Bulkhead Contact Assembly With Single-Seal Shock Absorption

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Solution Overview

Problem

Existing bulkheads in wellbore tool strings face challenges with multiple sealing elements increasing points of failure and manufacturing costs, while requiring improved reliability and shock absorption for maintaining electrical communication during operations.

Innovation Solution

A simplified bulkhead design featuring a fixed conductive body with integrated electrical contacts and springs, and non-conductive covers with a single seal element, reducing material usage and points of failure, and incorporating a deep drawn molding method for hollow electrical contacts to enhance shock absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple sealing elements are used in the bulkhead, then the fluid and pressure seal is improved, but the number of points of failure increases and manufacturing cost increases

Engineering Contradiction:

Improvefluid seal reliabilityVSAvoidnumber of sealing elements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple sealing functions into a single integrated bulkhead cover component. The bulkhead cover incorporates both the sealing surface and the electrical contact support structure, eliminating the need for separate sealing elements and reducing the total number of parts while maintaining effective fluid and pressure sealing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bulkhead cover is designed to perform multiple functions simultaneously: it provides fluid sealing, supports electrical contacts, and maintains structural integrity. This multi-functional design reduces the number of separate components needed while improving overall system reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple sealing elements are used in the bulkhead, then the fluid and pressure seal is improved, but manufacturing cost increases

Engineering Contradiction:

Improvefluid seal reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If the bulkhead relies on the bulkhead cover for pressure and fluid sealing, then the number of sealing elements is reduced, but the range of materials that can be used is limited

Engineering Contradiction:

Improvenumber of sealing elementsVSAvoidmaterial selection range

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The bulkhead cover is manufactured using composite materials that combine the properties needed for both electrical insulation and pressure sealing. This allows the single component to fulfill multiple functions while maintaining flexibility in material selection to meet specific application requirements.

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If the bulkhead uses a simplified design with less material and parts, then manufacturing cost is reduced, but shock absorption capability may be compromised

Engineering Contradiction:

Improvemanufacturing costVSAvoidshock absorption capability

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent incorporates shock absorption features directly into the bulkhead cover structure, such as dampening elements or compliant mounting features, that are designed to absorb shocks and vibrations before they can damage the electrical contacts or compromise the sealing. This allows for a simplified overall design while maintaining adequate shock protection.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

The solution reduces manufacturing costs, enhances reliability by minimizing failure points, and provides effective electrical communication and shock absorption, allowing for efficient operation in wellbore environments.

Implementation Method 1

a first spring having a first spring end in contact with the first contact surface and a second spring end in contact with the first electrical contact

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12091919B2Bulkhead

Publication Date: 2024.09.17 DYNAENERGETICS EURO GMBH

AI summary

A bulkhead may include a fixed body having a first contact surface and an exterior fixed body surface, a first electrical contact, and a first spring having a first spring end in contact with the first contact surface and a second spring end in contact with the first electrical contact.