In-Well Dry Mate Connectors Using Shape Memory Alloy Sealing
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Solution Overview
Problem
Existing downhole electrical connectors face challenges in forming sealed connections that can withstand tensile loading while maintaining environmental sealing, particularly in well applications where connections between cables and components are subject to tensile forces during testing.
Innovation Solution
A dry mate connector system utilizing a shape memory alloy sealing system and retainer system, activated via temperature changes, to form a secure seal and grip cables or components, ensuring the connection remains sealed and resistant to tensile loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing mechanisms are used in downhole connectors, then the connector can be manufactured with standard materials and processes, but the connector fails to maintain reliable sealing under tensile loading conditions
Solution Approach 1:
The patent utilizes temperature-induced phase changes in shape memory alloy materials to transform the mechanical properties of the connector components. By heating the shape memory alloy retainer and sealing elements above their transformation temperature, the material transitions from a martensitic (soft, formable) state to an austenitic (hard, elastic) state, automatically providing both sealing force and tensile load resistance without additional mechanical complexity
Solution Approach 2:
The connector employs composite construction combining shape memory alloy materials with conventional metals and polymers. The shape memory alloy provides intelligent responsive behavior under temperature change, while conventional materials handle structural support and electrical functions, creating a multi-material system that achieves superior performance without excessive complexity
2Strength
If the connector is designed to withstand high tensile forces, then the connection strength is improved, but the sealing capability deteriorates due to separation of mating surfaces
Solution Approach 1:
The connector separates the tensile load-bearing function and sealing function into distinct but coordinated components. The shape memory alloy retainer ring provides tensile resistance through its elastic recovery force, while the shape memory alloy sealing element maintains sealing pressure on the O-ring. Both components are activated simultaneously by temperature change but perform different functions independently
Solution Approach 2:
Temperature change simultaneously alters the mechanical properties of both the retainer and sealing elements. Above the transformation temperature, both components exhibit high elastic modulus and generate sufficient force to maintain both tensile strength and sealing pressure, resolving the trade-off between these two competing requirements
3Ease of manufacture
If traditional sealing and retention mechanisms are used separately, then each function can be optimized independently, but the overall connector requires multiple components increasing complexity
Solution Approach 1:
The patent merges the sealing mechanism and retention mechanism into a single integrated connector body. Both the shape memory alloy retainer ring and sealing element are contained within the same housing and activated by the same temperature change, eliminating the need for separate actuation systems and reducing the overall component count while maintaining both functions
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 connector system provides a reliable, inexpensive, and efficient means to create sealed connections that can withstand substantial tensile forces, reducing installation errors and enhancing reliability in downhole environments.
Implementation Method 1
a shape memory alloy sealing system, which may be activated to form a secure seal with a corresponding cable or other component feature
Implementation Method 2
a shape memory alloy retainer system, which may be activated to securely grip the corresponding cable or other component feature so as to withstand substantial tensile loading
Data Source
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AI summary
A technique facilitates formation of secure connections for use in downhole environments. According to an embodiment, a connector may be constructed as a dry mate connector which provides both a sealed connection and a connection able to withstand a predetermined tensile loading. The connector comprises connector ends combined with an outer connector housing. Additionally, the connector comprises a shape memory alloy sealing system which may be activated to form a secure seal with a corresponding cable or other component feature. The connector also comprises a shape memory alloy retainer system which may be activated to securely grip the corresponding cable or other component feature so as to withstand substantial tensile loading acting on the corresponding cable or other component feature.