Metallic Barrier on Thermoplastic Substrate for Oil Well Electrical Interfaces

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Solution Overview

Problem

Electrical connections in oil wells are susceptible to corrosion and damage due to harsh environments, leading to disruption of electrical conduction as existing insulation materials degrade, particularly at the interface between metallic encapsulating materials and thermoplastic substrates.

Innovation Solution

A metallic layer is deposited onto a thermoplastic substrate of a conductor to create an impermeable barrier between the metallic encapsulating material and the thermoplastic substrate, with a dielectric material sandwiched between the metallic layer and the metallic barrier sleeve to prevent environmental permeation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thermoplastic substrate is used to protect the copper pin from harsh well environment, then the pin is protected from corrosion and damage, but the interface between the metallic encapsulating material and thermoplastic substrate remains insufficient as a barrier against environmental permeation

Engineering Contradiction:

Improveprotection of copper pinVSAvoidenvironmental permeation at interface

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by creating a multi-layer structure consisting of a metallic layer deposited on the thermoplastic substrate, with a dielectric material sandwiched between the metallic layer and the metallic barrier sleeve. This composite structure combines the corrosion resistance of thermoplastic materials with the impermeability of metallic and dielectric layers, effectively preventing environmental permeation at the interface while maintaining protection of the copper pin.

Inventive Principle:

Principle #40Composite materials

2Reliability

If high dielectric materials such as tapes and rubber are used to insulate the connection between copper pins and cable, then electrical insulation is provided, but these materials rapidly degrade their dielectric properties due to harsh well environment

Engineering Contradiction:

Improveelectrical insulationVSAvoidservice life of dielectric material

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent replaces conventional high dielectric materials (tapes and rubber) with a composite barrier structure consisting of a metallic layer, dielectric material, and metallic encapsulating material. This composite structure provides both electrical insulation and resistance to environmental degradation, significantly extending the service life of the insulation while maintaining dielectric properties in harsh well environments.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The metallic layer and metallic encapsulating material create an inert barrier environment that protects the dielectric material from direct exposure to harsh well environment elements such as moisture, chemicals, and corrosion. This inert barrier prevents the rapid degradation that would otherwise occur with conventional dielectric materials.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Device complexity

If the metallic encapsulating material is directly bonded to the thermoplastic substrate, then the structure is simplified, but the barrier against harsh oil well environment is insufficient

Engineering Contradiction:

Improvestructure of electrical connectionVSAvoidbarrier protection

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent introduces a composite barrier structure with a metallic layer deposited on the thermoplastic substrate and a dielectric material sandwiched between the metallic layer and metallic barrier sleeve. While this increases structural complexity compared to direct bonding, it significantly enhances barrier protection against harsh oil well environments by preventing environmental permeation at the interface.

Inventive Principle:

Principle #40Composite materials

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

This solution effectively protects the electrical interface from harsh well environments by preventing the permeation of vapors, gases, or liquids while maintaining dielectric strength, thus ensuring continuous electrical conduction.

Implementation Method 1

depositing a metallic layer onto a thermoplastic substrate of a conductor to create an impermeable barrier

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 2

a dielectric material sandwiched between the metallic layer and the metallic barrier sleeve to prevent environmental permeation

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS11398710B2Protective barrier for the dielectric materials of an electrical connection/interface in an oil well environment and a method of forming the same

Publication Date: 2022.07.26 ANDERSON DAVID

AI summary

A method for protecting an electrical interface in an oil well environment, the method providing the deposition/application of a metallic layer onto a thermoplastic substrate of a conductor of the electrical interface to create an impermeable barrier between a metallic encapsulating material and the thermoplastic substrate.