Downhole Connector Pressure Isolation via Remote Housing
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Solution Overview
Problem
Current downhole connectors for optical fibers and electrical wires are complex, prone to damage during manufacturing, and have limited pressure compensation ranges, making them inadequate for the harsh downhole environment.
Innovation Solution
A connector system with a remotely located housing and pressure isolator, where the housing and connecting lines are interposed between the main control line and the connector body, allowing for pressure compensation and isolation, using pressure compensators like metal bellows to equalize downhole pressure without being integrated within the connector body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure compensating features are integrated within the connector body, then the connector can compensate for pressure changes, but the device becomes complex and prone to damage during manufacture
Solution Approach 1:
The connector system is divided into separate functional components: the connector body for electrical/optical connection and the pressure compensator as a distinct element. This segmentation allows each component to be optimized independently, reducing manufacturing complexity while maintaining pressure compensation capability.
Solution Approach 2:
The pressure compensating features are extracted from the connector body and implemented as separate pressure compensators positioned remotely. This extraction eliminates the complexity of integrating pressure compensation mechanisms within the connector body, reducing damage risk during manufacture while preserving the essential pressure compensation function.
2Volume of moving object
If all features are integrated within the connector body, then the connector is compact, but the compensating range is limited and damage risk increases
Solution Approach 1:
The pressure compensators are positioned in a different spatial dimension - remotely from the connector body along the hydraulic line. This dimensional separation allows the connector body to remain compact for electrical/optical connections while the pressure compensators extend the functional range without increasing connector body volume.
3Stability of the object's composition
If pressure compensating features are integrated within the connector body, then the connector structure is unified, but manufacturing damage risk and complexity increase
Solution Approach 1:
The connector system is segmented into the connector body and separate pressure compensators, allowing each to be manufactured independently using appropriate processes. The connector body can be manufactured with precise electrical/optical interfaces while pressure compensators are manufactured as separate mechanical components, then assembled together.
Solution Approach 2:
The pressure compensating function is extracted from the connector body manufacturing process. This extraction simplifies the connector body manufacturing by removing complex pressure compensation features, reducing damage risk while maintaining structural stability through proper assembly of the separated components.
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 simplifies manufacturing, reduces damage risk, and effectively isolates pressure between the connector bodies and main control lines, enabling reliable communication in high-pressure downhole environments.
Implementation Method 1
a first pressure isolator associated with the first housing, the first pressure isolator isolating pressure within the first main control line from pressure within the first connecting line and the first connector body
Implementation Method 2
The connector system includes pressure compensators, such as metal bellows, to equalize downhole pressure
Data Source
AI summary
A connector system including a first connector configured to electrically and/or optically connect to a second connector. The first connector includes a first connector body configured to engage with the second connector; a first housing remotely located from the first connector body; a first connecting line including at least one of an electrical control line and an optical fiber connecting the first housing to the first connector body; a first main control line including at least one of an electrical control line and an optical fiber connected to the first housing; and, a first pressure isolator associated with the first housing, the first pressure isolator isolating pressure within the first main control line from pressure within the first connecting line and the first connector body. The first housing and the first connecting line are interposed between the first main control line and the first connector body.