Downhole Connector Assembly with Nested Segmented Design
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Solution Overview
Problem
Existing coupling systems require manual termination of one connector end after insertion, increasing complexity and labor time, and there is a need for a pre-terminated connector assembly that can be inserted into hollow portions of tools, fixtures, or housings to streamline the installation process and reduce labor costs.
Innovation Solution
A connector assembly with two terminated end portions, featuring a first outer body with a hollow portion and radially inward retaining portions that secure the terminated end portions, allowing for easy insertion and assembly within a tool, fixture, or housing, reducing the need for on-site termination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a connector with two pre-terminated ends is used, then assembly time and labor cost are reduced, but the connector cannot be inserted into a hollow portion that is too small for the connector's outer width
Solution Approach 1:
The connector is divided into two separate components: an inner body containing the terminated ends and an outer body that provides structural support. This segmentation allows the inner body to be slender enough for insertion while the outer body can be assembled separately, resolving the contradiction between pre-termination benefits and insertability constraints.
Solution Approach 2:
The inner body is nested within the outer body, with the inner body having a smaller outer diameter than the hollow portion, allowing it to be inserted first. The outer body is then assembled around it, creating a nested structure that satisfies both the insertion constraint and the structural requirements of a robust connector.
2Ease of operation
If the hollow portion radial width is increased to accommodate a pre-terminated connector, then easier insertion is achieved, but the housing structure becomes more complex and larger
Solution Approach 1:
By segmenting the connector into inner and outer bodies with different dimensional requirements, the inner body can have a small outer diameter for easy insertion into the existing hollow portion, while the outer body provides the necessary structural support without requiring an enlarged housing.
Solution Approach 2:
The design transitions from requiring a large radial width to achieving connector robustness through longitudinal arrangement and nested structure, allowing the same functional requirements to be met with a smaller radial footprint that fits the existing hollow portion dimensions.
3Ease of operation
If manual termination of the second end is required after insertion, then the connector can fit in the hollow portion, but complexity and labor time increase
Solution Approach 1:
Both ends of the connector are pre-terminated before assembly, eliminating the need for on-site termination operations. The inner body is prepared with both ends terminated, and the outer body is prepared with retention features, so that the final assembly step simply involves joining the two pre-prepared components together.
Solution Approach 2:
The outer body is designed with integrated retention features (such as clips, latches, or interference-fit structures) that automatically secure the inner body in place during assembly, eliminating the need for additional fastening operations or tools. The structure self-secures upon insertion.
Data Source
AI summary
A connector assembly for insertion into a hollow portion of a tool, fixture, or housing. The connector assembly may have a connector having two terminated end portions for reducing assembly time and cost with on-site termination. The connector assembly may include a first outer body having a hollow portion for insertion of at least a portion of a first insert-assembly sleeve portion. The connector assembly may have at least one retaining portion extruding radially inward and configured to be positioned into at least one radially inward groove of the first insert-assembly sleeve portion for securing at least a portion of the first terminated end portion in the first outer body. With this assembly, one of the terminated end portions without an outer body may be passed through the hollow portion and then assembled to the corresponding outer body and reinserted into an end of the hollow portion.