Vacuum-Housed Pressure Sensor for Leak-Resistant Borehole Sensing

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Solution Overview

Problem

Existing pressure sensors in downhole environments suffer from leaks, assembly complexity, and require skilled assembly, particularly those using hydraulic oil and crystal transducers.

Innovation Solution

A pressure sensor design featuring a transducer crystal in a vacuum housing with a driver connected to a deflectable member exposed to ambient pressure, eliminating the need for hydraulic oil and reducing assembly complexity by using a direct mechanical linkage to transmit pressure readings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hydraulic oil and crystal transducer assembly is used, then pressure sensing function is achieved, but assembly complexity increases and requires skilled assembly

Engineering Contradiction:

Improvepressure sensing functionVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the hydraulic oil from the system entirely, extracting the problematic fluid component that caused leaks and assembly complexity. The pressure sensing function is achieved through a direct mechanical linkage between the deflectable member and crystal transducer, eliminating the need for hydraulic fluid while maintaining reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a deflectable member (such as a diaphragm or bellows) as an intermediary component that directly transmits pressure forces to the crystal transducer through a mechanical driver. This intermediary mechanism replaces the complex hydraulic oil system with a simpler solid-mechanical transmission path, reducing assembly complexity while preserving the pressure sensing function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If hydraulic oil is used in the bellows, then pressure transmission is achieved, but leaks occur that reduce effectiveness

Engineering Contradiction:

Improvepressure transmissionVSAvoidleaks

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and removes the hydraulic oil from the bellows assembly, eliminating the source of leaks entirely. Pressure transmission is achieved through the deflectable member and driver mechanism that uses solid mechanical components instead of fluid, thereby eliminating leak-related harmful factors while maintaining reliable pressure transmission.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the hydraulic mechanical system (using fluid pressure transmission) with a direct solid mechanical system. The deflectable member and driver create a mechanical linkage that transmits pressure forces directly to the crystal transducer without requiring hydraulic oil, thereby eliminating leaks while achieving reliable pressure transmission.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If hydraulic oil and crystal transducer assembly is used, then pressure sensing is achieved, but assembly requires particular skill and experience

Engineering Contradiction:

Improvepressure sensingVSAvoidassembly skill requirement

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent removes the hydraulic oil and associated complex assembly requirements, simplifying the manufacturing process. The direct mechanical linkage between the deflectable member and crystal transducer creates a more straightforward assembly that requires less specialized skill and experience, while maintaining reliable pressure sensing functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The deflectable member serves as a simplified intermediary that easeS the assembly process by providing a clear mechanical interface between the pressure environment and the crystal transducer. This intermediary component creates a more intuitive assembly structure that reduces the skill and experience required compared to the hydraulic oil system.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 new design minimizes leaks and simplifies assembly, providing reliable pressure readings without hydraulic fluid infiltration and enabling standard electrical connections, suitable for use in borehole systems.

Implementation Method 1

a deflectable member in contact with the driver on one surface and exposed to ambient pressure on the opposite surface

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 2

a transducer crystal disposed in the housing in vacuum conditions, a driver in contact with the transducer

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS12460540B2Pressure sensor and borehole system

Publication Date: 2025.11.04 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

A pressure sensor including a transducer housing, a transducer crystal disposed in the housing in vacuum conditions, a driver in contact with the crystal transducer, and a deflectable member in contact with the driver on one surface and exposed to ambient pressure on the opposite surface thereof. A borehole system including a borehole in a subsurface formation, a string in the borehole, and a sensor connected to the string.