Downhole Splice Connector Pressure Seals
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Solution Overview
Problem
Existing electrical connectors in high-pressure environments, such as downhole systems, face challenges in preventing fluid leaks due to increased hydrostatic pressure and adverse environmental conditions, which affect the reliability of pressure seals and lead to potential fluid migration across connector interfaces.
Innovation Solution
The development of electrical splice connectors with integrated glass ceramic sleeves forming glass-to-metal joints, along with a three-part body design and internal pressure barriers, provides a robust pressure seal to prevent fluid penetration and enhance connectivity reliability across the connector interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional elastomeric or thermoplastic seals are used in pressure barriers, then ease of manufacture is improved, but reliability deteriorates under high hydrostatic pressure and temperature conditions
Solution Approach 1:
The patent employs a composite sealing system combining multiple materials: an elastomeric seal (O-ring) works in conjunction with a thermoplastic seal (face seal) and metal-to-metal contact surfaces. This multi-material approach leverages the advantages of each material - the elastomeric seal provides initial sealing and compliance, the thermoplastic seal maintains structural integrity under pressure, and the metal-to-metal contact provides a reliable final sealing barrier that is insensitive to temperature and pressure variations.
2Reliability
If metal-to-metal seals or weld joints are used in pressure barriers, then reliability is improved under high pressure, but device complexity increases
Solution Approach 1:
The sealing function is divided into three distinct segments or stages: the elastomeric O-ring seal provides the first line of sealing, the thermoplastic face seal provides the second line, and the metal-to-metal contact surfaces provide the third line. This segmentation allows each sealing mechanism to be optimized independently and work in sequence, distributing the sealing function across multiple specialized components rather than relying on a single complex seal.
Solution Approach 2:
The thermoplastic seal acts as an intermediary element between the elastomeric seal and the metal-to-metal contact surfaces. It provides a compliant interface that distributes pressure evenly, protects the metal surfaces from direct high-stress contact, and maintains the sealing geometry under varying pressure and temperature conditions, thereby simplifying the overall sealing system design.
3Ease of operation
If sealed connectors are installed in compartment bulkheads, then electrical connectivity is achieved across pressure barriers, but potential leak paths increase
Solution Approach 1:
The elastomeric O-ring seal functions as a flexible membrane that conforms to the mating surfaces and compensates for manufacturing tolerances, surface irregularities, and thermal expansion/contraction. This flexible sealing element creates a compliant barrier that maintains sealing effectiveness across the connector interface while allowing for the necessary mechanical movements and adjustments.
4Adaptability or versatility
If environmental conditions such as temperature changes occur, then material properties of sealing devices change, but fluid leak prevention becomes more difficult
Solution Approach 1:
The sealing system is designed to accommodate parameter changes in temperature and pressure by utilizing materials with complementary thermal and pressure characteristics. The elastomeric seal provides low-temperature flexibility and high-temperature resilience, the thermoplastic seal maintains dimensional stability across temperature ranges, and the metal-to-metal contact surfaces provide temperature-insensitive sealing. This multi-material parameter adaptation ensures reliable sealing under varying environmental conditions.
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 solution effectively prevents external and internal fluid pressure breaches, ensuring reliable electrical connectivity and mechanical integrity in high-pressure environments, thereby increasing the reliability of downhole electrical systems.
Implementation Method 1
at least one glass ceramic sleeve forming glass-to-metal joints
Data Source
AI summary
Components and systems include devices for implementing downhole splice connections within a wellbore. In some embodiments, a downhole splice connector includes at least one connector body having an inner diameter defining a cavity within which at least one connector receptacle is disposed, and at least one conductive center pin disposed within the at least one connector receptacle. The downhole splice connector further includes at least one pressure sleeve annularly disposed between an inner diameter of the connector body and an outer diameter of the center pin, such that a pressure barrier is formed between an outer diameter of the pressure sleeve and an inner diameter of the connector body and a pressure barrier is formed between an inner diameter of the pressure sleeve and an outer diameter of the center pin.