Patent ID: 10243295

Abstract:
An electrical connector assembly for electric submersible pumps (ESPs) has a fluid impenetrable seal 3D-printed between the power cable and an internal housing component of the electrical connector assembly. Electrical insulation or dielectric for a conductor of the power cable may also be 3D-printed integrally with the fluid seal. The housing component, such as an internal electrical housing, may also be 3D-printed integrally with the printed seal. Likewise, in an implementation, the 3D-printed seal, the internal housing component, and an outer pothead case may all be 3D-printed as a unit onto the power cable. The 3D-printed seal and associated pothead components may be composed of a variety of chemical-resistant materials, such as printed polyarylether-ketones, printed fluorinated polymers, and metal alloys. The 3D-printed seal may also include barrier materials or reinforcement fillers to enhance strength and chemical resistance to well fluids and gases.