Spring-Activated Connector Sealing for Harsh Pressure Environments
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Solution Overview
Problem
Existing connectors fail to maintain a fluid-tight seal and optimal signal transmission in harsh environments with high pressures and corrosive fluids, such as subsea oil and gas wells, due to elastomeric O-ring failures and interference from seawater and high pressures.
Innovation Solution
A connector design featuring a housing, contact, plunger, and dual-lipped spring activated seals with flexible portions and springs to form multiple fluid-tight seals, using dielectric fluid and pressure compensation to maintain seal integrity under high pressures and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastomeric O-ring seals are used in connectors, then the connector can provide sealing in normal conditions, but the seal fails under high pressures and corrosive fluids in harsh environments
Solution Approach 1:
The patent changes the material parameter from elastomeric O-ring to spring-activated metal-to-metal seal, enabling the connector to withstand high pressures (exceeding 10,000 PSI) and corrosive fluids by utilizing the elastic properties of spring and the chemical inertness of metal surfaces, thereby resolving the seal failure issue in harsh environments
Solution Approach 2:
The patent employs a composite sealing mechanism combining spring (providing elastic force), metal seal surfaces (providing chemical resistance), and optional intermediate layers (such as PTFE or elastomeric materials), creating a multi-material system that simultaneously addresses high pressure resistance and corrosive fluid protection while maintaining seal integrity
2Strength
If metal-to-metal seals are used to withstand high pressure, then seal strength improves, but signal transmission may be interfered with by seawater and high pressure
Solution Approach 1:
The patent segments the connector into sealed and unsealed sections using the spring-activated metal-to-metal seal, creating a barrier that prevents seawater and high-pressure fluids from reaching the signal transmission components (electrical contacts or optical fibers), thereby protecting signal integrity while maintaining strong sealing capability
Solution Approach 2:
The spring-activated metal-to-metal seal acts as an intermediary barrier between the harsh external environment (seawater, high pressure) and the internal signal transmission components, physically isolating the two and preventing harmful interactions while allowing the seal to withstand extreme conditions
3Reliability
If spring activated seals are used to prevent fluid ingress, then seal reliability improves, but the connector complexity increases
Solution Approach 1:
The patent employs a dynamic spring-activated seal mechanism that automatically adjusts to pressure changes and maintains sealing force without requiring complex control systems, using the inherent elastic properties of the spring to provide continuous sealing pressure that adapts to varying external conditions, thereby achieving high reliability with relatively simple structure
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 connector maintains fluid-tight seals and optimal signal transmission up to 30,000 PSI and extreme temperatures, preventing fluid ingress and ensuring reliable electrical and optical signal integrity in harsh conditions.
Implementation Method 1
The spring is configured to urge the flexible portion to contact the housing and at least one of the plunger and a contact of the secondary device to form a fluid tight seal therebetween
Data Source
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AI summary
A connector comprising a contact, a plunger, and a spring activated seal is provided. The contact is positioned within the housing and configured to transmit at least one of an electrical signal and an optical signal between the connector and a secondary device. The plunger is positioned within the housing and in communication with the contact. The spring activated seal comprises a flexible portion and a spring configured to urge the flexible portion to contact the housing and at least one of the plunger and a contact of the secondary device to form a fluid tight seal therebetween.