Overmolded Shaped Charge Cartridge for Focused Blast Containment
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Solution Overview
Problem
Conventional shaped charges used in downhole operations suffer from inadequate confinement of explosive energy, vulnerability to environmental damage, and are typically designed for single-use due to irreversible deformation and damage during firing, leading to inefficiencies and increased costs.
Innovation Solution
The development of overmolded shaped charges encased in a protective cartridge, allowing for enhanced containment and directional focus of explosive energy, improved environmental resistance, and the ability to be reused by firing individually, reducing the need for bulkheads and optimizing system design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional shaped charges are used without overmolding, then the device structure is simpler, but the explosive energy is not adequately confined leading to collateral damage
Solution Approach 1:
An overmold layer is introduced as an intermediary between the explosive charge and the surrounding environment. This overmold confines the explosive energy and directs it along the desired path, preventing collateral damage while maintaining operational effectiveness.
Solution Approach 2:
The shaped charge device is segmented into distinct functional layers: the explosive charge core, the overmold confinement layer, and the protective cartridge. This segmentation allows each layer to perform its specific function optimally while working together as an integrated system.
2Reliability
If conventional shaped charges are directly exposed to the environment, then the device is easier to manufacture, but it is vulnerable to environmental damage compromising operation
Solution Approach 1:
The shaped charge is pre-assembled and overmolded within a protective cartridge structure before deployment. This preliminary encapsulation protects the explosive components from environmental factors such as moisture, corrosion, and physical damage, ensuring reliable operation when needed.
Solution Approach 2:
A protective cartridge shell encapsulates the overmolded shaped charge, providing a barrier against environmental damage. This shell structure maintains protection while allowing the device to be handled and deployed effectively in downhole conditions.
3Productivity
If conventional shaped charges are designed without overmolding, then the manufacturing process is simpler, but oversized designs are required to compensate for low explosive efficiency
Solution Approach 1:
The overmold acts as a mediator that channels and concentrates explosive energy in the desired direction. This confinement increases the efficiency of the explosive material, allowing smaller, more compact charge designs to achieve the same penetration效果 as larger conventional charges.
Solution Approach 2:
The introduction of the overmold changes the energy distribution parameters of the explosive device. By confining and directing the explosive force, the energy density and directional focus are improved, resulting in higher explosive efficiency and reduced charge size requirements.
4Productivity
If conventional shaped charges are used, then the initial device cost is lower, but reusability is limited due to damage from the blast
Solution Approach 1:
The system is segmented into the disposable shaped charge cartridge and the reusable launcher/barrel. The cartridge containing the overmolded charge is designed for single use, while the launcher structure withstands the blast and can be reloading and reused, improving overall operational productivity.
Solution Approach 2:
The shaped charge cartridge is designed as a disposable, low-cost component that is consumed in the blasting operation. This allows the more expensive launcher and associated equipment to be preserved and reused, improving the economic efficiency and productivity of repeated operations.
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 approach enables deeper penetrations with smaller explosive loads, reduces system length, enhances reliability, allows for customizable geometries, and lowers operational costs through reusable components and efficient loading processes.
Implementation Method 1
When the explosive is detonated, the resulting blast wave is focused by the shape of the device
Implementation Method 2
an explosive material is shaped into a conical or cylindrical form, with a hollow cavity in the center
Data Source
AI summary
One example apparatus includes a shaped charge, and an overmold that includes one or more layers surrounding a portion of the shaped charge. The overmold may contact, and conform to, a case within which the shaped charge is received, and the overmold may further contact, and conform to, a cartridge wall within which the shaped charge and the overmold are positioned. An electrical or electronic component may be partly embedded in the overmold.