Hughes Tool Company, Cross-Appellant v. Dresser Industries, Inc., Cross-Appellee

816 F.2d 1549, 2 U.S.P.Q. 2d (BNA) 1396, 1987 U.S. App. LEXIS 207, 55 U.S.L.W. 2599
CourtCourt of Appeals for the Federal Circuit
DecidedApril 13, 1987
DocketAppeal 85-2471, 85-2502
StatusPublished
Cited by19 cases

This text of 816 F.2d 1549 (Hughes Tool Company, Cross-Appellant v. Dresser Industries, Inc., Cross-Appellee) is published on Counsel Stack Legal Research, covering Court of Appeals for the Federal Circuit primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
Hughes Tool Company, Cross-Appellant v. Dresser Industries, Inc., Cross-Appellee, 816 F.2d 1549, 2 U.S.P.Q. 2d (BNA) 1396, 1987 U.S. App. LEXIS 207, 55 U.S.L.W. 2599 (Fed. Cir. 1987).

Opinions

RICH, Circuit Judge.

This appeal is from the final amended judgment of March 11, 1985, of the United States District Court for the Northern District of Texas, Mahon, Judge, holding Hughes Tool Company’s (Hughes Tool) U.S. Patent No. 3,397,928 (’928 patent)1 valid and infringed by Dresser Industries, Inc. (Dresser), awarding damages in the amount of $132,096,430.92, and from orders denying various Dresser post-trial motions to reopen the record, amend the judgment, and for a new trial. We affirm in part, vacate in part, and remand.

I. Background

The ’928 patent claims in suit are directed to combinations of elements in a rock bit used in drilling oil and gas wells. Those combinations involve the use of a packing or seal of the O-ring type in the enclosed journal bearings of the rock bit cutters, wherein the O-ring is compressed by not less than 10% and preferably 15% of the thickness of the O-ring prior to its assembly.

A. Rock Bits

The first rolling cutter rock bit was invented in 1909 by Howard Hughes, Sr. The modern rock bit, the product of technical improvements made over the last seventy-five years to Mr. Hughes’ original, is a sophisticated piece of machinery costing up to several thousand dollars apiece. A rock bit, generally, is comprised of a supporting body structure or “head” to be threaded onto the lower end of a string of drill pipe, and carries three rotatable, generally conical cutters having either steel teeth or tungsten carbide insert (“TCI”) cutting elements. These conical cutters turn on internal bearings and are mounted on three shafts or axles on the head.

In drilling wells using rock bits, the drill pipe with the rock bit attached is lowered, section by section, into the drill hole and rotated under the great weight of the string against the bottom. This causes the bit to work against the rock formation, chipping or crushing the rock as the cones drag and roll upon the bottom of the hole. A drilling fluid, usually water or a thin mud, is pumped downward through the pipe, and emerges from nozzles in the bit, picking up cuttings loosened at the bottom of the hole. The cuttings are carried upward from under the bit outside the pipe to the surface.

Much of the time and expense of rotary drilling is spent in the process of “tripping” —removing a spent bit from the end of a drill pipe at the bottom of the hole and replacing it with a new one. When a rock bit fails, as it inevitably will, the drilling crew must raise the drill stem, uncouple and stack the ninety-foot pipe sections one at a time, substitute a new bit, then recou[1551]*1551pie and lower the pipe into the hole and resume drilling. In drilling wells of several thousand feet and more, the trip time required to change a bit may take up to ten or twelve hours, during which time no drilling gets done and injuries to the crew and other catastrophes such as blow-outs and well fires are most apt to occur.

The goal of rock bit engineers has thus been to increase the useful drilling life of the bit. There have been two primary approaches to solving that problem: improving the effectiveness and durability of the teeth or cutters, and prolonging the life of the bearings on which the cutters turn. Failure of either necessitates a “trip.” This case relates to bearings.

B. Bearings

The ’928 patent is directed to solving the bearing portion of the rock bit design problem. The ’928 patent discloses a design providing a bearing capacity which could outlast the life of the cutters.

Historically, there have been two main classes of bearings involved in rock bit technology: “journal” or “friction” bearings and “anti-friction” bearings which contain roller and possibly also ball bearings. Journal bearings are the simplest and sturdier form. The first rolling cutter rock bits dating from 1909 utilized journal bearings which were unsealed against grease loss and the intrusion of abrasive drilling fluid. The bearing was lubricated by a long lubricator sub-assembly from which grease flowed downward into the bearings and outward from the bottom of the bit. Various attempts were made during the early years to seal the journal bearings of Mr. Hughes’ original design. While a sealed bearing would have prevented the drilling fluid from entering the bearing and retained the lubricating grease in the bearing, none of the early attempts to seal journal bearings succeeded.

Due to the perceived inability to seal them, journal bearings were abandoned in the early 1930’s in favor of anti-friction roller bearings, which were better able to withstand the severe drilling environment without being sealed. In the original roller bearing bits, the drilling fluid was permitted to circulate through the roller bearings, a process known as “slush lubrication.” The roller bearing bit soon became the standard in the industry.

C. Seals

There were many problems in designing a sealed bearing rock bit, because of the severe conditions in which such bits operate — the very limited space available in a rock bit, the extreme weight and high temperatures at the bottom of the drill hole, and the rapid and peculiar movements of the cutters and shafts of the bits when slightly worn. An effective seal would have to possess both the resiliency to follow the erratic movements of the cutters but also be able to maintain an effective seal against changes in relative hydraulic pressures of the grease and drilling fluid.

Although the first patents disclosing sealed bearings were issued as early as 1918, it was not until the late 1950’s that the first successful sealed-bearing rock bits were developed. Those first commercially successful sealed bearing rock bits utilized the then conventional roller bearings, an internal supply of grease, and the so-called “Belleville” seal, disclosed in Hughes Tool’s Atkinson et al. U.S. Patent No. 3,075,781. The Belleville seal makes use of a saucer-shaped, annular, steel spring covered with rubber or plastic that surrounds the bearing shaft, providing continuous pressure against the opposed sealing surfaces of the head and cutter throughout the compound movements of the cutters during operation of the bit.

Although the Belleville-sealed bearing bits increased bit life dramatically, rock bit design engineers continued to work on improving bearing performance, hoping to design a bearing that would outlast the useful life of the cutters. Although synthetic rubber O-ring seals, which had developed rapidly in the World War II period, were known to be effective seals in other industrial applications, they were usually recommended for use only when the bearing surfaces to be sealed were free of abrasive substances and where movements such as [1552]*1552wobbling between the parts to be sealed would be small.

O-rings had been used as seals in rock-bit bearings before the present invention. Neilson U.S. Patent No. 3,127,942, issued in April, 1964 (Neilson patent) discloses a roller-bearing bit having an O-ring seal. Both U.S. Patent No. 2,075,997, issued to Clarence Reed in 1935 (Reed patent) and U.S. Patent No. 2,814,461, issued in 1957 to William Green (Green patent) relate specifically to a packing ring in a journal bearing bit.

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816 F.2d 1549, 2 U.S.P.Q. 2d (BNA) 1396, 1987 U.S. App. LEXIS 207, 55 U.S.L.W. 2599, Counsel Stack Legal Research, https://law.counselstack.com/opinion/hughes-tool-company-cross-appellant-v-dresser-industries-inc-cafc-1987.