Printed Electrical Interconnections on Drill String Chassis
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Solution Overview
Problem
The existing methods for connecting electronic components in downhole drilling tools, such as wiring harnesses and soldered connections, are costly, time-consuming, and prone to failures, reducing the reliability of these tools.
Innovation Solution
The use of printed electrical interconnections formed through an additive manufacturing process, which are integrated into the chassis component of the drill string to provide reliable and efficient electrical connections between electronic components, allowing for interchangeability of modular components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wiring harnesses and soldered connections are used to connect electronic components, then electrical connections can be established, but the assembly becomes costly and time-consuming
Solution Approach 1:
The patent merges the electrical connection function directly into the chassis component by forming printed electrical interconnections on the chassis surface. This eliminates the need for separate wiring harnesses and soldering operations, as the chassis itself becomes the electrical interconnection medium. The printed interconnections are integrated during chassis manufacturing, combining structural and electrical functions into a single component.
Solution Approach 2:
The patent replaces traditional mechanical electrical connection methods (wiring harnesses, connectors, soldering) with a printed electrical system. The printed electrical interconnections use conductive traces deposited on the chassis surface, eliminating the need for mechanical assembly of electrical components. This substitution reduces assembly complexity and time while maintaining connection reliability.
2Reliability
If traditional wiring harnesses are used for electrical connections, then connections can be made, but the assembly process becomes time-consuming
Solution Approach 1:
The printed electrical interconnections are formed on the chassis surface during the chassis manufacturing process itself, before the electronic components are installed. This preliminary formation of electrical paths eliminates the need for time-consuming on-site wiring and connection assembly. The electrical interconnections are pre-integrated into the chassis structure, enabling faster overall assembly of the downhole drilling tool.
3Ease of manufacture
If conventional connection methods are used, then electrical connections can be established, but failures are prone and reliability is reduced
Solution Approach 1:
The patent combines the chassis structural function with the electrical interconnection function into a single integrated component. The printed electrical interconnections are formed directly on the chassis surface, eliminating the need for separate wiring harnesses and connectors that are prone to failure. This merging reduces the number of potential failure points while simplifying the manufacturing and assembly process.
Data Source
AI summary
An apparatus having one or more printed electrical interconnections is disclosed. The apparatus may include a chassis component of a drill string. The chassis component is configured to receive an electronic component. The apparatus also includes one or more printed electrical interconnections disposed proximate to the chassis. The one or more printed electrical interconnections are configured to communicatively connect with the electronic component.