Connector Feedthrough Stress Decoupling via Pressure Sleeve
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Solution Overview
Problem
High-pressure and high-temperature conditions in subsea hydrocarbon extraction systems cause stress on ceramic insulators due to the differential expansion of copper conductor pins, potentially compromising the integrity of the connector assembly.
Innovation Solution
A connector system with a pressure sleeve that allows relative movement between the conductor pin and insulator, using materials with matched thermal expansion properties to absorb the difference in expansion, combined with curved metalized grooves to reduce electrical stress and a vent port for pressure relief during brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If copper conductor pins are used in high-temperature and high-pressure environments, then electrical conductivity is improved, but thermal expansion causes stress on the ceramic insulator
Solution Approach 1:
The connector assembly is divided into distinct functional segments: a copper conductor pin for electrical conductivity, a ceramic insulator for electrical isolation, and a pressure sleeve for mechanical stress management. This segmentation allows each component to optimize its specific function while the pressure sleeve mediates the thermal expansion stress between the conductor pin and insulator, preventing stress concentration on the insulator.
Solution Approach 2:
The pressure sleeve acts as an intermediary component between the copper conductor pin and the ceramic insulator. It absorbs and distributes the thermal expansion forces generated by the conductor pin, preventing these forces from being transmitted directly to the insulator. This intermediary structure resolves the contradiction by allowing the conductor pin to expand freely while protecting the insulator from stress.
2Reliability
If ceramic insulator is used to withstand high pressure and temperature, then electrical insulation is improved, but it becomes less pliable and more susceptible to stress from conductor expansion
Solution Approach 1:
The system separates the functions of electrical insulation and mechanical compliance into different components. The ceramic insulator provides reliable electrical insulation, while the pressure sleeve provides mechanical compliance and stress absorption. This functional segmentation allows the ceramic to maintain its insulating properties without requiring it to also accommodate thermal expansion, thus resolving the contradiction between insulation reliability and mechanical pliability.
Solution Approach 2:
The pressure sleeve serves as a mediator that decouples the mechanical stress from the ceramic insulator. It allows the conductor pin to expand thermally while preventing this expansion from stressing the rigid ceramic insulator, thereby preserving both the insulator's electrical insulation properties and the system's adaptability to thermal changes.
3Device complexity
If fixed connection between conductor pin and insulator is used, then structural simplicity is improved, but stress concentration occurs under thermal expansion
Solution Approach 1:
The connection structure is segmented into multiple functional zones: the conductor pin, the pressure sleeve, and the ceramic insulator. This segmentation transforms a simple fixed connection into a distributed stress-management system, where each component has a specific role in handling thermal and mechanical loads, thereby improving reliability without excessive complexity.
Solution Approach 2:
The connection between the conductor pin and insulator is made dynamic through the pressure sleeve, which allows controlled relative movement and stress distribution. Instead of a rigid fixed connection, the pressure sleeve enables the system to adapt dynamically to thermal expansion, maintaining reliability under varying temperature and pressure conditions while adding only moderate 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
The solution effectively relieves stress on the insulator, maintaining the integrity of the connector system under extreme conditions and ensuring reliable operation over the system's lifetime.
Implementation Method 1
a conductor can move relative to an insulator, thereby relieving the stress on the insulator as the conductor expands due to high temperature or high pressure conditions
Implementation Method 2
a vent port for pressure relief during brazing
Data Source
AI summary
A feedthrough for a connector system includes an insulator comprising a passage therethrough, a conductor pin located in the passage, and a pressure sleeve located between the insulator and the conductor pin. The pressure sleeve is coupled to the insulator and to the conductor pin, and the conductor pin is movable relative to the insulator under thermal or pressure expansion or contraction.