A deepwater connector apparatus for introducing high current into a high voltage environment

Abstract

This invention relates to the field of extreme environment manufacturing technology, and more specifically to a deep-water connector device for introducing high current into high-voltage environments. It includes a deep-water connector body, a sealing assembly, and a power transmission assembly. The deep-water connector body is used for device installation and ensures the correct relative positions of the sealing assembly and the power transmission assembly. The sealing assembly provides insulation between the deep-water connector body and the power transmission assembly during assembly and provides sealing protection during device operation. The power transmission assembly forms a high-current conduction path. The deep-water connector body has end-face sealing ring grooves and battery cell channels. The device can be installed and connected using one or more of threaded connections, flange connections, and welded connections. This device can be applied to deep-water and other high-voltage environments, providing equipment support for in-situ welding and repair of metal components in deep wells and deep-water extreme environments, and providing a reference for high-current application scenarios in high-voltage environments.

Description

Technical Field

[0001] This invention relates to the field of extreme environment manufacturing technology, and more specifically to a deep-water connector device that introduces high current into a high-voltage environment. Background Technology

[0002] In deep-sea engineering fields such as offshore oil and gas extraction, underwater welding, and underwater power transmission, it is often necessary to safely and efficiently transmit high currents to deep-sea environments via cables. As a core component connecting surface power supply systems and underwater power equipment, the performance and reliability of deep-water joints directly determine the stable operation and operational capability of the entire underwater energy system.

[0003] However, existing deep-water joint technologies still have significant shortcomings in terms of the synergistic adaptation of high current transmission capacity and high-pressure deep-water environments. Traditional underwater cable joints mostly rely on basic mechanical seals and single insulation structure designs, which can meet the requirements in shallow water or low-pressure conditions. However, as the water depth increases, the hydrostatic pressure rises sharply, and conventional sealing structures are prone to seal failure due to pressure penetration or material creep, which in turn causes leakage of the insulating medium, resulting in serious faults such as short circuits or insulation breakdown.

[0004] Furthermore, when the connector carries a large current (>200A) for a long time, the Joule heating effect caused by the conductor resistance and contact resistance is significant. If the heat dissipation design is insufficient, the internal temperature of the connector will continue to rise, which will not only accelerate the thermal aging and performance degradation of the sealing material, but also cause carbonization of the insulating material and a decrease in dielectric properties, further weakening the long-term reliability of the connector under high-voltage conditions.

[0005] Therefore, in the face of the increasing demand for high-power power access in deep-sea energy development and high-end underwater equipment, there is an urgent need to develop a new type of deep-sea connector device with excellent sealing performance, efficient heat dissipation capacity and strong insulation structure to ensure the stable transmission of high current in deep-sea high-pressure environment, which has become one of the key technologies to promote the development of deep-sea engineering equipment. Summary of the Invention

[0006] In view of this, the technical problem to be solved by the present invention is to provide a deep-water connector device that introduces a large current into a high-pressure environment. This device can be applied to deep water and other high-pressure environments, providing equipment support for in-situ welding and repair of metal parts in deep wells and extreme deep-water environments, and providing a reference for high-current application scenarios in high-pressure environments.

[0007] A deep-water connector device includes a deep-water connector body, a sealing assembly, and a power transmission assembly. The deep-water connector body is used for device installation and ensures the correct relative positions of the sealing assembly and the power transmission assembly. The sealing assembly provides insulation between the deep-water connector body and the power transmission assembly during assembly and provides sealing protection during device operation. The power transmission assembly forms a high-current conduction path.

[0008] The deep-water connector body has an end face sealing ring groove and a battery cell channel. The installation and connection methods of the device include one or more of threaded connection, flange connection, and welding connection.

[0009] The sealing assembly includes a low-pressure side positioning rubber ring, a low-pressure side sealing packing, an end face sealing ring, an insulating gasket, a high-pressure side sealing packing, and a high-pressure side positioning rubber ring.

[0010] The power transmission component includes a low-voltage side terminal, a battery cell, and a high-voltage side terminal.

[0011] The low-pressure side positioning rubber ring is located on the upper end of the low-pressure side sealing packing and is used to keep the battery cell and the battery cell channel coaxial during the assembly process.

[0012] The low-pressure side sealing filler is a high-viscosity, high-pressure resistant, and high-temperature resistant material. It is located below the low-pressure side positioning rubber ring and above the insulating gasket, wrapping the small diameter of the battery cell and sealingly connecting it to the main body of the deep-water connector.

[0013] The end face sealing ring is embedded in the end face sealing ring groove of the deep water connector body.

[0014] The insulating gasket is located between the cell shoulder and the cell channel shoulder of the deep-water connector body.

[0015] The high-pressure side sealing packing and the low-pressure side sealing packing are made of the same material and are located above the high-pressure side positioning rubber ring and below the insulating gasket; the high-pressure side positioning rubber ring is located at the lower end of the high-pressure side sealing packing.

[0016] The low-voltage side terminal is fixedly connected to the upper end of the battery cell by bolts; the battery cell is inserted into the battery cell channel of the deep-water connector body, and the sealing assembly is provided between the battery cell and the battery cell channel; the lower end of the battery cell is fixedly connected to the high-voltage side terminal by bolts.

[0017] The beneficial effects of this invention are:

[0018] This invention overcomes the bottleneck of synergistic technology between high-pressure sealing and high-current transmission, achieving highly reliable power supply under extreme environments. Traditional deep-water connectors often struggle to balance high-pressure sealing and high-current carrying capacity. This invention optimizes the contact interface design by employing a special composite material with sealing glass as the main component and incorporating a mutually cooperating axial limiting shoulder structure between the deep-water connector body and the battery cell. Combined with a pressure self-compensating sealing mechanism, it significantly reduces contact resistance while ensuring withstands extreme external pressures >100MPa, effectively suppressing the Joule heating effect caused by high currents >200A. The low thermal resistance of the special composite material and the insulating and pressure-resistant properties of the sealing filler, combined with the effective constraint of the axial displacement of the battery cell by the shoulder interlocking structure, achieve long-term stability of the contact interface from both material and structural levels. The high thermal conductivity of the special composite material provides an effective path for heat dissipation under high current conditions, while the shoulder interlocking structure avoids damage to the sealing filler and fluctuations in the contact state caused by pressure difference, suppressing excessive Joule heat accumulation from the source. The synergistic effect of the two enables the invention to maintain a low contact resistance state under high current transmission conditions, achieving efficient heat dissipation and long-term reliable operation in extreme high-pressure environments. This design fundamentally solves the problem of material aging and sealing performance degradation caused by temperature rise, achieving high safety and long-term stability of energy transmission in deep-sea and deep-earth high-pressure environments.

[0019] Integrating a modular structure and rapid docking capabilities, this invention significantly improves engineering efficiency and system maintainability. Employing a standardized, modular interface design, it supports plug-and-play rapid connection and disconnection in underwater or well environments, significantly shortening the deployment, retrieval, and maintenance cycle of equipment. This structure not only reduces reliance on specialized tools and complex operations but also enhances the system's deployment flexibility and reconfigurability in harsh marine environments, providing an efficient and reliable power access solution for deep-sea exploration and underwater production systems. Attached Figure Description

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and specific implementation methods.

[0021] Figure 1 A schematic diagram of the overall structure of the deep-water joint device;

[0022] Figure 2 A schematic diagram of the exploded structure of a deep-water joint device;

[0023] Figure 3 This is a cross-sectional view of the deep-water joint device;

[0024] Figure 4 Cross-sectional view of the main body and sealing components of the deep-water connector;

[0025] Figure 5 This is a schematic diagram of the power transmission assembly structure for a deep-water joint.

[0026] In the figure: Deep water connector body 1; sealing assembly 2; low-pressure side positioning rubber ring 2.1; low-pressure side sealing filler 2.2; end face sealing ring 2.3; insulating gasket 2.4; high-pressure side sealing filler 2.5; high-pressure side positioning rubber ring 2.6; power transmission assembly 3; low-pressure side terminal 3.1; battery cell 3.2; high-pressure side terminal 3.3. Detailed Implementation

[0027] The present invention will be described in detail with reference to the accompanying drawings in the embodiments of the present invention.

[0028] This invention mainly consists of three parts: a deep-water connector body 1, a sealing component 2, and a power transmission component 3. The deep-water connector body 1 is used for device installation and ensures the correct relative positions of the sealing component 2 and the power transmission component 3. The sealing component 2 is used to achieve insulation between the deep-water connector body 1 and the power transmission component 3 during assembly, as well as sealing protection during device service. The power transmission component 3 is used to form a high-current conduction path. The whole is designed with a modular structure, supporting rapid docking and disassembly, which facilitates installation and maintenance on the engineering site.

[0029] See appendix Figure 1-5 , Figure 5 The dashed line in the middle represents the direction of the current.

[0030] The deep-water connector body 1 serves as the basic support component of the device. Its structural features include an open battery cell channel and an end face sealing ring groove. The battery cell channel provides space for the installation of the power transmission component 3 and the sealing component 2, and the end face sealing ring groove is used to embed the end face sealing ring 2.3. The entire device is installed and fixed by threads, adapting to the installation requirements of different engineering scenarios. At the same time, the deep-water connector body 1 and the battery cell 3.2 are respectively provided with mutually cooperating axial limiting shoulder structures. After assembly, the two form a mechanical interlock, which can directly bear the axial load of the external pressure difference acting on the battery cell 3.2, effectively preventing the battery cell 3.2 from displacing to the low-pressure side and avoiding damage to the sealing packing.

[0031] This device is a general-purpose device that can introduce large current into a high-pressure environment. The low-pressure side refers to a scenario with lower environmental pressure, and the high-pressure side refers to a scenario with higher environmental pressure. Its core function is to introduce large current from the low-pressure side to the high-pressure side. There are no specific limitations on the devices connected to the low-pressure side and the high-pressure side. It generally refers to power supply and power consumption equipment that operates in the corresponding pressure environment.

[0032] The sealing component 2 is a multi-stage sealing and insulation structure, specifically including a low-pressure side positioning rubber ring 2.1, a low-pressure side sealing filler 2.2, an end face sealing ring 2.3, an insulating gasket 2.4, a high-pressure side sealing filler 2.5, and a high-pressure side positioning rubber ring 2.6. Among them, the low-pressure side sealing filler 2.2 and the high-pressure side sealing filler 2.5 are the same special composite material, the main component of which includes sealing glass, and the auxiliary materials include alumina ceramic powder and high-temperature curing agent filler. By mass, the sealing glass accounts for 60%-70%, the alumina ceramic powder accounts for 15%-20%, and the remainder is high-temperature curing agent and trace additives. It is suitable for glass sintering sealing process, and after curing, it has high insulation, high pressure resistance and good thermal conductivity. After curing, the composite material has high volume resistivity, excellent high pressure stability and good thermal conductivity, providing a material basis for heat dissipation under high current conditions.

[0033] The low-pressure side positioning rubber ring 2.1 is located on the upper end of the low-pressure side sealing filler 2.2. It is used to keep the battery cell 3.2 and the battery cell channel coaxial during the assembly process, and to ensure that the insulation distance between the battery cell 3.2 and the deep water connector body 1 is uniform, so as to avoid the risk of breakdown caused by insufficient local insulation thickness.

[0034] The low-pressure side sealing filler 2.2 is located below the low-pressure side positioning rubber ring 2.1 and above the insulating gasket 2.4. It is a special composite material with high viscosity, high pressure resistance, and high temperature resistance. It wraps around the small diameter of the battery cell 3.2 and is sealed to the deep water connector body 1. It is used to ensure the insulation between the small diameter of the battery cell 3.2 and the deep water connector body 1 and to provide high-pressure sealing protection during the service of the device.

[0035] The end face sealing ring 2.3 is embedded in the end face sealing ring groove of the deep water connector body 1 to achieve high pressure sealing of the mounting end face of the deep water connector body 1 and prevent external high pressure medium from penetrating into the device from the mounting surface.

[0036] The insulating gasket 2.4 is located between the shoulder of the battery cell 3.2 and the shoulder of the battery cell channel of the deep-water connector body 1. This prevents the battery cell 3.2 from moving towards the low-voltage side due to the huge pressure difference between the high and low voltage sides during the operation of the device, which would affect the insulation performance between the battery cell 3.2 and the deep-water connector body 1. At the same time, it achieves insulation isolation at the shoulder.

[0037] This invention improves the transmission stability of the battery cell by optimizing the contact interface design. Axial limiting shoulder structures that cooperate with each other are set on the deep-water connector body and the battery cell, forming a mechanical interlock after assembly. When an external pressure difference is applied to the battery cell, this interlock structure directly bears the axial load, effectively preventing the battery cell from shifting to the low-pressure side or "ejecting," avoiding impact damage to the sealing packing, and providing stable installation boundary conditions for the sealing assembly. This ensures that the sealing packing is always within the design compression range, preventing fluctuations in the sealing gap caused by battery cell movement, and structurally guaranteeing the long-term stability and low resistance characteristics of the contact interface.

[0038] This invention achieves long-term stability of the contact interface from both material and structural perspectives by combining the low thermal resistance of special composite materials with the insulating and pressure-resistant properties of the sealing filler, and the effective constraint of the 3.2 axial displacement of the battery cell by the shoulder interlocking structure. The high thermal conductivity of the special composite materials provides an effective path for heat dissipation under high current conditions, while the shoulder interlocking structure avoids damage to the sealing filler and fluctuations in the contact state caused by pressure difference, thus suppressing excessive Joule heat accumulation from the source. The synergistic effect of these two components enables the invention to maintain a low contact resistance state under high current transmission conditions. The introduction of a pressure self-compensating sealing mechanism achieves efficient heat dissipation and long-term reliable operation in extreme high-pressure environments.

[0039] The high-pressure side sealing packing 2.5 is made of the same material and has the same proportion as the low-pressure side sealing packing 2.2. It is located above the high-pressure side positioning rubber ring 2.6 and below the insulating gasket 2.4. It is used to ensure the insulation between the large diameter of the battery cell 3.2 and the deep-water connector body 1 and the high-pressure sealing protection during the service of the device. It forms a double-layer packing seal with the low-pressure side sealing packing 2.2 to improve the sealing reliability.

[0040] The high-voltage side positioning rubber ring 2.6 is located at the lower end of the high-voltage side sealing filler 2.5. During the assembly process, it keeps the battery cell 3.2 and the battery cell channel coaxial. It cooperates with the low-voltage side positioning rubber ring 2.1 to achieve bidirectional coaxial positioning of the battery cell 3.2 and ensure that the sealing filler uniformly wraps the battery cell 3.2.

[0041] The power transmission component 3 is the core component for high current transmission, including a low-voltage side terminal 3.1, a battery cell 3.2, and a high-voltage side terminal 3.3. The low-voltage side terminal 3.1 is used to connect wires operating in low-voltage environments, and the high-voltage side terminal 3.3 is used to connect wires operating in high-voltage environments. It is a universal wiring design that can adapt to various engineering power needs.

[0042] The low-voltage side terminal 3.1 is fixedly connected to the upper end of the battery cell 3.2 by bolts. The connection is firm and the contact resistance is low, ensuring stable input of large current.

[0043] The battery cell 3.2 is inserted into the battery cell channel of the deep-water connector body 1. The sealing component 2 is installed between the battery cell 3.2 and the battery cell channel. The upper end is connected to the low-voltage side terminal 3.1 and the lower end is connected to the high-voltage side terminal 3.3. It is the core conductor for high current transmission and is used to form a complete current path. The battery cell 3.2 and the shoulder structure of the deep-water connector body 1 form a mechanical interlock, which effectively prevents axial movement and ensures low resistance of the contact interface and stability of the sealing structure.

[0044] The high-voltage side terminal 3.3 is fixedly connected to the lower end of the battery cell 3.2 by bolts. The connection is firm and the contact resistance is low, ensuring a stable output of large current to the high-voltage side equipment.

[0045] Device usage steps

[0046] Selection and Assembly:

[0047] Based on the high current transmission requirements and high voltage environment parameters of the actual project, the key dimensions of cell 3.2 are calculated and suitable conductive materials are selected to ensure the current carrying capacity and structural strength of cell 3.2. Based on the material of cell 3.2 and the actual service conditions, the key dimensions of low-voltage side positioning rubber ring 2.1, low-voltage side sealing filler 2.2, end face sealing ring 2.3, insulating gasket 2.4, high-voltage side sealing filler 2.5, and high-voltage side positioning rubber ring 2.6 are calculated and suitable materials are selected. Among them, low-voltage side sealing filler 2.2 and high-voltage side sealing filler 2.5 are prepared according to a predetermined ratio. The core component includes sealing glass, and the auxiliary materials include alumina ceramic powder and high-temperature curing agent filler.

[0048] After all components are prepared, assembly begins. First, assemble the deep-water connector body 1, battery cell 3.2, low-voltage side positioning rubber ring 2.1, insulating gasket 2.4, and high-voltage side positioning rubber ring 2.6 according to… Figure 3 The positional relationship shown completes the initial assembly, ensuring the initial coaxiality of cell 3.2 and cell channel; then, the prepared low-voltage side sealing filler 2.2 and high-voltage side sealing filler 2.5 are filled into the cells respectively. Figure 3 At the corresponding positions shown, during the filling process, check and fine-tune the position of battery cell 3.2 to ensure it is completely coaxial with the battery cell channel of the deep-water connector body 1, avoiding excessively low local thickness of the sealing filler which increases the risk of insulation breakdown; after the low-voltage side sealing filler 2.2 and the high-voltage side sealing filler 2.5 are completely cured, proceed according to... Figure 3 Assemble the remaining parts as shown to complete the overall assembly of the device.

[0049] Installation and key performance checks:

[0050] The assembled device is installed on the high-pressure reactor with the high-pressure side terminal 3.3 facing the high-pressure side of the actual service environment via threads. The high-pressure reactor is a device with an internal pressure much higher than atmospheric pressure. It is often used for catalysis, high-temperature and high-pressure synthesis, hydrogenation reactions and dynamic monitoring of chemical reactions. It is a common device with a large pressure difference between the inside and outside of the container. It is a typical application scenario for the device of this invention and can simulate the actual high-pressure service environment of deep sea and deep well.

[0051] Connect the low-voltage side terminal 3.1 to the low-voltage side power supply equipment with a wire. Similarly, connect the high-voltage side terminal 3.3 to the high-voltage side test element to form a complete current loop, ensuring that all connections are secure and free from looseness or poor connection.

[0052] Performance testing is divided into sealing performance testing and insulation and conductivity performance testing:

[0053] Sealing performance check: Close the high-pressure reactor and gradually adjust the temperature and pressure environment parameters inside the reactor to the actual service level of the device through the pressure control and temperature control system of the reactor. Keep the environmental parameters stable and continuously observe whether there is any leakage of medium at the connection between the device and the reactor and at the sealing structure of the device itself. If there is no leakage, it proves that the sealing performance of sealing component 2 is good and can meet the sealing requirements of high-pressure environment.

[0054] Insulation and conductivity performance check: Connect a multimeter to the low-voltage side of the deep water connector body 1 to test the insulation performance of the device. Then turn on the switch of the test element to allow a large current to pass through the device to form a circuit. Observe for a period of time. If the multimeter reading is 0 and the test element responds normally, it proves that the insulation performance of the sealing component 2 is good and the conductivity performance of the power transmission component 3 is good. The device can achieve stable and safe transmission of large current under high voltage environment.

Claims

1. A deepwater connector apparatus, characterized by: The device includes a deep-water connector body, a sealing assembly, and a power transmission assembly. The deep-water connector body is used for device installation and ensures the correct relative positions of the sealing assembly and the power transmission assembly. The sealing assembly provides insulation between the deep-water connector body and the power transmission assembly during assembly and provides sealing protection during device operation. The power transmission assembly forms a high-current conduction path.

2. A deep water connection device according to claim 1, characterised in that: The deep-water connector body has an end face sealing ring groove and a battery cell channel. The installation and connection methods of the device include one or more of threaded connection, flange connection, and welding connection.

3. A deep-water connector device according to claim 2, characterized in that: The sealing assembly includes a low-pressure side positioning rubber ring, a low-pressure side sealing packing, an end face sealing ring, an insulating gasket, a high-pressure side sealing packing, and a high-pressure side positioning rubber ring.

4. A deep-water connector device according to claim 3, characterized in that: The power transmission component includes a low-voltage side terminal, a battery cell, and a high-voltage side terminal.

5. A deep-water connector device according to claim 3, characterized in that: The low-pressure side positioning rubber ring is located on the upper end of the low-pressure side sealing packing and is used to keep the battery cell and the battery cell channel coaxial during the assembly process.

6. A deep-water connector device according to claim 3, characterized in that: The low-pressure side sealing filler is a high-viscosity, high-pressure resistant, and high-temperature resistant material. It is located below the low-pressure side positioning rubber ring and above the insulating gasket, wrapping the small diameter of the battery cell and sealingly connecting it to the main body of the deep-water connector.

7. A deep-water connector device according to claim 3, characterized in that: The end face sealing ring is embedded in the end face sealing ring groove of the deep water connector body.

8. A deep-water connector device according to claim 3, characterized in that: The insulating gasket is located between the cell shoulder and the cell channel shoulder of the deep-water connector body.

9. A deep-water connector device according to claim 3, characterized in that: The high-pressure side sealing packing and the low-pressure side sealing packing are made of the same material and are located above the high-pressure side positioning rubber ring and below the insulating gasket; the high-pressure side positioning rubber ring is located at the lower end of the high-pressure side sealing packing.

10. A deep-water connector device according to claim 3, characterized in that: The low-voltage side terminal is fixedly connected to the upper end of the battery cell by bolts; the battery cell is inserted into the battery cell channel of the deep-water connector body, and the sealing assembly is provided between the battery cell and the battery cell channel; the lower end of the battery cell is fixedly connected to the high-voltage side terminal by bolts.

Images