Vented Igniter Temperature-Sensitive Seal for Downhole Reliability

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Solution Overview

Problem

Pyrotechnic materials used in downhole operations degrade due to prolonged exposure to elevated temperatures, leading to thermal decomposition and loss of ignitability, resulting in operational downtime.

Innovation Solution

A pyrotechnic device with a hermetically sealed chamber containing a temperature-sensitive material that vents off gases by melting or phase change, allowing communication between the chamber and exterior, thereby preventing gas accumulation and maintaining the pyrotechnic material's integrity at high temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the pyrotechnic material is hermetically sealed within the device for storage, then the material is protected from environmental degradation, but thermal decomposition products accumulate and accelerate deactivation at elevated temperatures

Engineering Contradiction:

Improveigniter reliabilityVSAvoidoff gas accumulation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

A vent passage is pre-configured in the device structure, sealed with a temperature-sensitive material (such as low-melting-point solder or wax) before operation. When the device is exposed to elevated temperatures, the sealing material automatically melts or decomposes, opening the vent passage to allow off gases to escape. This preliminary configuration enables automatic venting without requiring active control systems.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A temperature-sensitive sealing material (such as low-melting-point solder, wax, or polymer) is introduced as an intermediary substance that blocks the vent passage during storage but automatically opens it when exposed to elevated temperatures. This intermediary material mediates between the need for hermetic sealing during storage and the need for venting during operation, enabling automatic response to temperature conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the pyrotechnic material is exposed to elevated temperatures, then the device can operate in downhole environments, but the material undergoes thermal decomposition and loses ignitability

Engineering Contradiction:

Improvedownhole environment capabilityVSAvoidpyrotechnic material stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The invention converts the harmful effect of thermal decomposition into a beneficial venting mechanism. The same elevated temperatures that cause pyrotechnic material degradation also trigger the temperature-sensitive sealing material to melt or decompose, opening the vent passage. This allows off gases from pyrotechnic decomposition to escape, converting the harmful accumulation of decomposition products into a controlled venting process that slows further degradation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Duration of action of stationary object

If a vent passage is added to allow gas escape, then thermal deactivation is slowed, but the device complexity increases

Engineering Contradiction:

Improveigniter service lifeVSAvoiddevice structure

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The vent passage is merged with the existing device structure, integrating the venting function into the housing or chamber wall rather than adding a separate component. The temperature-sensitive sealing material is applied directly to the vent passage opening, combining the sealing and venting functions in a single integrated feature. This minimizes additional complexity while enabling the venting function.

Inventive Principle:

Principle #5Merging (Combining)

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 solution effectively slows thermal deactivation of pyrotechnic materials, ensuring reliable ignition and output even after prolonged exposure to elevated temperatures, reducing operational downtime in downhole environments.

Implementation Method 1

The orifice is hermetically sealed with a solid solder material that, upon heating of the igniter to a predetermined temperature, melts thereby unsealing the passage

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

a temperature-sensitive material that, upon heating of the device to a predetermined temperature, unseals the vent passage

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS9784548B2Vented-at-temperature igniter

Publication Date: 2017.10.10 CARTRIDGE ACTUATED DEVICES

AI summary

A vented pyrotechnic device is provided that hermetically seals the pyrotechnic material contained therein under ambient storage conditions, but vents upon exposure to elevated-temperature conditions at or below the outgassing temperature for the pyrotechnic material. The vent passage communicating the chamber containing the pyrotechnic material with the exterior of the device is initially sealed at ambient storage conditions by a temperature-sensitive material. When exposed to a predetermined temperature condition, the temperature-sensitive material undergoes a physical change unblocking the passage and permitting venting of off gases produced by the pyrotechnic material.