Circular Downhole Ultrasonic Phased Array for Pressure Balance
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Solution Overview
Problem
Ultrasonic downhole imaging tools face challenges in withstanding pressure differentials in boreholes, requiring pressure-compensated designs that involve oil-filled cavities and complex connectors, which can be cumbersome and prone to damage.
Innovation Solution
A downhole acoustic measurement tool design featuring a transducer with a backing, mechanically coupled structures allowing for longitudinal force transfer, and an acoustically transparent canister to manage pressure differentials without oil-filling or complex connectors, using materials like polymers and metals to distribute forces and ensure acoustic integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pressure-compensated designs with oil-filled cavities and bulk connectors are used, then transducers can withstand increased pressure differential, but device complexity increases and reliability decreases due to cumbersome connectors prone to damage
Solution Approach 1:
The patent removes the oil-filled cavity and bulk connectors from the transducer assembly, extracting the problematic pressure compensation mechanism. Instead, the transducer is directly mounted in a pressure-balanced environment where the back of the transducer is exposed to the same pressure as the front, eliminating the need for complex sealing and connector systems while maintaining pressure withstanding capability
Solution Approach 2:
The patent segments the tool into distinct functional modules: the transducer assembly, the housing, and the pressure balancing system. The transducer is mounted in a manner that allows independent pressure equalization on both sides, separating the pressure management function from the electrical connection function, thereby simplifying the overall design
2Strength
If pressure-compensated designs with oil-filled cavities are used, then transducers can withstand increased pressure differential, but reliability decreases due to components prone to damage
Solution Approach 1:
The patent extracts the vulnerable bulk connectors and oil-filled cavity from the design. The transducer elements are directly mounted with their backs exposed to the borehole pressure environment, eliminating the intermediate oil-filled cavity and bulk connectors that were prone to damage and failure under high pressure conditions
Solution Approach 2:
The transducer assembly is designed to self-compensate for pressure changes. The back of each transducer element is directly exposed to the ambient pressure, allowing the transducer to automatically balance pressure differential without requiring external pressure compensation systems or vulnerable sealing mechanisms
3Adaptability or versatility
If complex connectors and oil-filled cavities are used for pressure compensation, then transducers can operate at depth, but ease of operation decreases due to cumbersome assembly and maintenance
Solution Approach 1:
The patent removes the complex oil-filled cavity and bulk connector assembly, dramatically simplifying the transducer mounting process. The transducers are directly mounted in a pressure-balanced environment, eliminating the need for careful oil filling, sealing, and connector assembly that made the system cumbersome to operate and maintain
Solution Approach 2:
The patent changes the pressure compensation approach from a closed oil-filled system to an open pressure-balanced design. By allowing the back of the transducer to be directly exposed to ambient pressure, the system achieves depth operation capability without the operational complexity of maintaining sealed oil-filled cavities and bulk connectors
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 design effectively withstands borehole pressures without oil-filling or complex connectors, maintaining transducer integrity and enabling reliable ultrasonic imaging in cased and uncased boreholes.
Implementation Method 1
a plurality of piezoelectric transducers disposed around an outer surface of the backing
Implementation Method 2
at least one transducer for emitting acoustic excitation signals and/or receiving echo signals to perform downhole measurements
Data Source
AI summary
A downhole tool having an acoustic transducer for downhole measurements. A backing is in contact with an inner surface of the transducer. A first structure is coupled to a first housing. A second structure is coupled to a second housing. A member includes first, second, and third portions. The first portion is coupled to the first structure. The second portion is coupled to the second structure. At least one of the first and second structures is coupled to the member and has a degree of freedom relative to the member. The third portion extends longitudinally through the backing between the first and second portions such that compressional forces on the first and second housings are transferred through the first and second structures and the backing. A canister contacts an outer surface of the transducer and exerts radial forces on the transducer when exposed to pressures higher than atmospheric pressure.