Patent ID: 12224521

DETAILED DESCRIPTION

Certain embodiments commensurate in scope with the present disclosure are summarized below. These embodiments are not intended to limit the scope of the disclosure, but rather these embodiments are intended only to provide a brief summary of certain disclosed embodiments. Indeed, the present disclosure may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

As used herein, the term “coupled” or “coupled to” may indicate establishing either a direct or indirect connection (e.g., where the connection may not include or include intermediate or intervening components between those coupled), and is not limited to either unless expressly referenced as such. The term “set” may refer to one or more items. Wherever possible, like or identical reference numerals are used in the figures to identify common or the same elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale for purposes of clarification.

Furthermore, when introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment,” “an embodiment,” or “some embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, the phrase A “based on” B is intended to mean that A is at least partially based on B. Moreover, unless expressly stated otherwise, the term “or” is intended to be inclusive (e.g., logical OR) and not exclusive (e.g., logical XOR). In other words, the phrase A “or” B is intended to mean A, B, or both A and B.

Conventional subsea wellheads include a number of large operational steel assemblies that form a pressure enclosure yet allow the wellhead to be deployed in sections and work-over operations to be carried out in service. The wellhead sections form sub-assemblies that provide the interface points for the electrical and hydraulic feed through systems. Due to the operational requirements of these wellheads, there exists a need for the electrical and hydraulic connectors to accommodate large variations in the relative positions of the wellhead parts, which form these connector interfaces. As wellheads are deployed in more aggressive deeper locations, the need for more reservoir data increases, therefore there is a drive towards more space saving couplers and devices.

This application is related to U.S. Pat. No. 7,112,080, filed on Dec. 16, 2003, which is incorporated by reference herein, and is related to an International Application having Serial No. PCT/GB02/01205, filed on Mar. 14, 2002, which is incorporated by reference herein. The present disclosure relates to the enhancement features to the dual contact wet mateable connector described in U.S. Pat. No. 7,112,080, which provides significant improvements to the connector's operational performance.

As such, in certain embodiments of the present disclosure, a first connector (e.g., female connector or receptacle) may be mated with a second connector (e.g., male connector or plug) in two connection stages. In the first connection stage, a central pin of the first connecter engages a shuttle pin of the second connector along a bore of the second connector. The central pin may depress the shuttle pin via a shuttle spring until radial contacts disposed about the bore of the second connector align with mating radial contacts on the central pin of the first connector. The shuttle pin may also engage a two-stage release latch, which enables a disengagement of a movable support disposed within the second connector to initiate a second connection stage. In the second connection stage, the shuttle pin, via an abutment between the shuttle pin and movable support, may cause an axial path of travel of the movable support, and a concurrent engagement of axial contacts and mating axial contacts over an axial distance within the second connector.

In certain embodiments, the second connector may include a housing insulation that encapsulates the interior of the second connector. Furthermore, the second connector interior may include axial contacts and corresponding mating axial contacts. The axial contacts and corresponding mating axial contacts may additionally be individually enclosed in insulation. In this manner, the axial contacts and corresponding mating axial contacts are enclosed via two layers of insulation providing improved insulation resistance.

In certain embodiments, a mount is coupled to the second connector. The mount includes a rotatable arm coupling a mounting flange with a base portion of the second connector. The rotatable arm includes an outer sleeve disposed about an inner conduit. The inner conduit is configured to flex during rotation of the rotatable arm. The mount includes a first ball and socket joint between the rotatable arm and the base portion of the mating connector, a second ball and socket joint between the rotatable arm and the mounting flange, or a combination thereof.

FIG.1is an exploded view of a subsea electrical connection system10having a connector12configured to removably couple with a connector14. The connector12may be described as a first connector, a female connector, a female contact connector, or a connector receptacle, whereas the connector14may be described as a second connector, a male connector, a male contact connector, or a connector plug. Each of the connectors12and14include both mechanical and electrical connections, wherein the mechanical connections structurally secure the connectors12and14together and the electrical connectors complete one or more electrical paths between the connectors12and14. As discussed in detail below, the subsea electrical connection system10includes a multi-stage connection system (e.g., two-stage connection system) configured to couple together the connectors12and14in a plurality of connection stages (e.g., at least first and second connection stages). Additionally, one or both of the connectors12and14may include multiple layers of insulation, pressure balancing barriers, fluid seals, and flexible mounts. The connectors12and14are configured to insulate, seal, and protect internal electrical paths before, during, and after connections between the connectors12and14.

The connector12includes an outer housing16(e.g., annular housing), which encloses a cable termination portion18on a first axial side20of the connector12and a first connector portion22on a second axial side24of the connector12. The outer housing16may be a metallic outer housing having internal insulation. The first axial side20includes a port26configured to receive a first cable28. The first cable28may include any number of electrical conductors, such as 1, 2, 3, 4, 5, or more, and may be disposed in a metallic jacket for protection and sealing purposes. In the illustrated embodiment, the first cable28includes at least two electrical conductors. The second axial side24of the connector12includes a first axial opening30(e.g., annular opening) and a frustoconical guide32(e.g., tapered annular guide) enclosing the first axial opening30, such that a side34of the tapered guide28having a larger dimension (e.g., diameter) faces outwardly in longitudinal direction36.

The connector14includes an outer housing38(e.g., annular housing), which includes a second connector portion40on a first axial side42of the connector14and a mounting portion44on a second axial side46of the connector14. The outer housing38may be a metallic outer housing having internal insulation. The second connector portion40includes a mating portion48coupled to a base portion52of the connector portion40via a mating edge50(e.g., annular shoulder or abutment). The outer housing38includes one or more pressure ports53(e.g., along the base portion52) for enabling pressure balancing between an exterior (e.g., exterior fluid such as seawater) and an interior (e.g., interior fluid such as oil or lubricant) of the connector14via a pressure balancing barrier126(seeFIG.2). In the illustrated embodiment, a dimension54(e.g., diameter) of the mating portion48is smaller than a dimension56(e.g., diameter) of the base portion52. For example, the dimension54may be 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 percent less than the dimension56. A first axial end58(e.g., opposite of longitudinal direction36) of the mating portion48is tapered (e.g., frustoconical), such that a dimension60of the axial end58is smaller than the dimension54of the mating portion48. The axial end58includes a second axial opening62(e.g., annular opening) having a tapered (e.g., frustoconical) profile, such that a side of the second axial opening62having a larger dimension faces outwardly, opposite of longitudinal direction36. A shuttle pin64(e.g., shuttle, actuation pin, latch release actuator, etc.) protrudes through the side of the second axial opening62having the smaller dimension (e.g., side facing longitudinal direction36) and includes an indentation66(e.g., conical indentation). The mounting portion44includes a mounting flange68having one or more flange holes70(e.g., bolt receptacles) configured to enable a mounting of the connector14on a subsea structure (e.g., tree). A second axial end72of the connector14(e.g., at a surface of the mounting flange68), includes an opening to receive a second cable74.

In the illustrated embodiment, the connector12is configured to engage (e.g., removably couple with) the connector14, thereby aligning a first central axis76of the connector12with a second central axis78of the connector14. The mating edge50is configured to abut the frustoconical guide32of the connector12in response to the connector12fully engaging the connector14. In certain embodiments, the mating edge50may also be configured to transfer a load (e.g., force) exerted by the connector14onto the connector12. The connector12may engage the connector14by an axial movement of the connector14relative to the connector12, an axial movement of the connector12relative to the connector14or, in certain embodiments, concurrent axial movements of both the connector12and the connector14. In the illustrated embodiment, the connectors12and14are shown as having an annular (e.g., circular) shape, however, in certain embodiments, the connectors12and14may have a non-annular shape. Furthermore, the illustrated embodiment shows the connector12as a female connector (e.g., female contact connector) and the connector14as a male connector (e.g., male contact connector). That is, engagement of the connector12with the connector14is achieved via an insertion of the mating portion48of the connector14into the first axial opening30of the connector12. In certain embodiments, the connector12may be a male connector and the connector14may be a female connector. That is, in certain embodiments, engagement of the connector12with the connector14may be achieved via an insertion of a portion of the connector12into the connector14.

FIG.2is an exploded cross-sectional view of the subsea electrical connection system10ofFIG.1. In the illustrated embodiment, the connector12includes the first axial opening30extending into an axial chamber100(e.g., annular chamber). The connector12also includes a central pin102(e.g., male pin or annular connector shaft) disposed inside the axial chamber100, and extending along the first central axis76of the connector12. The central pin102is electrically coupled to the first cable28and is mechanically coupled to the remaining structure of connector12, such that the central pin102is at least partially retained by the connector12in the longitudinal direction36. The connector12also includes a wiper assembly104(e.g., annular wiper assembly) disposed inside the axial chamber100and disposed about the central pin102. The wiper assembly104includes a wiper106(e.g., annular wiper), configured to make sealing contact with and slide axially along the central pin102. The wiper assembly104may contain a fluid (e.g., oil, insulating grease) to insulate and/or pressure balance the wiper106, allowing free movement at depth pressure. The connector12also includes a wiper spring108coupled to the wiper assembly104and configured to exert a biasing force on the wiper assembly104. The wiper spring108is disposed about the central pin102and extends to the first axial side20of the connector12. The wiper assembly104is configured to make contact with the first axial end58of the connector14in response to an insertion of the mating portion48into the first axial opening30of the connector12. As the mating portion48is further inserted into the axial chamber100, the connector14exerts a load onto the wiper assembly104, thereby causing the wiper assembly104to travel axially through the axial chamber100(e.g., opposite of direction36) while axially compressing the wiper spring108. As the wiper assembly104moves axially along the central pin102, the wiper106presses against the central pin102, thereby wiping the central pin102to block contaminants from entering the connector14when coupling together the connectors12and14. The wiper106also may seal against or around the central pin102, thereby blocking the ingress of contaminants (e.g., seawater, debris, etc.) into the connector12. In response to the mating portion48being removed from the axial chamber100, the wiper spring108may provide a biasing force on the wiper assembly104, causing the wiper assembly104to return to its initial position.

The illustrated embodiment also shows the first axial opening30and frustoconical guide32. As shown in the illustrated embodiment, the first axial opening30is frustoconical in shape and enclosed (e.g., circumferentially surrounded) by the frustoconical guide32. The slightly larger diameter of the first axial opening30may assist in aligning the first central axis76of the connector12with the second central axis78of the connector14, thereby guiding the mating portion48of the connector14into the first axial opening30.

In the illustrated embodiment, the connector14includes a connector assembly110disposed in the mating portion48and base portion52, and inside the outer housing38. The connector assembly110includes a shuttle pin spring112(e.g., shuttle spring) coupled to the shuttle pin64, and a movable support114disposed around the shuttle pin spring112. The movable support114includes one or more connector portions116(e.g., 1, 2, 3, 4, 5, or more electrical connector portions), which each include one or more radial contacts118(e.g., 1, 2, 3, 4, 5, or more radial electrical contacts). The radial contacts118may include annular contacts, circumferentially spaced radial contacts, axially spaced radial contacts, or a combination thereof. The radial contacts118include electrical contacts (e.g., electrically conductive and/or metallic contacts). The connector14includes a housing insulation layer120(e.g., electrical insulation layer) disposed along and/or lining an interior surface of the housing38, wherein the housing insulation layer120extends around (e.g., enclosing) the connector assembly110. In certain embodiments, the housing insulation layer120may provide an encapsulating electrical insulation inside the outer housing38, thereby electrically insulating electrical paths through the interior of the connector14(e.g., movable support114and connector portions116). In some embodiments, the housing insulation layer120may be composed of a polymer material (e.g., organic thermoplastic polymer, polyaryletherketone polymers, polyether ether ketone (PEEK)), although other insulative materials may be used in certain embodiments.

Furthermore, the connector14includes a housing fluid chamber122(e.g., annular fluid chamber) disposed inside the housing38along the housing insulation layer120(e.g., outside connector portions116) and, in certain embodiments, fluidly coupled to fluid paths124(e.g., internal fluid paths). The housing fluid chamber122and the fluid paths124may be configured to contain an internal fluid, such as a gas and/or liquid (e.g., lubricant, oil, electrically non-conductive fluid, etc.). A pressure balancing barrier126(e.g., pressure diaphragm) is disposed between the housing fluid chamber122(e.g., annular fluid chamber) and the outer housing38or, in certain embodiments, a secondary fluid chamber disposed between the pressure balancing barrier126and the outer housing38. The pressure balancing barrier126is configured to expand and/or contract in response to changes in pressure of an internal fluid within the housing fluid chamber122and/or fluid paths124and an external fluid (e.g., seawater) entering through pressure ports53, thereby pressure balancing between the internal and external fluids. Additionally, in certain embodiments, the housing fluid chamber122may be pressure compensated to allow axial movement of the movable support114and components coupled to the movable support114(e.g., connector portions116).

In the illustrated embodiment, the mounting portion44of the connector14includes a rotatable arm138having an outer sleeve (e.g., split spine sleeve140). The split spine sleeve140may include two spline halves (e.g., C-shaped sleeve portions split along longitudinal direction36), which may be joined together via threaded fasteners142(e.g., threaded bolts, nuts, screws, etc.). The split spine sleeve140is disposed about an inner conduit144(e.g., conduit stem) configured to route or pass the second cable74to the connector portion40of the connector14. In certain embodiments, the second cable74may be divided into two separate cables and routed through two separate inner conduits. The second cable74may include any number of electrical conductors, such as 1, 2, 3, 4, 5, or more. In the illustrated embodiment, the second cable74includes at least two electrical conductors.

In certain embodiments, a first socket profile146on a first axial end of the split spine sleeve140may be configured to engage a first ball mount148coupled to the base portion52, thereby forming a first ball and socket joint149. Additionally or alternatively, a second socket profile150on a second axial end of the split spine sleeve140may be configured to engage a second ball mount152coupled to the mounting flange68, thereby forming a second ball and socket joint153. Although the first and second ball mounts148,152and corresponding first and second socket profiles146,150may be spherical, other curved geometries may be used to enable rotational movement of the rotatable arm138relative to the base portion52and the mounting flange68. The rotatable arm138(e.g., split spine sleeve140) is configured to rotate via the first and/or second ball and socket joints149,153.

In certain embodiments, the split spline sleeve140includes overhangs154that extend into gaps156disposed between the ball mounts148and152, and the base portion52and mounting flange68, respectively. In certain embodiments, the overhangs154are configured to enable a partial rotation (e.g., relief rotation, relief angle) of the split spine sleeve140(e.g., mating portion48). For example, the split spine sleeve140may be configured to rotate up to a threshold angle in each direction, such as up to a maximum of 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 degrees relative to the second central axis78of the connector14. In certain embodiments, the inner conduit144is configured to flex (e.g., bend) during rotation of the split spine sleeve140. It may be appreciated that the mounting portion44(e.g., first and second ball and socket joints149,153) along with the flexible inner conduit144may provide improved axial alignment of the connector12and connector14during mating.

In the illustrated embodiment, connector12is shown as having a female-type outer housing16, with a male central pin102. That is, the connector12may be described as having a male electrical portion (e.g., central pin102) concentrically disposed inside a female outer housing16. Additionally, connector14is illustrated as having a male outer housing38, with a female axial opening62(e.g., central bore). That is, connector14may be described as having a female electrical portion concentrically disposed inside a male outer housing38. In some embodiments, the genders associated with the outer housings and electrical portions for the connectors12and14may be reversed.

FIG.3is a first cross-sectional view of the subsea electrical connection system10ofFIG.1at a first connection stage between the connectors12and14. In the illustrated embodiment, the connector assembly110further includes a stationary support180having a central bore182(e.g., annular bore) along the second central axis78. The connector assembly110also includes one or more springs184(e.g., two springs, three springs, etc.) coupling the movable support114to the stationary support180. In this manner, the springs184may be configured to exert a biasing force on the movable support114, such that the movable support114is compressed against the first axial end58of the connector14. In certain embodiments, the springs184may be supported by posts186(e.g., telescopic posts) disposed through each of the springs184. In certain embodiments, the posts186may be coupled to the stationary support180via bolts188.

In the illustrated embodiment, the shuttle pin64is disposed in an inner bore190(e.g., annular inner bore) of the movable support114, and configured to engage the central pin102of the connector12through the second axial opening62of the connector14. The shuttle pin64includes one or more shuttle protrusions189(e.g., radially protruding shuttle bumps) disposed on an end portion of the shuttle pin64. In certain embodiments, the one or more shuttle protrusions189may include an annular radial protrusion or a plurality of circumferentially spaced radial protrusions. A dimension191(e.g., diameter) of the inner bore190is defined by a dimension193(e.g., diameter) of the central pin102. For example, the inner bore dimension191may be slightly larger than the shuttle pin dimension193(e.g., a radial clearance of at least 1 or 2 mm), such that the central pin102is configured to travel through the inner bore190. The shuttle pin spring112is disposed in the inner bore190, such that one end of the shuttle pin spring112couples to the shuttle pin64, and the other end of the shuttle pin spring112couples to the movable support114. In this manner, the shuttle pin spring112may be configured to exert a biasing force on the shuttle pin64, such that the shuttle pin64is compressed against the first axial end58of the connector14. In certain embodiments, the biasing force generated by the shuttle pin spring112is smaller than the biasing force generated by the springs184. For example, the biasing force generated by the shuttle pin spring112may range from 5-12 lbf, while the biasing force generated by the springs184may range from 15-30 lbf. In certain embodiments, the shuttle pin spring112may be supported by a post192(e.g., central telescopic post).

In the illustrated embodiment, the movable support114includes a plurality of connector portions116, such as a first connector portion194and a second connector portion196, each having respective radial contacts118. For example, the first connector portion194includes a first radial contact198disposed about the inner bore190, and the second connector portion196includes a second radial contact200also disposed about the inner bore190, spaced by an axial spacing202. In the illustrated embodiment, the radial contacts118(e.g.,198and200) include annular electrical contacts (e.g., electrically conductive and/or metallic contacts). In certain embodiments, the first and second connector portions194and196(e.g., first and second radial contacts198and200) are positioned at the same axial position and different circumferential positions. For example, the first radial contact198may be disposed on one radial half (e.g., radial side) of the inner bore190, and the second radial contact200may be disposed on a second radial half of the inner bore190. The first connector portion194includes a first pressure balancing barrier204(e.g., first pressure diaphragm) disposed about the first radial contact198. Additionally, the second connector portion196includes a second pressure balancing barrier206(e.g., second pressure diaphragm) disposed about the second radial contact200. The first connector portion194and second connector portion196will be described in more detail in regards toFIG.7.

As shown in the illustrated embodiment, the connector14is inserted a first axial distance208into the axial chamber100of the connector12during a first connection stage. The first axial end58of the mating portion48is configured to abut the wiper assembly104, thereby axially moving or depressing the wiper assembly104via the wiper spring108opposite the longitudinal direction36into the axial chamber100. The central pin102is configured to remain substantially stationary relative to the connector12as the mating portion48of the connector14is inserted into the axial chamber100of the connector12, thereby causing an insertion of the central pin102into the second axial opening62of the connector14and into the inner bore190. The central pin102is configured to abut the shuttle pin64via the indentation66and axially move or depress the shuttle pin64via the shuttle pin spring112(e.g., compressing the shuttle spring) in response to the central pin102traveling a second axial distance209along the inner bore190, via a concentric arrangement of the central pin102and the inner bore190.

A first mating radial contact210and a second mating radial contact212are disposed on the central pin102and separated by the axial spacing202, such that the first and second mating radial contacts210and212are configured to axially align and radially contact (e.g., electrically and mechanically contact) with the first and second radial contacts198and200, respectively, in response to the central pin102traveling the second axial distance209. As discussed above, the radial contacts198,200,210, and212may include annular contacts (e.g., annular electrical contacts) configured to contact one another after the central pin102pushes the shuttle pin64over the second axial distance209, thereby completing the first connection stage. However, in certain embodiments, the first and second mating radial contacts210and212are positioned at the same axial position and different circumferential positions along the central pin102, while the first and second radial contacts198and200are similarly positioned at the same axial position and different circumferential positions along the shuttle pin64. For example, the first mating radial contact210may be disposed on one radial half (e.g., radial side) of the central pin102, and the second mating radial contact212may be disposed on a second radial half of the central pin102. Regardless of the particular configuration of the radial contacts198,200,210, and212, the first connection stage is configured to axially align and radially contact (e.g., electrically and mechanically contact) the first and second radial contacts198and200of the mating electrical connector14with the first and second mating radial contacts210and212of the connector12, respectively, in response to a travel (e.g., axial path of travel) of the shuttle pin64pushed by the central pin102through the inner bore190.

FIG.4is a second cross-sectional view of the subsea electrical connection system10ofFIG.1at the first connection stage. The second cross-sectional view ofFIG.4is rotated by an angle (e.g., 90 degrees) relative to the first cross-sectional view ofFIG.3, thereby illustrating details of the connector portions116. In the illustrated embodiment, the movable support114includes the connector portions116(e.g., first and second connector portions194and196). The first connector portion194includes a first electrical path250from the first radial contact198electrically coupled to a first axial contact252extending in the longitudinal direction36. Additionally, the second connector portion196includes a second electrical path254from the second radial contact200electrically coupled to a second axial contact256extending in the longitudinal direction36. The first and second axial contacts252and256are metallic and/or electrically conductive axial contacts. In certain embodiments, the first and second axial contacts252and256are disposed radially outward from the inner bore190and offset 90 degrees in a circumferential direction258relative to the springs184(shown inFIG.3). While the illustrated embodiment shows first and second connector portions194and196, one or more connector portions116(e.g., and corresponding radial contacts118) may be used in certain embodiments of the connector14.

As shown in the illustrated embodiment, the stationary support180includes a first mating connector portion270having a first mating electrical path272with a first mating axial contact274electrically coupled to the second cable74. Additionally, the stationary support180includes a second mating connector portion276having a second mating electrical path278with a second mating axial contact280electrically coupled to the second cable74. The first and second mating axial contacts274and280are metallic and/or electrically conductive axial contacts. The first mating axial contact274extends in the direction opposite longitudinal direction36and is electrically coupled to the first axial contact252, thereby joining the first electrical path250with the first mating electrical path272. Additionally, the second mating axial contact280extends in the direction opposite longitudinal direction36and is electrically coupled to the second axial contact256, thereby joining the second electrical path254with the second mating electrical path278. The stationary support180also includes first and second anti-tracking devices282and284(e.g., electrical tracking) coupled to the first and second mating connector portions270and276(e.g., first and second mating axial contacts274and280), respectively, which may extend a creepage distance associated with the first and second mating connector portions270and276, and in certain embodiments, may seal with the housing insulation layer120. In some embodiments, the anti-tracking devices may be composed of Viton or Perfluoroelastomer, though other materials may be used.

In the illustrated embodiment, the movable support114includes a first insulation layer290disposed about the first electrical path250and the first mating electrical path272. The movable support114also includes a first seal292(e.g., wiper) disposed at an axial end of the first insulation layer290and disposed about the first mating electrical path272. Additionally, the movable support114includes a second insulation layer294disposed about the second electrical path254and the second mating electrical path278. The movable support114also includes a second seal295(e.g., wiper) disposed at an axial end of the second insulation layer294and disposed about the second mating electrical path278. In certain embodiments, the housing fluid chamber122is disposed between the first and second insulation layers290,294and the housing insulation layer120. In certain embodiments, the first and second insulation layers290and294may include any suitable electrically non-conductive insulation material, such as PEEK insulation. The first and second insulation layers290and294are independent or separate from the housing insulation layer120.

The first and second axial contacts252and256are configured to slide alone and/or telescopically engage with the respective first and second mating axial contacts274and280, such as by using tubular contacts (e.g., female contacts) engaged with pin contacts (e.g., male contacts). In the illustrated embodiment, the first and second axial contacts252and256are tubular contacts (e.g., female contacts), and the first and second mating axial contacts274and280are pin contacts (e.g., male contacts). As shown in the illustrated embodiment, the first and second mating axial contacts274and280may be axially inserted in axial openings (e.g., central openings, central channels) of the first and second axial contacts252and256, respectively, thereby axially overlapping the axial contacts274and280with the axial contacts252and256. Additionally, as shown in the illustrated embodiment, the first and second axial contacts252and256both include axial channels296(e.g., axial fluid channels or pressure relief channels) disposed around the periphery of the contacts, which will be described in more detail in regards toFIG.7. In certain embodiments, the first and second axial contacts252and256may be pin contacts (e.g., male contacts), and the first and second mating axial contacts274and280may be tubular contacts (e.g., female contacts). While the illustrated embodiment shows first and second axial contacts252,256and first and second mating axial contacts274and280, one or more axial contacts (e.g., and corresponding mating axial contacts) may be used in certain embodiments. Additionally, while the illustrated embodiment shows the first axial contact252being longer than the second axial contact256, in some embodiments the second axial contact256may be longer, and in other embodiments the first and second axial contacts252and256may have the same length.

FIG.5is a third cross-sectional view of the subsea electrical connection system10ofFIG.1at the first connection stage. The third cross-sectional view ofFIG.5is rotated by an angle relative to the first cross-sectional view ofFIG.3and the second cross-sectional view ofFIG.4, thereby illustrating latching details of the connector assembly110. As shown in the illustrated embodiment, the connector assembly110of the connector14includes a two-stage release latch320(e.g., two-stage release collet) coupled to the stationary support180and disposed along the second central axis78of the connector14. The two-stage release latch320includes latch arms322, which extend opposite longitudinal direction36alongside the circumference of the inner bore190. Each of the latch arms322includes a latch groove324, each latch groove324being disposed near an axial end of each latch arm322and facing radially inward toward the inner bore190. Additionally, each latch arm322includes a first latch protrusion326and a second latch protrusion328on each axial side of the latch groove324. The first latch protrusion326is tapered, such that the first latch protrusion326tapers inwardly (e.g., toward the second central axis78) along a travel in the longitudinal direction36.

Additionally, as shown in the illustrated embodiment, the movable support114includes an overhang330(e.g., annular overhang, annular lip) configured to extend radially outward toward the interior wall of the inner bore190. The overhang330is configured to engage (e.g., mate with) the latch grooves324of the latch arms322. The latch arms322are configured to radially contract (e.g., inward), such that the first and second latch protrusions326and328protrude a small distance (e.g., less than or equal to 1, 2, 3, 4, or 5 mm) into the inner bore190. For example, the first and second latch protrusions326and328may extend into the inner bore190, thereby at least partially retaining the movable support114at an axial position of the inner bore190.

As shown in the illustrated embodiment, the shuttle pin64includes the shuttle protrusions189disposed on an axial end of the shuttle pin64(e.g., end of the shuttle closest to the stationary support180) and facing radially outward toward the interior wall of the inner bore190. In response to the axial movement of the shuttle pin64pushed by the central pin102in the first connection stage, the first and second mating radial contacts210and212of the central pin102align with the first and second radial contacts198and200, respectively, while also releasing the two-stage release latch320. In particular, the shuttle pin64(e.g., via the shuttle protrusions189) is configured to abut the tapered portion of the first latch protrusions326, thereby causing the latch arms322to expand radially outward. The outward expansion of the latch arms322causes the second latch protrusions328to radially extend past the interior wall of the inner bore190, thereby removing axial retention of the movable support114by the latch arms322, and enabling the movable support114to axially travel through the central bore182(e.g., or continue axial travel through inner bore190). The release of the two-stage release latch320enables the connectors12and14to continue into the second connection stage as discussed in further detail below.

Although illustrated embodiment shows the latch arms322as having the latch grooves324and the movable support114as having the overhangs330, in certain embodiments, the latch arms322may include protrusions (e.g., overhangs) and the movable support114may include corresponding grooves. Although two latch arms322are visible in the illustrated embodiment, the two-stage release latch320may include four latch arms around the inner bore190, radially spaced by 90 degrees. In certain embodiments, the latch arms322may be radially offset by a substantial 45 degrees with respect to the springs and/or contacts. In some embodiments, the two-stage release latch320may include two or more latch arms. For example, the two-stage release latch320may include three latch arms, four latch arms, five latch arms, six latch arms, etc.

FIG.6is a perspective view of the two-stage release latch320of the subsea electrical connection system10ofFIG.1. In the illustrated embodiment, the two-stage release latch320includes the latch arms322(e.g., four arms) extending axially from a latch manifold section400. In certain embodiments, the two-stage release latch320may be constructed from a resilient material, such as a resilient plastic, configured to provide some spring biasing force in the latch arms322. The latch manifold section400includes first and second axial spring mounting holes402and404, as well as first and second axial contact holes406and408. The two-stage release latch320also includes a latch base section410coupled to the latch manifold section400. The latch arms322include the first and second latch protrusions326and328. The second latch portion328is configured to be axially positioned further along the longitudinal direction36, and the latch groove324axially disposed between the first and second latch protrusions326and328. The latch arms322are circumferentially spaced (e.g., equally circumferentially spaced) about an inner bore portion412, and the inner bore portion412is disposed along a central axis414of the two-stage release latch320.

In the illustrated embodiment, the latch arms322are coupled to the latch manifold section400via structural supports416, disposed at the base of each latch arm322. The structural supports416have a larger thickness than the latch arms, thereby providing structural support (e.g., mechanical support) to the latch arms322. The structural supports416are disposed about the inner bore portion412such that an interior wall418of the structural supports416form a perimeter wall of the inner bore portion412. An exterior wall420of the structural supports416is shaped so as to provide clearance for the first and second axial spring mounting holes402,404and the first and second axial contact holes406and408. As shown in the illustrated embodiment, the structure supports416are rotated substantially 45 degrees relative to the first and second axial spring mounting holes402,404, and first and second axial contact holes406and408. In this configuration, the exterior wall420includes partial annular cutaways422disposed between each of the structural supports416, such that the partial annular cutaways422provide clearance for the springs and axial contacts.

In the illustrated embodiment, the first and second spring mounting holes402and404are blind holes in the latch manifold section400. In this manner, the first and second spring mounting holes402and404are configured to provide a mounting of the springs directly onto the two-stage release latch320. As shown in the illustrated embodiment, the first and second axial contact holes406and408extend completely through the latch manifold section400, thereby enabling the mating axial contacts (e.g., or axial contacts) to pass through the latch manifold section400of the two-stage release latch320.

As shown in the illustrated embodiment, the latch arms322are disposed (e.g., equally circumferentially spaced) about the inner bore portion412such that the first and second protrusions326and328are directed toward the central axis414. The first latch protrusions326include a tapered portion424, such that the first latch protrusion326tapers inward along a travel in the longitudinal direction36. In the illustrated embodiment, the first latch protrusions326extend further radially inward than the second latch protrusion328although, in certain embodiments, the first and second latch protrusions326and328radially extend the same distance. The first and second latch protrusions326and328are configured to retain the movable support114(e.g., an annular portion of the movable support114) in the latch grooves324. The tapered portions424are configured to abut the shuttle protrusions via the shuttle abutting the tapered portion424of each latch arm322(e.g., concurrently), thereby causing a radial expansion of the latch arms322. In response to the radial expansion of the latch arms322, the second latch protrusions328expand beyond the diameter of the inner bore (e.g., inner bore portion412), thereby enabling an axial movement (e.g., in direction36) of the movable support114through the inner bore portion412. In certain embodiments, the inner bore portion412may extend though the manifold section400and/or the base portion410of the two-stage release latch320.

FIG.7is a cross-sectional view of an axial connector assembly450of the subsea electrical connection system10ofFIG.1. The axial connector assembly450includes a connector portion452(e.g., first and second connector portions194and196) and a mating connector portion454(e.g., first and second mating connector portions270and276). The connector portion452includes an axial contact456(e.g., first and second axial contacts252and254) coupled to a radial contact118configured to encircle an inner bore portion458. The axial contact456is configured to be radially offset from the inner bore portion458. The axial contact456includes louvers460, radial ports462, a contact bore463, axial channels464, a fluid chamber465. The connector portion452also includes an insulation layer466(e.g., PEEK insulation) configured to enclose the axial contact456. The insulation layer466includes an insulation cap468(e.g., annular insulation cap) disposed on an axial end of the axial contact456, a seal470(e.g., annular seal) disposed inside the insulation cap468, and a wiper472(e.g., annular wiper) disposed about an axial opening473of the connector portion452. In certain embodiments, the insulation layer466may include one or more insulation coatings disposed around a body (e.g., tubular body) of the connector portion452. In some embodiments, the insulation layer466may at least partially, substantially, or completely form the body (e.g., tubular body) of the connector portion452. For example, as shown in the illustrated embodiment, the axial contact456extends through the connector portion452(e.g., coated or surrounded with insulation) over a first distance, whereas the connector portion452is composed of the insulation layer466over a second distance. In certain embodiments, the first distance may be at least 20, 30, 40, 50, 60, or 70 percent of a length of the connector portion452, while the second distance may be a remaining portion of the length of the connector portion452.

As shown in the illustrated embodiment, the connector portion452also includes a pressure balancing barrier474(e.g., diaphragm) disposed about the fluid chamber465of the connector portion452. The pressure balancing barrier474may include a resilient wall, such as an elastomeric wall, configured to flex and pressure balance fluids on opposite sides of the pressure balancing barrier474. The fluid chamber465is configured to extend through the connector portion452, including the axial contact456and, in certain embodiments, around the radial contact118. The pressure balancing barrier474is configured to extend around the radial contact118and, in certain embodiments, at least partially through the axial contact456. The pressure balancing barrier474may be disposed between the housing fluid chamber122and the fluid chamber465, where the housing fluid chamber122is disposed outside the axial connector assembly450(e.g., connector portion452).

In the illustrated embodiment, the mating connector portion454includes a cable connector portion476, a base portion478, and a contact pin480. The cable connector portion476includes louvers482configured to accept a wire of a cable, and is coupled to the base portion478. The base portion478includes protrusions484that, in certain embodiments, may be configured to partially retain axial movement of the mating connector portion454. The contact pin480extends from the base portion478. Additionally, the mating connector portion454includes an insulation layer486(e.g., PEEK insulation) disposed about the base portion478and cable connector portion478. In certain embodiments, the connector portion452and mating connector portion454are pressure-balanced (e.g., via the pressure balancing barrier474) between an internal connector fluid and an internal housing fluid surrounding the connector portion452and mating connector portion454inside of the outer housing38. For example, the internal connector fluid may be contained at least partially within and/or internally between the connector portion452and mating connector portion454, at least partially around the radial contact118, and separate from the internal housing fluid, wherein the pressure balancing barrier474may define a resilient housing or enclosure (e.g., annular diaphragm enclosure) around the radial contact118. It may be appreciated that the individually pressure-compensated connector portion452and mating connector portion454, and a resulting fluid film separation (e.g., non-conductive fluid or oil separation) between the contact elements (e.g., axial contact456, contact pin480) may improve tracking (e.g., electrical tracking) between the axial contact456and/or contact pin480and the insulation layers466,486. Furthermore, the dual insulation (e.g., housing insulation layer and insulation layers466,486) of the connector portion452and mating connector portion454may provide improved insulation resistance and longevity in service conditions.

The mating connector portion454is configured to mate (e.g., connect with) the connector portion452in response to an insertion of the contact pin480into the axial opening473of the connector portion452. The mating connector portion454and connector portion452make electrical contact in response to the contact pin480making physical contact with the louvers460of the axial contact456. The louvers460are configured to maintain electrical continuity as the contact pin480travels an axial path through the contact bore463. In response to the contact pin480traveling through the contact bore463, fluid (e.g., oil) residing in the contact bore463may flow through the radial ports462, and into the axial channels464and fluid chamber465. In certain embodiments, the pressure balancing barrier474may expand and/or contract in response to the flow of fluid through the fluid chamber465. As the contact pin480travels through the contact bore463, the seal470and/or wiper472make contact with the insulation layer486of the base portion478of the mating connector portion454, thereby sealing the contact bore463from the fluid in the housing fluid chamber. In this manner, the interior of the connector portion462(e.g., contact bore463) may be substantially shielded from fluid disposed in the housing fluid layer disposed outside of the connector portion452and mating connector portion454.

Although the illustrated embodiment shows only a single connector portion452and mating connector portion454, one or more connector portions and corresponding mating connector portions may be used for connector portion116discussed in detail above. In this manner, each connector portion116may include a separate pressure balancing barrier disposed about the corresponding radial contact118and corresponding axial contact. Furthermore, while the illustrated embodiment shows the connector portion452as being a tubular connector (e.g., female connector) and the mating connector portion454as being a contact pin connector (e.g., male connector), in certain embodiments, the connector portion454may be a contact pin connector (e.g., male connector) and the mating connector portion454may be a tubular connector (e.g., female connector).

FIG.8is a first cross-sectional view of the subsea electrical connection system10ofFIG.1at a second connection stage. The first cross-sectional view ofFIG.8may be in the same plane as the cross-section ofFIG.5, further illustrating the second connection stage upon release of the two-stage release latch320. In the illustrated embodiment, the second connection stage includes a subsequent axial travel (e.g., insertion) of the mating portion48of the connector14into the axial chamber100of the connector12. The insertion may result from a relative movement of the connector14with respect to the connector12in the direction opposite longitudinal direction36, a relative movement of the connector12with respect to the connector14in the longitudinal direction36, or a combination thereof. As a result of the insertion of the mating portion48, the wiper assembly104is depressed (e.g., via wiper spring108) to a rear side of the axial chamber100, and the mating edge50of the connector14abuts the frustoconical guide32of the connector12. Furthermore, due to the central pin102being retained (e.g., substantially rigidly retained) by the connector12, the central pin102travels a second axial distance within the connector14.

As shown in the illustrated embodiment, the movable support114(e.g., and connector portions116) is configured to move along a second axial path of travel (e.g., stack up) in longitudinal direction36during the second connection stage in response to the expansion of the two-stage release latch320, thereby enabling the movable support114to travel an axial distance through the central bore182(e.g., or through the inner bore190). In certain embodiments, the second axial path of travel may include an axial distance (e.g., stack up distance) of 1, 2, 3, 4, 5, or more cm. Because the central pin102and the movable support114are both configured to move along the same axial path of travel during the second connection stage, the first and second radial contacts198and200remain axially aligned with the first and second mating radial contacts210and212, respectively. As shown in the illustrated embodiment, the shuttle pin64is configured to abut the movable support114in the inner bore190. In certain embodiments, in response to the abutment between the shuttle pin64and the movable support114, the shuttle pin64and the movable support114are configured to move together (e.g., concurrently) along the second axial path of travel during the second connection stage.

In certain embodiments, a cavity520(e.g., annular cavity), disposed between the first axial end58of the connector14and the movable support114, may form in response to the movable support114traveling down the second axial path of travel. In some embodiments, an internal fluid (e.g., oil) disposed in the housing fluid chamber122may flow around the movable support114(e.g., via fluid paths124) to fill the volume of the cavity520.

FIG.9is a second cross-sectional view of the subsea electrical connection system10ofFIG.1at the second connection stage. The second cross-sectional view ofFIG.9may be in the same plane as the cross-section ofFIG.3, further illustrating the second connection stage. As shown in the illustrated embodiment, the springs184are compressed in response to the movable support114traveling the second axial path of travel during the second connection stage. In certain embodiments, the movable support114is coupled to the stationary support180via the springs184such that the springs184exert a biasing force on the movable support114during the second connection stage. As shown in the illustrated embodiment, the posts186disposed through the springs184decrease in length as a result of the movable support114traveling the second axial path of travel (e.g., via a telescoping action). In certain embodiments, the shuttle pin spring112is coupled to the shuttle pin64and the movable support114. In this manner, the shuttle pin spring112may remain unchanged from the first connection stage due to a concurrent second axial path of travel of both the shuttle pin64and the movable support114. In other embodiments, the shuttle pin spring112may further compress during the second connection stage (e.g., due to relative motion between the shuttle pin64and movable support114).

FIG.10is a third cross-sectional view of the subsea electrical connection system10ofFIG.1at the second connection stage. The third cross-sectional view ofFIG.10may be in the same plane as the cross-section ofFIG.4, further illustrating the second connection stage. In the illustrated embodiment, the first and second connector portions194and196overlap with first and second mating connector portions270and276, respectively. In this manner, the first and second axial contacts252and256axially engage and axially overlap with the first and second mating axial contacts274and280, respectively, over a first axial distance in response to the movable support114traveling the second axial path of travel. As shown in the illustrated embodiment, the first and second axial contacts252and256engage the contact pins of the first and second mating axial contacts274and280, respectively, in response to the second axial travel of the of the movable support114. The first and second axial contacts252and256continually engage the contact pins of the first and second mating axial contacts274and280, respectively, throughout the second axial path of travel via the louvers disposed within the first and second axial contacts252and256. Additionally, the first and second seals292and295(e.g., wipers472) engage with the base portions478(e.g., insulation layer486) of the first and second mating axial contacts274and280, respectively, in order to shield the first and second axial contacts252,256, and the contact pins of the first and second mating axial contacts274and280from fluid (e.g., oil from housing fluid chamber122, water) that may be disposed outside the insulation layer466of the first and second connector portions194and196.

In certain embodiments, the contact pins of the first and second mating axial contacts274and280remain electrically (e.g., and physically) coupled with the first and second axial contacts252and256, respectively, during both the first and second connection stages. That is, the first and second electrical paths250and254maintain electrical continuity throughout both the first and second connection stages. In other embodiments, the first and second mating axial contacts274and280are electrically decoupled from the first and second axial contacts252and256, respectively, during at least part of the first connection stage, and become electrically coupled at the end of the first connection stage and/or during the second connection stage. Accordingly, in some embodiments, a portion of the first and/or second axial path of travel of the first and second axial contacts252and256(e.g., or first and second mating axial contacts274and280) may include a first portion of axial travel having no electrical continuity. The first portion of axial travel may be followed by a second portion of axial travel where electrical continuity between the first and second axial contacts252,256and first and second mating axial contacts274,280is established and maintained throughout the second portion of axial travel. The two-stage connection of the connector12and connector14may improve stability of the first and second axial contacts252,256and first and second mating axial contacts274,280during the mating process. Furthermore, the second connection stage may allow the engagement of the first and second axial contacts252,256and first and second mating axial contacts274,280to be independent of spring forces exerted by the springs.

FIG.11is a cross-sectional view of the axial connector assembly450(e.g., axial connector portion452) ofFIG.7. As shown in the illustrated embodiment, the axial connector assembly450includes a radial contact118(e.g., annular electrical contact) disposed about an inner bore portion458. The axial connector assembly450also includes one or more radial bores462configured to fluidly couple the inner bore portion458with the contact bore463. Additionally, the axial connector assembly450is configured to electrically couple the radial contact118with the axial contact456. In certain embodiments, the axial connector assembly450may include insulation (e.g., insulation layer466) disposed about (e.g., between, around) an area spanning between the radial contact118and the axial contact456. As shown in the illustrated embodiment, the radial contact118and, in certain embodiments, a portion of the axial contact456are encapsulated by the pressure balancing barrier474. In certain embodiments, the pressure balancing barrier474may be configured to expand and/or contract radially in response to a flow of fluid (e.g., oil) into the pressure balancing barrier474due to an insertion of a contact pin into the contact bore463during the second connection stage. In certain embodiments, the pressure balancing barrier474may be composed of an elastomeric material and/or may be configured to provide a seal about the inner bore portion458while the central pin102is inserted.

While the above embodiments generally present a mating of the connector12and the connector14via a first connection stage followed by a second connection stage, it should be noted that the connector12and connector14may also be configured to disconnect via a reversal of the connection stages. That is, the mating portion48of the connector14may move in longitudinal direction36relative to connector12, and thereby extracted from the axial chamber100. In certain embodiments, a disconnection of the connector12and connector14may begin with a reversed second connection stage. The reversed second connection stage may include a movement of the movable support114toward the axial end58of the connector14via expansion of springs184. Concurrently, the first and second axial contacts252and256may engage the first and second mating axial contacts274and280, respectively, in a reversed (e.g., reversed direction) second axial path of travel. In response to the overhang (e.g., annular overhang) of the movable support114engaging the latch grooves of the two-stage release latch, the movable support114may be retained by the two-stage release latch320, thereby unable to continue moving toward the axial end58. In response to the retention of the movable support114, a reversed first connection stage may commence, in which the mating portion48is further extracted from the axial chamber100. As the mating portion48is extracted, the shuttle pin64moves toward the axial end58via the shuttle pin spring112until the central pin102exits the second axial opening62of the connector14.

As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.”

The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. Moreover, the order in which the elements of the methods described herein are illustrated and described may be re-arranged, and/or two or more elements may occur simultaneously. The embodiments were chosen and described in order to best explain the principals of the disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the disclosure and various embodiments with various modifications as are suited to the particular use contemplated.

Finally, the techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform] ing [a function] . . . ,” it is intended that such elements are to be interpreted under 35 U.S.C. § 112 (f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. § 112 (f).