SAW Transponder Dome Packaging for Down-Hole Reliability
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Solution Overview
Problem
Existing asset tagging systems for oil and gas exploration fail to withstand the high pressures, high temperatures, and caustic environments encountered in down-hole and above-ground applications, requiring a more durable and reliable solution for tracking equipment.
Innovation Solution
A Surface Acoustic Wave (SAW) piezoelectric device is attached directly to an antenna substrate, enclosed within a dome structure with a gas seal, and covered in a radio frequency transparent material to create a robust and hermetically sealed transponder device that can operate in extreme conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a passive RFID tag is installed on each asset for tracking, then inventory management capability is improved, but the device cannot withstand high pressures, high temperatures, and caustic environments in down-hole applications
Solution Approach 1:
The patent combines the RFID antenna and SAW device into a single integrated assembly where the SAW device is directly mounted on the antenna substrate. This merging eliminates the need for separate packaging of these components while maintaining their individual functions, thereby improving environmental withstand capability without proportionally increasing overall device complexity.
Solution Approach 2:
The patent employs a nested packaging structure where the dome enclosure contains the SAW device and antenna assembly, which is then placed within an overmolded protective housing. This nested arrangement protects sensitive components from harsh environments (high pressure, temperature, caustic conditions) while keeping the overall structure compact and manageable.
2Reliability
If multiple components are assembled to create a hermetically sealed RFID device, then environmental protection is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-attaching the SAW device to the antenna substrate before final assembly into the dome enclosure. This pre-assembly step ensures proper positioning and electrical connections are established beforehand, simplifying the subsequent hermetic sealing process and reducing the complexity of the overall manufacturing procedure.
Solution Approach 2:
The patent utilizes a dome enclosure with a hermetic seal that creates a protective barrier around the SAW device and antenna. This flexible sealing structure provides hermetic protection against environmental factors while allowing for relatively simple manufacturing processes compared to rigid multi-component assemblies.
3Device complexity
If the SAW device is directly attached to the antenna substrate, then device complexity is reduced, but protection against harsh environments may be compromised
Solution Approach 1:
The integrated SAW device and antenna assembly is nested within a dome enclosure that provides hermetic sealing, which is then placed within an overmolded protective housing. This nested protection scheme shields the simple direct-attachment configuration from harsh environmental factors including high pressure, temperature extremes, and caustic conditions.
Solution Approach 2:
The patent employs composite packaging structures combining the dome enclosure material with the overmolded protective housing material. This composite approach provides enhanced protection against environmental harmful factors while maintaining the simplicity of the internal SAW device to antenna substrate direct attachment configuration.
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 solution provides a durable asset tagging system capable of withstanding extreme temperatures, pressures, and caustic environments, enabling effective tracking of equipment in harsh oil and gas exploration settings while maintaining operational integrity.
Implementation Method 1
Surface Acoustic Wave (SAW) transponder
Implementation Method 2
SAW piezoelectric device
Implementation Method 3
enclosed within a dome structure with a gas seal
Implementation Method 4
covered in a radio frequency transparent material
Data Source
AI summary
A method and apparatus for packaging a surface acoustic wave transponder for use in harsh environments is provided. An exemplary transponder comprises a surface acoustic wave piezoelectric device, wire bonds, an antenna element, an antenna substrate, a dome structure, and casing. The exemplary surface acoustic wave piezoelectric device is attached directly onto the antenna substrate and wire bonded to an antenna element. The surface acoustic wave piezoelectric device is protected under the dome structure, which is sealed and attached to the antenna substrate. The components are encased and sealed within a transponder casing. The transponder may be part of or incorporated into substantially any shape or form factor.