Source Connector Pigtail Reinforcement for Seismic Air Guns
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Solution Overview
Problem
Underwater electrical connectors face premature failure due to extreme environmental conditions, including salt, humidity, wave action, and repeated explosive forces from seismic operations, leading to leakage and operational defects, with existing solutions providing limited durability and requiring frequent replacement.
Innovation Solution
A ruggedized source connector design featuring reinforcing synthetic fibers, improved wire fatigue resistance, and a fatigue-resistant strain relief overmold, along with an external blast shield, which redistributes stress concentrations and extends the service life by providing a protective exoskeleton.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If traditional connector designs are used, then manufacturing simplicity is maintained, but service life is limited due to stress concentrations and environmental exposure
Solution Approach 1:
The patent applies composite materials by combining synthetic fibers (such as aramid or polyester) with the connector housing material. This creates a hybrid structure that leverages the high strength-to-weight ratio and fatigue resistance of synthetic fibers while maintaining the protective and structural functions of the housing material, thereby extending service life under explosive and environmental stresses.
Solution Approach 2:
The patent implements local quality by strategically placing reinforcing synthetic fibers at specific high-stress regions within the connector, such as near the cable entry point and around explosive exposure zones. This localized reinforcement provides enhanced durability where needed most without requiring complete structural redesign, thus improving service life while limiting overall complexity increase.
2Strength
If rigid reinforcement is added to prevent bending, then cable protection is improved, but flexibility and stress distribution worsen
Solution Approach 1:
The patent employs flexible synthetic fiber reinforcements that can bend and flex with the connector and cable movements. These flexible reinforcing elements maintain cable protection and structural integrity while accommodating the dynamic environmental conditions and movement inherent in marine operations, thus preserving both strength and flexibility.
Solution Approach 2:
The patent applies dynamics by designing the reinforcement structure to be adaptable and responsive to operational stresses. The synthetic fiber reinforcement and housing design allow the connector to dynamically adjust to bending, tugging, and explosive forces rather than resisting them rigidly, maintaining both protection and flexibility through controlled deformation.
3Reliability
If connector durability is enhanced through reinforcement, then service life extends, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the connector into modular sections with discrete reinforcement elements. This allows the synthetic fiber reinforcement to be integrated as separate components during assembly rather than requiring complex molded structures, thereby enhancing durability while maintaining relatively simple manufacturing processes through modular construction.
Data Source
AI summary
The present invention provides a ruggedized heavy duty source connector adapted for use on large air guns. The source connector comprises reinforcing fibers in the cable jacket that are anchored to the connector front shell, an external blast shield in place of a rear shell, and a fatigue resistant strain relief overmold.