Injection Molded Electrical Connector Seals
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Solution Overview
Problem
Existing hydrocarbon well power cable connectors, such as pothead assemblies, face challenges with elastomeric seals that can be damaged by chemicals, gases, and extreme temperatures, requiring time-consuming and expensive machining techniques for effective sealing.
Innovation Solution
An injection molding process is used to create a sealed feature between connector and electrical components, forming a robust and reliable seal that prevents fluid leakage, eliminating the need for elastomer seals and enabling automated manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastomeric seals are used to prevent fluid leakage, then sealing function is achieved, but the seals can be damaged by chemicals, gases, and extreme temperatures
Solution Approach 1:
The patent removes elastomeric seals from the system entirely and replaces them with an injection molded feature that integrates the sealing function directly into the connector housing. This extraction eliminates the vulnerability of elastomeric materials to chemical and thermal damage while maintaining the sealing function through a more robust integrated structure.
Solution Approach 2:
The patent uses an injection molded feature made from materials that combine the structural integrity of the connector housing with sealing capabilities. This composite approach integrates the sealing function into the housing itself, creating a unified structure that resists damage from chemicals, gases, and extreme temperatures while maintaining reliable fluid prevention.
2Reliability
If elastomeric seals and machining techniques are used to form adequate seals, then fluid sealing is achieved, but the process becomes time-consuming and expensive
Solution Approach 1:
The patent merges the sealing function with the connector housing by integrating an injection molded feature directly into the housing structure. This consolidation eliminates separate elastomeric seal components and their associated machining operations, reducing manufacturing steps, time, and cost while maintaining effective fluid sealing.
Solution Approach 2:
The patent replaces traditional mechanical sealing methods (elastomeric seals requiring precision machining) with an injection molding process. This substitution eliminates time-consuming machining operations while achieving equivalent or superior sealing effectiveness through the integrated molded feature.
3Reliability
If traditional sealing mechanisms are used in pothead assemblies, then fluid prevention is achieved, but the construction becomes complex and requires multiple components
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated injection molded feature that is part of the connector housing. This merger reduces the number of separate sealing components and simplifies the overall assembly while maintaining comprehensive fluid prevention capabilities across all necessary interfaces.
Solution Approach 2:
The injection molded feature serves multiple sealing functions simultaneously, providing fluid prevention at various interfaces within the connector assembly. This multi-functional design eliminates the need for multiple specialized sealing components, reducing complexity while maintaining reliable fluid prevention throughout the pothead assembly.
Data Source
AI summary
A technique facilitates construction of a sealed electrical connector, e.g. sealed pothead assembly. Depending on the application, the electrical connector may be used to connect a power cable and a powered component such as an electric submersible pumping system. The electrical connector comprises at least one connector component and at least one electrical component. An injection molding process is used to construct an injection molded feature sealed to a corresponding component, e.g. to the at least one electrical component. The injection molded feature is readily formed and located between the at least one electrical component and the at least one connector component to form a simple and reliable seal which prevents unwanted passage of fluids.