Downhole Flanged Coupling Member for Axial Fastener Failure

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Solution Overview

Problem

Flanged connections in downhole pump assemblies experience significant stress and failure due to weight and axial forces, leading to costly fishing jobs and unproductive downtime when threaded fasteners break.

Innovation Solution

A redundant coupling member with an axial tension member and shear member portions that span axial slots in a flanged connection, providing additional support and preventing the connection from disassembling if primary fasteners fail.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If threaded fasteners are used to secure the flanged connection, then the connection can be assembled and disassembled, but the connection becomes vulnerable to failure under axial forces and weight

Engineering Contradiction:

Improveassembly and disassembly capabilityVSAvoidresistance to axial force failure

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The coupling member is divided into distinct functional segments: an axial tension member portion for spanning slots, a first shear member portion with shoulder for engaging the head member, and a second shear member portion with shoulder for engaging the base member. This segmentation allows each portion to handle specific forces independently, improving overall reliability while maintaining operability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coupling member is installed in advance within the axial slots of the head member and base member before the flanged connection is subjected to operational loads. The shear member shoulders are positioned to engage with the opposing members' shoulders, creating preliminary mechanical interlocking that prevents downward sliding and protects against fastener failure under axial forces.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If a redundant coupling member is added to prevent connection failure, then reliability improves, but device complexity increases

Engineering Contradiction:

Improveprotection against fastener failureVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The coupling member serves multiple functions simultaneously: it acts as a mechanical stop to prevent downward sliding, provides redundant support against axial forces, and maintains the structural integrity of the flanged connection. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity while achieving improved reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The coupling member is nested within the existing flanged connection structure, specifically within the axial slots of the head member and base member. This nesting approach allows the redundant coupling mechanism to be integrated into the existing design without requiring separate external components, thus minimizing the increase in overall device complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Strength

If the flanged connection is designed to withstand significant stress, then strength improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improveresistance to stress and failureVSAvoidslot alignment and engagement tolerance

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The coupling member concentrates its load-bearing capacity at specific local regions: the axial tension member portion spans the slots to distribute axial loads, while the shear member shoulders engage with the opposing members' shoulders at discrete contact points. This local quality approach allows the connection to withstand significant stress without requiring high precision across the entire assembly, as the critical load paths are localized to well-defined engagement regions.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12553295B2Coupling member for use with a connection

Publication Date: 2026.02.17 HALLIBURTON ENERGY SERVICES INC

AI summary

Provided in one example is a coupling member, a downhole tool, and a well system. The coupling member, in one aspect, includes an axial tension member portion, and a first shear member portion, the first shear member portion having a first shear member shoulder extending from a first end of the axial tension member portion, the first shear member shoulder configured to engage with an opposing head member shoulder to axially fix the axial tension member portion relative to the head member. The coupling member, according to one aspect, includes a second shear member portion, the second shear member portion have a second shear member shoulder extending from a second opposing end of the axial tension member portion, the second shear member shoulder configured to engage with an opposing base member shoulder to axially fix the axial tension member portion relative to the base member.