Downhole Control Line Connector Tangential Alignment

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Solution Overview

Problem

Conventional fiber optic connectors for downhole applications in subterranean wells face issues with debris accumulation and fiber buckling due to axial alignment and compression, leading to connectivity problems and potential breakage.

Innovation Solution

A control line connector assembly that uses tangential or curvilinear alignment and rotation to connect optical fibers, incorporating a retractable cover and penetrable lid to prevent debris entry and maintaining fibers in low stress compression to reduce buckling risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional fiber optic connectors use axial alignment and compression to mate optical fibers, then connection is established, but debris accumulation on mating faces and optical fiber buckling occur

Engineering Contradiction:

Improveconnection reliabilityVSAvoiddebris accumulation and fiber buckling

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Instead of aligning and compressing fibers axially, the patent inverts the approach by using tangential or curvilinear alignment. The connector housing guides the fibers along a curved path, allowing the fiber ends to meet tangentially rather than axially, which prevents debris accumulation and buckling while establishing reliable optical connection

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent transitions from one-dimensional axial alignment to two-dimensional tangential/curvilinear alignment. By introducing a curved alignment dimension, the connector achieves reliable fiber mating without the harmful effects of axial compression, effectively adding a dimensional approach to solve the contradiction

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If wet mate connectors are used in downhole environments, then optical communication can be established, but the mating process becomes difficult due to debris and contamination

Engineering Contradiction:

Improveoptical communication capabilityVSAvoidmating difficulty

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connector housing includes pre-formed curved alignment features and guiding structures that automatically align the fibers tangentially during the mating process. This preliminary structural preparation eliminates the need for complex manual alignment operations in harsh downhole environments, making wet mating easier while maintaining reliable optical communication

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent acknowledges that downhole environments contain debris and contamination, but designs the tangential mating interface to be less sensitive to these conditions. The curved alignment path naturally excludes debris from the critical fiber contact zone, converting the harsh environment from a hindrance to a manageable condition

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS10060196B2Methods of coupling a downhole control line connector

Publication Date: 2018.08.28 HALLIBURTON ENERGY SERVICES INC

AI summary

Methods of coupling a control line including axially aligning a first connector with a second connector, the first connector having a first housing and a pin connector, and the second connector having a second housing and a box connector. And angularly rotating one or both of the first and second connectors with respect to each other and thereby angularly aligning a pin mating face provided on the pin connector with a box mating face provided on the box connector, mating the pin connector to the box connector by further angularly rotating one or both of the first and second connectors. And communicably coupling one or more first communication media in the pin connector with one or more second communication media in the box connector.