Subsea Connector Component Assembly for Stronger Layer Interfaces
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Solution Overview
Problem
Subsea connectors face reliability and cost challenges due to complex manufacturing processes and the need for specialized facilities to apply conductive layers, which can result in ineffective interfaces and increased costs.
Innovation Solution
A method of assembling subsea connector components using compression fitting, casting, moulding, or additive manufacturing techniques to apply electrically insulating and conductive layers, with machining steps to create specific profiles and intimate contact between layers, and the use of corrosion-resistant metal alloys to protect against seawater degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing processes are used to apply conductive layers, then specialized facilities are required, but this increases manufacturing complexity and costs
Solution Approach 1:
The patent combines the application of insulating layers and conductive layers into a single integrated manufacturing process. The conductive layer is applied over the insulating layer in one continuous operation, eliminating the need for separate specialized facilities and reducing manufacturing complexity while maintaining interface integrity.
Solution Approach 2:
The manufacturing process is designed to perform multiple functions using a single system. The same equipment and process can apply both insulating and conductive layers, making the manufacturing system universal and eliminating the need for specialized facilities, thereby reducing complexity and costs.
2Reliability
If multiple separate manufacturing steps are used, then layer interface integrity may be compromised, but this increases manufacturing time and costs
Solution Approach 1:
The insulating layer is applied first as a preliminary step, creating a stable base that ensures proper adhesion for the subsequent conductive layer. This preliminary action establishes the foundation for interface integrity before the final conductive layer is applied, preventing adhesion failures.
Solution Approach 2:
The manufacturing process maintains continuous useful action by applying the conductive layer immediately over the insulating layer without interruption or separation. This continuous process ensures strong interfacial bonding and eliminates the need for multiple discrete steps, thereby maintaining reliability while improving manufacturing efficiency.
3Reliability
If corrosion-resistant metal alloys are used, then protection against seawater degradation is improved, but material costs increase
Solution Approach 1:
The patent uses composite material structures where corrosion-resistant metal alloys are combined with insulating and conductive layers. This composite approach provides superior protection against seawater degradation while optimizing material usage and costs, as the metal alloy is integrated into a multi-layer system that enhances overall durability.
Solution Approach 2:
The patent optimizes the parameters of corrosion-resistant metal alloys by selecting specific compositions and thicknesses that provide adequate protection against seawater degradation. By carefully controlling material parameters such as alloy composition and layer thickness, the solution achieves reliable corrosion protection while managing manufacturing costs effectively.
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
This method enhances the reliability and efficiency of subsea connector manufacturing by reducing the need for specialized facilities, improving interface integrity, and minimizing the risk of degradation from seawater exposure, while lowering costs and simplifying the assembly process.
Implementation Method 1
Compression fitting typically comprises providing compression at an interface between two layers resulting in intimate contact between the two layers.
Data Source
AI summary
A component of a subsea connector includes a conductor, an electrically insulating layer and an at least partially electrically conductive layer. A method of assembling the component includes providing the insulating layer radially outward of the conductor; and applying the at least partially conductive layer onto the insulating layer by casting, moulding, compression fitting, or additive manufacturing techniques.