Subsea Electrical Connector Rhomboidal Insulation
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Solution Overview
Problem
Existing electrical connector systems for subsea applications face challenges in high temperature, high pressure, and high voltage environments due to limited space constraints, where PEEK insulation is compromised at higher temperatures and ceramic insulation requires thicker diameters to maintain mechanical and dielectric strength, but this is not feasible in small diameter tube hanger feed-through holes.
Innovation Solution
The design incorporates a high voltage plug-pin connector with a conductive shaft and non-circular, rhomboidal cross-sectional insulation layers that fit within a smaller diameter space, utilizing ceramic insulation for mechanical strength and PEEK for electrical insulation, allowing for a compact and efficient packaging of insulation within the connector, while maintaining a hermetic seal and adequate insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic insulation is used to maintain mechanical strength at high temperatures, then structural integrity is improved, but the required insulation thickness increases due to lower dielectric strength
Solution Approach 1:
The patent applies asymmetry by using a non-circular (rhomboidal) cross-sectional shape for the ceramic insulation layer. This asymmetric geometry allows the insulation to be positioned closer to the conductor in certain directions while maintaining adequate dielectric clearance, thereby reducing the overall required insulation thickness compared to a conventional circular cross-section that must maintain uniform clearance in all directions.
Solution Approach 2:
The patent transitions from a two-dimensional circular cross-section to a four-sided rhomboidal cross-section, utilizing another geometric dimension to optimize space. This dimensional change in the cross-sectional shape allows for more efficient packing and positioning of the insulation layer within the constrained feed-through hole diameter, enabling closer proximity to the conductor while maintaining electrical clearance.
2Reliability
If thicker ceramic insulation is used to maintain adequate dielectric strength, then electrical insulation is improved, but the feed-through hole diameter must increase
Solution Approach 1:
The rhomboidal cross-sectional shape creates asymmetric clearance zones that optimize dielectric strength distribution. The non-uniform geometry allows thinner insulation in directions where electrical clearance is less critical while maintaining adequate thickness in directions where dielectric strength is most needed, thereby reducing the overall feed-through hole diameter requirement.
Solution Approach 2:
The patent applies local quality by varying the insulation thickness distribution according to local electrical clearance requirements. The rhomboidal shape provides different insulation thicknesses at different locations around the conductor, optimizing dielectric strength where most needed while minimizing overall material volume and feed-through hole diameter.
3Reliability
If PEEK insulation is used for electrical insulation, then dielectric strength is improved, but structural integrity is compromised at high temperatures
Solution Approach 1:
The patent employs composite materials by combining ceramic material for the insulation layer with metal components. The ceramic provides both the necessary dielectric strength for electrical insulation and the structural integrity to withstand high temperature and high pressure conditions, effectively merging the advantages of both material types into a single composite insulation system.
Solution Approach 2:
The patent changes the material parameter from organic PEEK to inorganic ceramic, which fundamentally alters the temperature-dependent mechanical properties. Ceramic maintains its structural integrity at high temperatures where PEEK would degrade, while still providing adequate dielectric strength when configured with the optimized non-circular cross-section.
Data Source
AI summary
Each feed-through pin of a multiple-phase, high voltage plug-pin connector comprises at least one conductor having a first insulation layer extending along at least part of its length, the insulation layer having an enlarged, load-bearing portion of non-circular cross-section having oppositely directed projections, configured for engagement in a correspondingly shaped bore portion of the connector shell. The load-bearing portions may be of a rhomboidal cross sectional shape with rounded corners, with a first diagonal length shorter than a second diagonal length. The pins are spaced around the central longitudinal axis of the shell with the shorter diagonal of each load-bearing portion extending radially and the oppositely directed projections extending into the radial spaces in the shell between adjacent pins. This arrangement allows space within a limited diameter feed through hole for the enlarged, load-bearing shoulder portions of the insulation layer.