Sealed Single-Conductor Connector for High-Pressure Gas Insulation
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Solution Overview
Problem
Conventional electrical connectors in high gas environments suffer from gas permeation leading to insulation failure and explosive decompression, posing safety risks and economic costs, while existing solutions are cumbersome and inefficient.
Innovation Solution
A multi-material boot design featuring a plastic body with elastomer bonding and a threaded O-ring seal, allowing for secure electrical connections through a complex geometry with venting ports and a double O-ring seal, preventing gas expansion and maintaining insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional elastomer boots are used to seal electrical connections in high gas environments, then electrical insulation is provided, but gas permeation causes explosive decompression and insulation failure
Solution Approach 1:
The patent uses a composite structure combining PTFE (polymer) and FFKM (elastomer) materials in the boot assembly. The PTFE provides gas-tight sealing properties while the FFKM elastomer provides mechanical flexibility and sealing capability, creating a composite material solution that resists gas permeation while maintaining functional performance in high-pressure gas environments
Solution Approach 2:
The patent employs a boot made from FFKM elastomer material that forms a flexible protective shell around the electrical connector. This flexible boot conforms to the connector geometry while providing mechanical protection and sealing, allowing the assembly to withstand pressure differentials without rigid structural constraints
2Reliability
If gas-tight sealing is implemented using conventional methods, then insulation is maintained, but the structure becomes complex and difficult to assemble
Solution Approach 1:
The patent integrates multiple sealing functions into a single boot component that combines PTFE and FFKM materials. Instead of using separate sealing elements and assembly steps, the multi-material boot provides both gas-tight sealing and electrical insulation in one integrated part, reducing assembly complexity while maintaining sealing reliability
Solution Approach 2:
The boot assembly serves multiple functions simultaneously: it provides electrical insulation, gas-tight sealing, mechanical protection, and pressure containment. This multi-functional design eliminates the need for separate components for each function, simplifying the overall connector assembly while ensuring reliable performance in high-pressure gas environments
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 effectively prevents insulation failure and explosive decompression, ensuring reliable electrical connections in high gas environments, reducing operational risks and costs.
Implementation Method 1
Gases diffusing radially in the conductor and flowing axially along the conductors, between the strands
Implementation Method 2
Gases diffusing radially in the conductor
Implementation Method 3
threaded O-ring seal, allowing for secure electrical connections through a complex geometry with venting ports and a double O-ring seal
Data Source
AI summary
Embodiments presented provide for a sealed connector for use in high gas pressure applications. The sealed connector may provide for electrical signals and power to be transmitted along a cable to a downhole apparatus, such as those used in hydrocarbon recovery operations. The sealed connector includes a body having a first body portion and a second body portion, where the first body portion includes an interior cavity having a connection portion and a sealing surface, and the second body portion is comprised of an elastomer having a bore. The elastomer of the second body portion is bonded to the first body portion, and an insert is disposed within the body. A wire is configured to extend through the bore of the second body portion, the elastomer of the second body portion seals against the wire, and the wire is coupled to the insert.