality of surfaces that move relative to one another and contact one another. For example, apparatuses may include radial bearings, or other bearings including arcuate bearing surfaces that more in relation to one another, without limitation. In one embodiment, a superhard bearing element may comprise a superhard table (e.g., polycrystalline diamond) forming an arcuate bearing surface. Further, such a superhard bearing element may comprise a chamfer formed about at least a portion of a periphery of the arcuate bearing surface. Bearing apparatuses including such bearing elements and various mechanical systems are disclosed.Type: GrantFiled: March 14, 2014Date of Patent: February 7, 2017Assignee: US Synthetic CorporationInventors: Craig H. Cooley, Timothy N. Sexton
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Patent number: 9429188Abstract: Bearing components, bearing assemblies and related methods are provided. In one embodiment, a bearing element includes a base layer and a polycrystalline diamond (PCD) layer comprising a plurality of PCD elements coupled with the base layer wherein each PCD element comprising a substrate and a diamond table. The plurality of PCD elements may be fit together to form a substantially continuous bearing surface. For example, the diamond tables may exhibit substantially square or rectangular geometries that are fit together to define the bearing surface. In other embodiments, the bearing elements may be spaced apart from one another. In other embodiments, the bearing element may include a single PCD element formed from a prefabricated PCD compact or cutting tool blank. Various bearing assemblies may incorporate such a bearing element including, for example, thrust bearings, journal bearings, and tilting pad bearing assemblies.Type: GrantFiled: February 3, 2015Date of Patent: August 30, 2016Assignee: US Synthetic CorporationInventors: S. Barrett Peterson, Craig H. Cooley, Timothy N. Sexton
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Patent number: 9382762Abstract: A subterranean drilling system may include a drill string and a rotary drill bit coupled to the drill string. The rotary drill bit may include a bit body and a cutting element coupled to the bit body, with the cutting element being structured to rotate in response to torque applied to the cutting element. The system also may include a cam assembly coupled to the drill string, a cam follower assembly in contact with a cam surface of the cam assembly, and a torque-applying structure coupled to the cam follower assembly. The torque-applying structure may be configured to apply torque to the cutting element in response to relative rotation between the cam assembly and the cam follower assembly.Type: GrantFiled: December 4, 2014Date of Patent: July 5, 2016Assignee: US Synthetic CorporationInventors: Craig H. Cooley, Timothy N. Sexton, S. Barrett Peterson, Jeffrey Lund, Christopher F. Johnson
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Patent number: 9347484Abstract: Bearing assemblies and apparatuses are disclosed. Such bearing assemblies may be employed in bearing apparatuses for use in downhole motors of a subterranean drilling system or other mechanical systems. In an embodiment of the present invention, a bearing apparatus includes a first bearing assembly including a first substantially continuous polycrystalline diamond bearing surface defining an annular surface, and a second bearing assembly including a second substantially continuous polycrystalline diamond bearing surface defining an annular surface. The second substantially continuous polycrystalline diamond bearing surface generally opposes the first substantially continuous polycrystalline diamond bearing surface.Type: GrantFiled: May 2, 2014Date of Patent: May 24, 2016Assignee: US SYNTHETIC CORPORATIONInventors: Craig H. Cooley, Timothy N. Sexton
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Patent number: 9255605Abstract: Embodiments relate to tilting superhard bearing element bearing assemblies and apparatuses. The disclosed assemblies/apparatuses may be employed in downhole motors of a subterranean drilling system or other mechanical systems. In an embodiment, a bearing assembly may include a support ring and a plurality of superhard bearing elements each of which is tilted and/or tiltably secured relative to the support ring and distributed circumferentially about an axis. Each of the superhard bearing elements includes a bearing surface and a base portion. The base portion of the at least one of the superhard bearing elements may include a tilting feature configured to allow the at least one of the superhard bearing elements to be tiltable about a tilt axis. The bearing assembly includes retaining features that secure the superhard bearing elements to the support ring.Type: GrantFiled: February 3, 2015Date of Patent: February 9, 2016Assignee: US SYNTHETIC CORPORATIONInventors: S. Barrett Peterson, Craig H. Cooley, Timothy N. Sexton
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Patent number: 9249829Abstract: Bearing assemblies, apparatuses, and motor assemblies using the same are disclosed. In an embodiment, a bearing assembly includes a plurality of superhard bearing elements distributed circumferentially about an axis. At least some of the superhard bearing elements may include a first end surface, a second end surface generally opposite the first end surface, a first side surface extending between the first end surface and the second end surface, a second side surface generally opposite the first side surface, and a bearing surface extending between the first end surface, the second end surface, the first side surface and the second side surface. Such superhard bearing elements may also include a ramped feature negatively sloping away from the bearing surface. The bearing assembly may further include a support ring that carries the plurality of superhard bearing elements.Type: GrantFiled: January 8, 2014Date of Patent: February 2, 2016Assignee: US SYNTHETIC CORPORATIONInventors: Craig H. Cooley, Timothy N. Sexton
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Patent number: 9222512Abstract: Various embodiments of the invention relate to bearing assemblies, apparatuses and motor assemblies that include geometric features configured to impart a selected amount of heat transfer and/or hydrodynamic film formation. In an embodiment, a bearing assembly may include a plurality of superhard bearing pads distributed circumferentially about an axis. At least some of the plurality of superhard bearing pads may include a plurality of sub-superhard bearing elements defining a bearing surface. At least some of the plurality of sub-superhard bearing elements may be spaced from one another by one or more voids to impart a selected amount of heat transfer and hydrodynamic film formation thereon during operation. The bearing assembly may also include a support ring that carries the plurality of superhard bearing pads. In addition, at least a portion of the sub-superhard bearing elements may extend beyond the support ring.Type: GrantFiled: July 17, 2012Date of Patent: December 29, 2015Assignee: US SYNTHETIC CORPORATIONInventors: Timothy N. Sexton, Craig H. Cooley, Cody W. Knuteson
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Publication number: 20150369283Abstract: In an embodiment, a bearing apparatus comprises a first bearing assembly including a plurality of circumferentially-spaced first bearing elements each of which includes a first bearing surface. The bearing apparatus further includes a second bearing assembly including a plurality of circumferentially-spaced second bearing elements each of which includes a second bearing surface oriented to engage the first bearing surfaces of the first bearing assembly during operation. At least one of the second bearing elements may be circumferentially spaced from an adjacent one of the second bearing elements by a lateral spacing greater than a lateral dimension of the at least one of the second bearing elements.Type: ApplicationFiled: August 28, 2015Publication date: December 24, 2015Inventors: Timothy N. Sexton, Craig H. Cooley
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Patent number: 9188158Abstract: Apparatuses and methods are provided for manufacturing bearing assemblies. In accordance with one embodiment, a fixture is provided for use in brazing bearing elements to a bearing ring. The fixture comprises a substantially annular body and at least one or more force-applying mechanism associated with the annular body. The force applying mechanisms include a push rod disposed within a channel that is formed in the annular body, the push rod being displaceable within the channel. A biasing member is configured to bias the push rod in a radial direction relative to the annular body. In one embodiment, a plurality of force-applying mechanisms are circumferentially spaced about the substantially annular body. In one embodiment, the push rods extend radially inwardly from a peripheral surface of the body, while in another embodiment the push rods extend radially outwardly from peripheral surface of the body.Type: GrantFiled: January 8, 2015Date of Patent: November 17, 2015Assignee: US Synthetic CorporationInventors: Timothy N. Sexton, John Corradini
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Patent number: 9163660Abstract: 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. The bearing assembly may also include a support ring structure having a support ring that carries the superhard bearing elements. The support ring structure may include at least one erosion resistant region exhibiting a higher erosion resistance than another region of the support ring.Type: GrantFiled: January 8, 2013Date of Patent: October 20, 2015Assignee: US SYNTHETIC CORPORATIONInventor: Timothy N Sexton