Bulkhead Connector with Pliable Contacts for Shock Resistance
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Solution Overview
Problem
Current bulkhead connectors fail to maintain hermetic seals and electrical connectivity in harsh downhole environments due to shear forces caused by shock and vibration, leading to contact failure and signal distortion, as they lack the ability to flex and distribute stress effectively.
Innovation Solution
The bulkhead connector design incorporates a pressure transfer guide plate and channels with free-floating contacts to distribute shear forces, allowing for pivotable movement and reducing stress concentrations, while maintaining a hermetic seal through the use of sealing rings and materials like ceramics and conductive metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid fixed contacts are used in bulkhead connectors, then hermetic seal integrity is maintained, but contacts are vulnerable to shear failure under shock and vibration
Solution Approach 1:
The patent transforms the static rigid contact design into a dynamic system where contacts can pivot and move within channels. The contact elements are mounted on pivots allowing them to rotate and absorb shock loads, converting the rigid fixed structure into a flexible dynamic one that adapts to vibrational forces while maintaining electrical connectivity
Solution Approach 2:
The patent introduces flexible mounting mechanisms where contacts are secured through flexible means such as spring-loaded retainers or elastic mounting structures within the channels. This flexibility allows the contacts to move and pivot under shock loads while maintaining continuous electrical contact, replacing the rigid fixed mounting approach
2Strength
If contacts are allowed to pivot and move, then resistance to shock and vibration improves, but hermetic seal integrity may be compromised
Solution Approach 1:
The patent divides the connector into separate functional zones: channels for contact movement, sealing zones with independent sealing elements, and mounting structures. The sealing function is segmented from the contact function, allowing contacts to pivot freely within channels while sealing elements independently maintain hermetic barriers at critical interfaces
Solution Approach 2:
The patent introduces intermediary sealing elements such as O-rings, gaskets, or flexible sealing membranes positioned at the bulkhead interface and within channel openings. These intermediary seals act as mediators that accommodate contact movement while maintaining hermetic separation between internal and external environments
3Strength
If shear forces are distributed across larger area, then contact failure is reduced, but device complexity increases
Solution Approach 1:
The patent transitions from two-dimensional planar contact surfaces to three-dimensional pivotable contact elements that can rotate and move through channels. This dimensional change allows shear forces to be distributed through rotational movement and pivot points rather than concentrated on flat contact surfaces, reducing stress concentrations without requiring significantly increased structural complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the durability and reliability of bulkhead connectors by reducing shear stress on contacts, maintaining hermetic seals, and preventing signal distortion even at extreme pressures and temperatures, thereby ensuring consistent electrical connectivity.
Implementation Method 1
The connectors must also easily connect and disconnect and function as conduits for electrical conduction in extreme hostile liquid and gaseous environments... provide a hermetic seal capable of withstanding high differential pressures and temperatures
Implementation Method 2
A major source of electrical signal distortion or failure using these bulkhead connectors is associated with the original purpose of their design. Namely, the one or more contacts (pins) that protrude from the bulkhead surface are subject to extremely high shear forces during operation in harsh (shock and vibration) environments
Implementation Method 3
function as conduits for electrical conduction in extreme hostile liquid and gaseous environments... maintain the ability to carry high voltages
Implementation Method 4
when these specific connectors are exposed to borehole fluids, a rubber boot seal is used that fits over the male end of the connector contacts, thereby providing a moisture-free seal for the conductive contact(s)
Data Source
AI summary
A high pressure and temperature, hermetically sealed bulkhead connector with pin and socket contacts for use in logging tools is described. The bulkhead connector comprises (a) one or more contact(s) placed within one or more channels wherein the channels provide a clearance path between contact(s) and bulkhead body and travel at least a partial longitudinal distance between proximal and distal ends. The contact(s) reside in the channel(s) and include at least; an optional movement limiter section, one central elongated section, and one fixed section where the contact(s) is attached to the bulkhead body at the distal end. The body correctly positions respective ends of the contact so that the body secures contact(s) to be parallel to each other and the contact(s) have terminal ends for connection. This arrangement provides at least one pivotable, pliable, free floating contact extending away from the fixed distal end of the bulkhead body.