CONNECTORS FOR HARSH ENVIRONMENTS

Description

FIELD OF USE

[0001] The present disclosure relates to connectors configured for use in harsh environments.BACKGROUND

[0002] Various types of connectors are known for providing electrical and / or optical connections in harsh environments. Examples include connectors for providing subsea electrical and / or optical connections in an oil and / or gas well environment. In the harsh environments, the connectors may be exposed to seawater and may experience pressures greater than 10,000 pounds per square inch (PSI). There are challenges with operating connectors in harsh environments.

[0003] Prior art document US6511335B1 discloses an electrical connector for use in providing power and data communications to electrical devices disposed in a wellbore. A metal-to-metal seal enclosing the male-to-female electrical contact area is disclosed, but the seal is not a spring activated seal. US2002 / 140184A1 discloses annular metal-to-metal seals for establishing pressure tight sealing engagement with one or more annular metal components. The metal-to-metal seal assembly has an elastic component providing a joint seal having a substantially constant radial sealing force.

[0004] Prior art document US2009194945A1 also discloses a metal to metal seal for use in downhole tools, the sealing device is spring energised and provides an ultra high pressure gas / fluid tight seal between concentric cylindrical members.SUMMARY

[0005] A connector not forming part of the claimed invention comprises a contact, a plunger, and a spring activated seal is provided. The contact is positioned within the housing and configured to transmit at least one of an electrical signal and an optical signal between the connector and a secondary device. The plunger is positioned within the housing and in communication with the contact. The spring activated seal comprises a flexible portion and a spring configured to urge the flexible portion to contact the housing and at least one of the plunger and a contact of the secondary device to form a fluid tight seal therebetween.

[0006] According to the invention as disclosed in claim 1, a connector comprising a housing, a contact, and a dual-lipped spring activated seal is provided. The contact is positioned within the housing and configured to transmit at least one of an electrical signal and an optical signal between the connector and a secondary device. The dual-lipped spring activated seal comprises a flexible portion comprising an electrically insulative material, and further a first spring, and a second spring. The flexible portion comprises a first concave portion and a second concave portion. The first spring is configured to urge the first concave portion to contact the housing and the secondary device to form a first fluid tight seal therebetween. The second spring is configured to urge the second concave portion to contact the housing and the secondary device to form a second fluid tight seal therebetween.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The features and advantages of the examples, and the manner of attaining them, will become more apparent, and the examples will be better understood, by reference to the following description taken in conjunction with the accompanying drawings, wherein: FIG. 1 is a front cross-sectional view of a portion of a non-limiting embodiment of a connector according to the present disclosure; FIG. 2A is a front cross-sectional view of the connector of FIG. 1 and a secondary connector in an unengaged configuration; FIG. 2B is a front cross-sectional view of the connector and the secondary connector of FIG. 2B in an engaged configuration; FIG. 3 is a detailed view of region A of the connector of FIG. 1; FIG. 4 is a perspective view of a non-limiting embodiment of a spring activated seal according to the present disclosure; FIG. 5 is a perspective view of a non-limiting embodiment of a spring activated seal according to the present disclosure; and FIG. 6 is a perspective view of a non-limiting embodiment of a dual-lipped spring activated seal according to the present disclosure.

[0008] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate certain embodiments, in one form, and such exemplifications are not to be construed as limiting the scope of the appended claims in any manner.DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0009] Various embodiments are described and illustrated herein to provide an overall understanding of the structure, function, and use of the disclosed apparatus. The various embodiments described and illustrated herein are non-limiting and non-exhaustive. Thus, an invention is not limited by the description of the various non-limiting and non-exhaustive embodiments disclosed herein. Rather, the invention is defined solely by the claims. The features and characteristics illustrated and / or described in connection with various embodiments may be combined with the features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. As such, the claims may be amended to recite any features or characteristics expressly or inherently described in, or otherwise expressly or inherently supported by, this specification. Further, Applicant reserves the right to amend the claims to affirmatively disclaim features or characteristics that may be present in the prior art. The various embodiments disclosed and described in this specification can comprise, consist of, or consist essentially of the features and characteristics as variously described herein.

[0010] The particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, or characteristics of one or more other embodiments without limitation. Such modifications and variations are intended to be included within the scope of the present embodiments.

[0011] As used herein, the term "subsea" means an environment under the surface of a body of water, such as, for example, the surface of an ocean, the surface of a lake, or the surface of a river. For example, a subsea environment can be at least 1 foot below a surface of a body of water, such as, for example, at least 10 feet below the surface, at least 100 feet below the surface, at least 1,000 feet below the surface, or at least 10,000 feet below the surface of a body of water.

[0012] As used herein, "wet-mateable" as applied to a connector means that the connector portions (e.g., pin and receptacle) can be mated (e.g., connected together) underwater.

[0013] Downhole electrical and / or optical connectors (e.g., a plug and a receptacle of wet-mateable connectors) can be used in harsh environments, such as, for example, subsea oil and gas well environments. A first connector can be connected to downhole equipment (e.g., pumps, sensors), while a second connector can be at the end of a power supply cable or signal communication cable, such as, for example, a tubing hanger. The first and second connectors can be mated and unmated at a location downhole and / or subsea in order to reliably connect electrical and / or optical signals to downhole equipment. In these applications, the connectors may be exposed to fluids, such as, for example, seawater, completion fluids, brines, petroleum fluids, which can corrode a portion of the connector and / or interfere with the electrical and / or optical signal. Thus, it can be desirable to inhibit fluids from entering the connectors and / or the connection between connectors, and / or ensure optimal transmission of the electrical and / or optical signal between the connectors.

[0014] Additionally, in subsea applications, the connectors may experience high pressures such as, for example, pressures greater than 10,000 PSI (69 Megapascals (MPa)). The high pressure can urge the fluids to enter conventional connectors and corrode or otherwise interfere with the electrical and / or optical signal. For example, a conventional connector comprising an elastomeric O-ring seal may experience a failure of the elastomeric O-ring seal at pressures greater than, for example, 10,000 PSI (69 MPa). In connectors comprising a pressure compensation chamber, the elastomeric O-ring may be exposed to pressures of 10,000 PSI (69 MPa) or greater from two directions (e.g., from the external environment and internally due to the pressure compensation). Thus, the O-ring in the conventional connector may be compressed from both directions and thereby lose sealing contact with a portion of the conventional connector, which can enable seawater to enter the conventional connector and / or interfere with the electrical and / or optical signal.

[0015] In view of the aforementioned issues, the present disclosure provides a connector that can operate at a pressure of at least 10,000 PSI (69 MPa) and can inhibit fluids from entering the connector and / or the connection between connectors. The connector comprises a housing, a contact, a plunger, and a spring activated seal. The contact is positioned within the housing and configured to transmit at least one of an electrical signal and an optical signal between the connector and a secondary device. The plunger is positioned within the housing and is in communication with the contact. The spring activated seal comprises a flexible portion and a spring configured to urge the flexible portion to contact at least one of the housing and at least one of the plunger and a contact of the secondary device to form a fluid tight seal therebetween.

[0016] Referring to FIGs. 1 and 2A-B, an embodiment not forming part of the claimed invention is shown. As illustrated, the connector 100 is a plug. It is contemplated that the teachings of the present disclosure are equally applicable to a connector in the form of a receptacle. The connector comprises a first end 100a (e.g., action end) and a second end 100b (e.g., static end). The first end 100a of the connector 100 is configured to be received by a secondary device, such as secondary device 200 illustrated in FIGs. 2A-B and described herein (e.g., a mating connector such as a receptacle).

[0017] The connector 100 can comprise a housing 102, a contact 104 (e.g., conductive element), a plunger 106, a spring activated seal 108, a spring activated seal 110, an inner housing 112, and an outer housing 140. The housing 102 can comprise a bore therethrough forming a cavity therein. The cavity of the housing 102 can be configured to receive the contact 104, plunger 106, spring activated seal 108, spring activated seal 110, and inner housing 112. The cavity of the housing 102 can be separated from the external environment by the spring activated seal 110. The cavity of the housing 102 can be filled with a dielectric fluid 128, such as, for example, silicone oil. The dielectric fluid 128 can maintain proper transmission of the electrical and / or optical signal through the connector 100.

[0018] The connector 100 can be a pressure compensated connector. For example, the connector 100 can comprise a moveable member 142, such as, for example, a piston, bellows, and / or an elastomeric wall. A first side 142a of the moveable member 142 can be in communication with the environment external to the connector 100a via ports 144. For example, in operation, the first side 142a can be in contact with seawater. A second side 142b of the moveable member 142 can be in contact with the dielectric fluid 128. The moveable member can move (e.g., inwards, outwards) responsive to a change in the surrounding pressure and / or temperature such that the pressure within the cavity of the housing 102 is substantially the same as the pressure of the external environment.

[0019] The inner housing 112 can comprise a bore therethrough forming a cavity therein. The cavity of the inner housing 112 can be separated from the dielectric fluid 128 by the spring activated seal 108. The cavity of the inner housing 112 can be configured to receive the contact 104, the plunger 106, and the spring activated seal 108. The cavity of the inner housing 112 can be filled with a dielectric fluid 126, such as, for example, silicone oil. The redundant spring activated seals, 108, 110, can ensure proper transmission of the electrical and / or optical signal through the connector 100.

[0020] The contact 104 can be positioned within the inner housing 112 proximal to the first end 100a of the connector 100. The contact 104 can be configured to transmit at least one of an electrical signal and an optical signal between the connector 100 and the secondary device 200. The contact 104 can be a springing contact and the contact 104 can be connected to a contact body 124 positioned within the inner housing 112.

[0021] The plunger 106 can be positioned within the inner housing 112 proximal to the first end 100a of the connector 100. The plunger 106 can comprise a first end 106a and a second end 106b. In the disengaged configuration of the connector 100, as illustrated in FIGs. 1 and 2A, the plunger 106 is in a first position. The first position of the plunger 106 can be maintained by a spring 114 configured to urge the plunger 106 towards the first end 100a of the connector 100, thereby contacting the spring activated seals 108, 110. The plunger 106 can be in communication with the contact 104. For example, in the first position of the plunger 106, the plunger 106 can be in contact with the contact 104.

[0022] Referring to FIGs. 2A-B, when the first end 100a of the connector 100 engages and / or mates with the secondary device 200, a contact 260 (e.g., a pin) of the secondary device 200 can urge the plunger 106 toward the second end 100b of the connector 100. For example, the contact 260 can contact the plunger 106 and overcome force applied to the plunger 106 by spring 114 in order to move the plunger 106 from the first position, as illustrated in FIGs. 1 and 2A, to a second position of the plunger 106, as illustrated in FIG. 2B. In the second position, the plunger 106 is not in contact with the spring activated seals 108, 110, and the contact 104. As illustrated in FIG. 2B, the contact 260 can be in contact with the spring activated seals 108, 110 and the contact 104, thereby establishing electrical and / or optical communication between the connector 100 and the secondary device 200.

[0023] Referring to FIGs. 2A-B, the spring activated seal 108 can be positioned within the inner housing 112 and configured to inhibit the dielectric fluid 126 from exiting the cavity of the inner housing 112. For example, the spring activated seal 108 can separate (e.g., isolate) the dielectric fluid 126 from the dielectric fluid 128 by forming a fluid tight seal between the cavity of the inner housing 112 and the cavity of the housing 102. A threaded nut 130 can be connected to the inner housing 112 and configured to retain the spring activated seal 108 within the cavity of the inner housing 112. The threaded nut 130 can be internally threaded and can engage threads (not shown) on the inner housing 112. The spring activated seal 108 can be in contact with a contact body 124 within the inner housing 112. In various non-limiting embodiments, a washer 132 can be positioned intermediate a portion of the threaded nut 130 and the spring activated seal 108. In various non-limiting embodiments, the connector 100 does not include the washer 132.

[0024] The spring activated seal 108 can comprise a flexible portion 116 and a spring 118 which can be configured to urge the flexible portion 116 to contact the inner housing 112 and the plunger 106 when the plunger 106 is in the first position, as illustrated in FIGs. 1 and 2A, to form a fluid tight seal therebetween. When the plunger 106 is in the second position, as illustrated in FIG. 2B, the spring 118 can be configured to urge the flexible portion 116 to contact the inner housing 112 and the contact 260 of the secondary device 200 to form a fluid tight seal therebetween. The fluid tight seal formed therein can inhibit the dielectric fluid 126 from exiting the cavity of the inner housing 112 and / or from intermixing with the dielectric fluid 128. As illustrated, in certain non-limiting embodiments a cross-section of the spring activated seal 108 can be generally torus shaped.

[0025] FIG. 4 is a perspective view of the spring activated seal 108. As illustrated, the spring activated seal 108 can be generally torus-shaped and can comprise a concave portion 408a configured to receive the spring 118. In various embodiments, the spring activated seal 108 also can comprise a protrusion 156 configured to contact the plunger 106 of the connector 100 and / or contact 260 of the secondary device 200 in order to scrape or otherwise remove debris from the plunger 106 and / or contact 260.

[0026] Referring yet again to FIGs. 2A-B, the spring activated seal 110 can be positioned within the housing 102 and configured to inhibit the dielectric fluid 128 from exiting the cavity the housing 102 and / or otherwise intermixing with the external environment. For example, the spring activated seal 110 can be configured to separate (e.g., isolate) the dielectric fluid 128 from an external environment outside of the connector 100 such as, for example, seawater 234. The spring activated seal 110 can be positioned within a relief portion 138 (e.g., counter-bore) of the housing 102. The spring activated seal 110 can be retained within the cavity of the housing 102 by a threaded nut 136 connected to the housing 102. The threaded nut 136 can be externally threaded and can engage threads (not shown) on the housing 102.

[0027] The spring activated seal 110 comprises a flexible portion 120 and a spring 122 which can be configured to urge the flexible portion 120 to contact the housing 102 and the plunger 106 when the plunger 106 is in the first position as illustrated in FIGs. 1 and 2A to form a fluid tight seal therebetween. When the plunger 106 is in the second position, as illustrated in FIG. 2B, the spring 122 can be configured to urge the flexible portion 120 to contact the housing 102 and the contact 260 of the secondary device 200 to form a fluid tight seal therebetween. The fluid tight seals formed therein can inhibit the dielectric fluid 128 from exiting the cavity of the housing 102 and / or otherwise intermixing with the external environment and can prevent ingress of external fluids. As illustrated, a cross-section of the spring activated seal 110 can be generally V-shaped.

[0028] FIG. 5 is a perspective view of a spring activated seal 110. As illustrated in FIG. 5, the spring activated seal 110 can comprise a concave portion 510a configured to receive the spring 118. In various embodiments, the spring activated seal 110 can comprise a protrusion 158 configured to contact the plunger 106 and / or contact 260 of the secondary device 200 in order to scrape or otherwise remove debris from the plunger and / or contact 260.

[0029] Referring to FIGs. 1 and 3, according to the invention a contact 164 is positioned within the outer housing 140 and configured to transmit at least one of an electrical signal and an optical signal between the connector 100 and a contact 362 of a secondary device 300. The connector 100 comprises a dual-lipped spring activated seal 146 comprising a flexible portion 148, a first spring 150, and a second spring 152. The flexible portion 148 can comprise a first concave portion 148a and a second concave portion 148b. The first spring 150 can be positioned within the first concave portion 148a and is configured to urge the first concave portion 148a to contact the outer housing 140 and the secondary device 300 to form a first fluid tight seal therebetween. The second spring 152 is configured to urge the second concave portion 148b to contact the outer housing 140 and the secondary device 300 to form a second fluid tight seal therebetween.

[0030] The dual-lipped spring activated seal 146 can be configured to inhibit the dielectric fluid 128 from exiting a connection cavity formed by the mating of the connector 100 and the secondary device 300 and / or otherwise mixing with the external environment. For example, the dual-lipped spring activated seal 146 can separate (e.g., isolate) the dielectric fluid 128 from the external environment outside of the connector 100 such as, for example, seawater 234. As illustrated, in certain embodiments a cross-section of the dual-lipped spring activated seal 146 can be generally X-shaped. FIG. 6 provides a perspective view of an embodiment of the dual-lipped spring activated seal 146.

[0031] Referring back to FIG. 3, a hat ring 356 and a hat ring 358 can be in contact with the dual-lipped spring activated seal 146 and the outer housing 140. The hat rings 356 and 358 can be configured to maintain a position of the dual-lipped spring activated seal 146 relative to the outer housing 140. For example, the dual-lipped spring activated seal 146 can be positioned intermediate the hat rings 356 and 358.

[0032] The flexible portions 116, 120, and 148 comprise each individually an electrically insulative material. In various embodiments, the flexible portions 116, 120, and 148 can each individually comprise at least one of a thermoplastic material and a thermoset material. For example, the flexible portions 116, 120, and 148 can each individually comprise at least one of polytetrafluoroethylene and a polytetrafluoroethylene derivative (e.g., polytetrafluoroethylene with polyimide fill). The flexible portions 116, 120, and 148 can each individually be non-elastomeric. That is, each flexible portion 116, 120, and 148 may not comprise an elastomer, such as, for example, rubber (e.g., silicone rubber, ethylene propylene rubber, ethylene propylene diene rubber, a fluoroelastomer, a perfluoroelastomer). However, it is contemplated that in various embodiments the flexible portions 116, 120, and 148 can be coated with an elastomer.

[0033] The springs 118, 122, 150, and 152 can be of various types and configurations which are configured to form their respective fluid tight seal. For example, each spring 118, 122, 150, and 152 individually can comprise at least one of a V-shaped spring (e.g., a cantilever spring), a canted spring (e.g., a canted coil spring), and a helical spring. As illustrated in FIGs. 1-6, the springs 122, 150, and 152 are V-shaped springs and spring 118 is a canted spring.

[0034] The connector 100 can be configured to operate at a pressure of at least 10,000 PSI (69 MPa), such as, for example, at least 15,000 PSI (103 MPa), at least 18,000 PSI (124 MPa), at least 20,000 PSI (138 MPa), at least 25,000 PSI (172 MPa), or at least 30,000 PSI (207 MPa).

[0035] The connector 100 can be configured to operate with in various ranges of temperature such as, for example, at least as low as -300 degrees Fahrenheit (-184 degrees Celsius), as low as -200 degrees Fahrenheit (-129 degrees Celsius), as low as -100 degrees Fahrenheit (-73 degrees Celsius), as low as 0 degrees Fahrenheit (-18 degrees Celsius), up to 100 degrees Fahrenheit (38 degrees Celsius), up to 200 degrees Fahrenheit (93 degrees Celsius), up to 250 degrees Fahrenheit (121 degrees Celsius), up to 300 degrees Fahrenheit (149 degrees Celsius), up to 350 degrees Fahrenheit (177 degrees Celsius), up to 400 degrees Fahrenheit (204 degrees Celsius), up to 450 degrees Fahrenheit (232 degrees Celsius), or up to 500 degrees Fahrenheit (260 degrees Celsius). For example, the connector 100 can be configured to operate with a temperature range of -400 degrees Fahrenheit (-184 degrees Celsius) to 500 degrees Fahrenheit (260 degrees Celsius), such as, for example, -100 degrees Fahrenheit (-73 degrees Celsius) to 500 degrees Fahrenheit (260 degrees Celsius), or 0 degrees Fahrenheit (-18 degrees Celsius) to 400 degrees Fahrenheit (204 degrees Celsius).

[0036] With reference to the embodiment shown in FIGs. 1 and 2A-B, the connector 100 can be applied as a portion of a single pin, wet-mateable electrical connector or feedthrough, such as the Electrical Feedthrough System for subsea wellhead completions manufactured by Teledyne DGO (a business unit of Teledyne Technologies Incorporated), Portsmouth, New Hampshire, USA. However, it will be understood that other wellhead plugs or connectors including a pin or multiple pins may be adapted to include similar spring activated seals.

[0037] The connector according to the present disclosure can be configured to undergo pressure and / or temperature cycling (e.g., 30 cycles or greater at 22,500 PSI (155 MPa), -40 degrees Fahrenheit (-40 degrees Celsius) to 35 degrees Fahrenheit (1.7 degrees Celsius), 158 degrees Fahrenheit (70 degrees Celsius) to 35 degrees Fahrenheit (1.7 degrees Celsius), 50 degrees Fahrenheit (10 degrees Celsius) and 0 PSI (0 MPa) to 302 degrees Fahrenheit (150 degrees Celsius) and 20,000PSI (138 MPa)), turbid liquid mating (at least 50 mates in a sand and silt environment), shock / vibrations (e.g., sweep and random vibration), and pressurized mating (at least 50 mates at 20,000PSI (138 MPa)) while maintaining optimal electrical and / or optical signal transmission. The configuration of the connector according to the present disclosure can enable a longer operational life, a higher operational pressure range, and / or a larger operational temperature range than convention connectors.

Claims

1. A connector (100) comprising: a housing (140); a contact positioned (164) within the housing (140) and configured to transmit at least one of an electrical signal and an optical signal between the connector (100) and a secondary device; characterised in that the connector (100) further comprises a dual-lipped spring activated seal (146) comprising: a flexible portion (148) comprising an electrically insulative material and further comprising a first concave portion (148a) and a second concave portion (148b); a first spring (150) configured to urge the first concave portion (148a) to contact the housing (140) and the secondary device to form a first fluid tight seal therebetween; and a second spring (152) configured to urge the second concave portion (148b) to contact the housing (140) and the secondary device to form a second fluid tight seal therebetween.

2. The connector of claim 1, wherein the flexible portion (148) comprises at least one of a thermoplastic material or a thermoset material.

3. The connector of claim 1, wherein the flexible portion (148) comprises polytetrafluoroethylene or a polytetrafluoroethylene derivative.

4. The connector of claim 1, wherein the flexible portion (148) is non-elastomeric.

5. The connector of claim 1, wherein the first spring (150) and the second spring (152) individually comprise at least one of a V-shaped spring, a canted spring or a helical spring.

6. The connector of claim 1, further comprising a hat ring (156) in contact with the dual-lipped spring activated seal and the body, the hat ring configured to maintain a position of the dual-lipped spring activated seal relative to the body.