SAW Transponder Package for Down-Hole Extreme Environments
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Solution Overview
Problem
Existing down-hole asset tagging devices fail to withstand the extreme conditions of high pressures, high temperatures, and caustic environments found in oil and gas wells, such as those encountered during drilling and production phases.
Innovation Solution
A surface acoustic wave (SAW) transponder package is designed with a hermetically sealed cavity formed by a radome and a metallic base, incorporating a circular dielectric disk and a conductive peripheral weld, which includes a SAW piezoelectric device and a predetermined gas to propagate acoustic waves, and is sealed to prevent caustic fluids from entering, while the dielectric disk and base operate as a directional antenna reflector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hermetically sealed cavity with multiple components (radome, metallic base, dielectric disk, SAW device) is used, then the device can withstand high pressures and temperatures, but the manufacturing complexity increases
Solution Approach 1:
The patent combines multiple protective functions into a single integrated hermetic seal structure that encapsulates the SAW device, antenna, and dielectric components together in one sealed cavity, eliminating the need for separate protective components and reducing overall assembly complexity while maintaining reliability under extreme conditions
2Reliability
If a hermetically sealed cavity with multiple components is used, then the device can withstand caustic environments, but the manufacturing complexity increases
Solution Approach 1:
The hermetic seal structure integrates environmental protection against caustic substances with the RF signal transmission function, creating a single component that serves both protective and functional purposes, thereby reducing the total number of parts needed while ensuring reliability in harsh chemical environments
3Device complexity
If a simplified package design is used, then manufacturing complexity is reduced, but the device may not withstand extreme down-hole conditions
Solution Approach 1:
The patent employs a radome structure that acts as a protective shell enclosing the internal components, providing mechanical strength and environmental sealing while maintaining RF signal transparency, thus achieving reliable protection against extreme pressures and temperatures through a streamlined shell-based design rather than multiple discrete protective components
4Loss of energy
If proper sealing and acoustic wave propagation medium are provided, then signal losses are reduced, but manufacturing complexity increases
Solution Approach 1:
The hermetic seal creates an inert, controlled internal environment that prevents signal degradation from external contaminants while maintaining the acoustic wave propagation medium in its optimal state, thereby reducing signal losses through environmental control rather than through complex active signal management systems
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 and readable RFID tag capable of withstanding pressures up to 25,000 psi and temperatures up to 400°C, reducing signal losses and manufacturing complexity, and enabling efficient tracking of down-hole tools with improved readability performance.
Implementation Method 1
Surface acoustic wave (SAW) transponder package
Implementation Method 2
SAW piezoelectric device
Implementation Method 3
hermetically sealed cavity... sealed to prevent caustic fluids from entering
Implementation Method 4
dielectric disk and base operate as a directional antenna reflector
Data Source
AI summary
A method and apparatus for packaging surface acoustic wave transponders for use in down-hole or other extreme environmental applications. An exemplary ID tag transponder may include a surface acoustic wave (SAW) piezoelectric device, wire bonds, antennae structure, an antenna reflector, a radome, and a base constructed of a conductive, non-magnetic metal or metal alloy adapted to withstand an extreme environment encountered in down-hole applications. The metallic base may have a notched lip or flange about its periphery that is adapted for pressure. An RF reflector is created inside an exemplary transponder tag device. A small amount of predetermined gas is held on top of the SAW piezoelectric device within the reflector cavity to accommodate acoustic wave propagation therein. Exemplary components of a transponder tag are enclosed and hermetically sealed within and between a radome top portion and the metallic base bottom portion.