Downhole Tool Igniter Assembly Using PCB Resistor Heating

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Solution Overview

Problem

Conventional well tools for oil and gas wells rely on flammable power charges for activation, which pose safety risks and require special handling during transportation.

Innovation Solution

An igniter assembly that uses an electrical heating element to ignite a power charge, eliminating the need for flammable materials, allowing safe transportation and operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If flammable power charges are used to activate downhole tools, then reliable activation is achieved, but safety risks and handling difficulties increase

Engineering Contradiction:

Improveactivation reliabilityVSAvoidsafety risks

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical ignition system (flammable power charges) with an electrical heating system. An electrical heating element is positioned in direct contact with the propellant charge, and electrical energy is transmitted through a conductor to heat the propellant to its ignition temperature, thereby activating the downhole tool without requiring flammable materials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the activation mechanism from chemical combustion to thermal heating. By controlling the temperature parameter through electrical heating, the propellant is brought to its ignition point in a controlled manner, eliminating the need for flammable power charges while maintaining reliable activation.

Inventive Principle:

Principle #35Parameter changes

2Power

If flammable power charges are used for tool activation, then sufficient energy for activation is provided, but transportation and handling become more difficult

Engineering Contradiction:

Improveactivation energyVSAvoidhandling ease

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

The patent substitutes the flammable power charge system with an electrical heating system. The electrical heating element provides the necessary energy to ignite the propellant charge through controlled heating, eliminating the need to transport and handle flammable materials while maintaining sufficient activation energy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an electrical heating element as an intermediary between the power source and the propellant charge. This intermediary converts electrical energy to thermal energy, which then activates the propellant, providing a safe and controllable method for delivering activation energy without requiring flammable materials.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If conventional igniters with flammable charges are used, then reliable ignition is achieved, but device complexity and safety requirements increase

Engineering Contradiction:

Improveignition reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the flammable components from the ignition system, retaining only the essential heating function. By removing the flammable power charge and keeping only the electrical heating element and propellant charge, the system achieves reliable ignition with reduced complexity and eliminated safety hazards associated with flammable materials.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the complex flammable charge ignition system with a simpler electrical heating system. The electrical heating element directly heats the propellant charge without requiring additional flammable materials, igniters, or complex safety mechanisms, thereby simplifying the overall system while maintaining reliable ignition.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 igniter assembly provides a safe and reliable means to activate downhole tools without the hazards associated with flammable charges, enabling efficient and compliant handling and deployment.

Implementation Method 1

an electrical heating element positioned on the exterior surface of the insulator cap and disposed adjacent to the energetic material of the power charge

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS12584364B2Electric igniter for downhole settings tools

Publication Date: 2026.03.24 DBK IND LLC

AI summary

Igniter assemblies for use with setting tools are disclosed. The igniter assemblies have an electronic heating element disposed adjacent to an energetic material within a setting tool. In some embodiments, the electronic heating element is a resistor or a PCB mounted resistor. Electrical connections are attached to the heating element to provide electrical current to activate the heating element. In some instances, the electrical heating element is disposed onto an insulator cap that is coupled to a pressure block attached to the setting tool, and in some instances the electronic heating element is attached to a non-explosive portion and the energetic material is disposed within an explosive portion. When the non-explosive portion and the explosive portion are assembled, the electronic heating element is adjacent to the energetic material. Other assemblies are described.