High pressure differential electrical connector

Abstract

The present invention is directed to a downhole, high-current, low-impedance, feed-through connector for passing electrical current, preferably high frequency AC current, between a tool compartment having relatively high pressure and another tool compartment having relatively low pressure. The primary intended application of the present invention is to connect a radio frequency transmitter/receiver antenna to the antenna's tuning capacitors, but the present invention is applicable to any downhole application requiring the transmission of high electrical current across a barrier having a high pressure differential. This invention minimizes the force acting on the connector due to the high pressure differential by providing a conductor preferably having either a wave-like cross-section or a multi-finned cross-section, thereby minimizing the overall cross-sectional area of the connector yet providing sufficient cross-sectional area of the conductor to carry the necessary amount of electrical current.

I claim:  
     
       1. An apparatus for carrying electrical current in a downhole tool between a first compartment having a relatively high pressure and a second compartment having a relatively low pressure, said first and second compartments being separated by a structure having an opening for receiving said apparatus, comprising: 
       an electrically insulting body capable of being inserted into said opening, said body having a first end for exposure to said relatively high pressure and a second end for exposure to said relatively low pressure;  
       a pressure seal for sealing said body between said first and second compartments; and  
       at least one conductor comprising an electrically conductive material traversing through said body between said first end and said second end, said at least one conductor being sealably bonded to said body and having a cross-sectional shape designed to minimize the cross-sectional area of said first end of said body and maximize the surface area of said at least one conductor.  
     
     
       2. The apparatus of claim  1  wherein said cross-sectional shape of said at least one conductor is wave-like. 
     
     
       3. The apparatus of claim  1  wherein said cross-sectional shape of said at least one conductor comprises a plurality of fins. 
     
     
       4. The apparatus of claim  1  wherein said cross-sectional shape of said at least one conductor is flat. 
     
     
       5. The apparatus of claim  1  wherein said body comprises a thermoplastic material. 
     
     
       6. The apparatus of claim  1  further comprising a back plate disposed on said second end of said body and having at least one opening, wherein said at least one conductor passes through said at least one opening of said back plate. 
     
     
       7. The apparatus of claim  6  wherein a portion of said body surrounding said at least one conductor passes through said at least one opening of said back plate. 
     
     
       8. The apparatus of claim  1  wherein said at least one conductor has at least one transverse hole in which a portion of the material of said body is disposed. 
     
     
       9. The apparatus of claim  1  wherein said at least one conductor has at least one notch in which a portion of the material of said body is disposed. 
     
     
       10. The apparatus of claim  1  further comprising a boot surrounding said at least one conductor on said first end of said body, said boot being sealably bonded to said body and said at least one conductor. 
     
     
       11. The apparatus of claim  1  further comprising a boot surrounding said at least one conductor on said second end of said body, said boot being sealably bonded to said body and said at least one conductor. 
     
     
       12. The apparatus of any one of claims  10  and  11  wherein said boot comprises a rubber material. 
     
     
       13. The apparatus of claim  1  wherein said at least one conductor comprises a transition portion having a first end with a first cross-sectional shape and a second end with a second cross-sectional shape, said second cross-sectional shape being different from said first cross-sectional shape. 
     
     
       14. The apparatus of claim  1  wherein said pressure seal comprises a filler element disposed about said body, a first O-ring between said body and said filler element, and a second O-ring disposed about said filler element for forming a seal between said filler element and said structure. 
     
     
       15. The apparatus of claim  14  further comprising a retaining ring to hold said filler element in place with respect to said structure. 
     
     
       16. The apparatus of claim  1  wherein said at least one conductor comprises two such conductors spaced apart from each other and wherein said body comprises a slot between said two conductors to prevent electrical arcing between said two conductors. 
     
     
       17. The apparatus of claim  16  wherein said two conductors are substantially parallel. 
     
     
       18. The apparatus of claim  16  wherein said two conductors have the same cross-sectional shape. 
     
     
       19. An apparatus for carrying electrical current in a downhole tool between a first compartment having a relatively high pressure and a second compartment having a relatively low pressure, said first and second compartments being separated by a structure having an opening for receiving said apparatus, comprising: 
       a metal housing capable of being inserted into said opening;  
       an electrically insulating body having a first end for exposure to said relatively high pressure and a second end for exposure to said relatively low pressure, said body being disposed within and sealably bonded to said housing with a layer of glass;  
       at least one conductor comprising an electrically conductive material traversing through said body between said first end and said second end, said at least one conductor being sealably bonded to said body with at least one sheath of glass; and  
       a pressure seal for sealing said housing between said first and second compartments;  
       wherein said at least one conductor has a cross-sectional shape designed to minimize the cross-sectional area of said first end of said body and maximize the surface area of said at least one conductor.  
     
     
       20. The apparatus of claim  19  wherein said cross-sectional shape of said at least one conductor is wave-like. 
     
     
       21. The apparatus of claim  19  wherein said cross-sectional shape of said at least one conductor comprises a plurality of fins. 
     
     
       22. The apparatus of claim  19  wherein said cross-sectional shape of said at least one conductor is flat. 
     
     
       23. The apparatus of claim  19  wherein said body comprises a ceramic material. 
     
     
       24. The apparatus of claim  19  wherein said housing further comprises a back plate disposed on said second end of said body and having at least one opening, wherein said at least one conductor passes through said at least one opening of said back plate. 
     
     
       25. The apparatus of claim  24  wherein a portion of said body surrounding said at least one conductor passes through said at least one opening of said back plate. 
     
     
       26. The apparatus of claim  19  wherein said at least one conductor has at least one transverse hole in which a portion of the material of said body is disposed. 
     
     
       27. The apparatus of claim  19  wherein said at least one conductor has at least one notch in which a portion of the material of said body is disposed. 
     
     
       28. The apparatus of claim  19  further comprising a boot surrounding said at least one conductor on said first end of said body, said boot being sealably bonded to said body and said at least one conductor. 
     
     
       29. The apparatus of claim  19  further comprising a boot surrounding said at least one conductor on said second end of said body, said boot being sealably bonded to said body and said at least one conductor. 
     
     
       30. The apparatus of any one of claims  28  and  29  wherein said boot comprises a rubber material. 
     
     
       31. The apparatus of claim  19  wherein said at least one conductor comprises a transition portion having a first end with a first cross-sectional shape and a second end with a second cross-sectional shape, said second cross-sectional shape being different from said first cross-sectional shape. 
     
     
       32. The apparatus of claim  19  wherein said pressure seal comprises an O-ring disposed about said housing for forming a seal between said housing and said structure. 
     
     
       33. The apparatus of claim  32  further comprising a retaining ring to hold said housing in place with respect to said structure. 
     
     
       34. The apparatus of claim  19  wherein said at least one conductor comprises two such conductors spaced apart from each other and wherein said body comprises a slot between said two conductors to prevent electrical arcing between said two conductors. 
     
     
       35. The apparatus of claim  34  wherein said two conductors are substantially parallel. 
     
     
       36. The apparatus of claim  34  wherein said two conductors have the same cross-sectional shape. 
     
     
       37. An electrical connector comprising: 
       an electrically insulating body having a first end and a second end; and  
       at least one conductor comprising an electrically conductive material traversing through said body between said first end and said second end, said at least one conductor being sealably bonded to said body and having a cross-sectional shape designed to minimize the cross-sectional area of said first end of said body and maximize the surface area of said at least one conductor.  
     
     
       38. The electrical connector of claim  37  wherein said cross-sectional shape of said at least one conductor is wave-like. 
     
     
       39. The electrical connector of claim  37  wherein said cross-sectional shape of said at least one conductor comprises a plurality of fins. 
     
     
       40. The electrical connector of claim  37  wherein said cross-sectional shape of said at least one conductor is flat 
     
     
       41. The electrical connector of claim  37  wherein said body comprises a thermoplastic material. 
     
     
       42. The electrical connector of claim  37  further comprising a back plate disposed on said second end of said body and having at least one opening, wherein said at least one conductor passes through said at least one opening of said back plate. 
     
     
       43. The electrical connector of claim  42  wherein a portion of said body surrounding said at least one conductor passes through said at least one opening of said back plate. 
     
     
       44. The electrical connector of claim  37  wherein said at least one conductor has at least one transverse hole in which a portion of the material of said body is disposed. 
     
     
       45. The electrical connector of claim  37  wherein said at least one conductor has at least one notch in which a portion of the material of said body is disposed. 
     
     
       46. The electrical connector of claim  37  further comprising a boot surrounding said at least one conductor on said first end of said body, said boot being sealably bonded to said body and said at least one conductor. 
     
     
       47. The electrical connector of claim  37  further comprising a boot surrounding said at least one conductor on said second end of said body, said boot being sealably bonded to said body and said at least one conductor. 
     
     
       48. The electrical connector of any one of claims  46  and  47  wherein said boot comprises a rubber material. 
     
     
       49. The electrical connector of claim  37  wherein said at least one conductor comprises a transition portion having a first end with a first cross-sectional shape and a second end with a second cross-sectional shape, said second cross-sectional shape being different from said first cross-sectional shape. 
     
     
       50. The electrical connector of claim  37  further comprising a pressure seal for sealing said electrical connector in a barrier structure having an opening for receiving said electrical connector. 
     
     
       51. The electrical connector of claim  50  wherein said pressure seal comprises a filler element disposed about said body, a first O-ring between said body and said filler element, and a second O-ring disposed about said filler element for forming a seal between said filler element and said barrier structure. 
     
     
       52. The electrical connector of claim  51  further comprising a retaining ring to hold said filler element in place with respect to said barrier structure. 
     
     
       53. The electrical connector of claim  37  wherein said at least one conductor comprises two such conductors spaced apart from each other and wherein said body comprises a slot between said two conductors to prevent electrical arcing between said two conductors. 
     
     
       54. The electrical connector of claim  53  wherein said two conductors are substantially parallel. 
     
     
       55. The electrical connector of claim  53  wherein said two conductors have the same cross-sectional shape. 
     
     
       56. An electrical connector comprising: 
       a metal housing;  
       an electrically insulating body having a first end and a second end, said body being disposed within and sealably bonded to said housing with a layer of glass; and  
       at least one conductor comprising an electrically conductive material traversing through said body between said first end and said second end, said at least one conductor being sealably bonded to said body with at least one sheath of glass;  
       wherein said at least one conductor has a cross-sectional shape designed to minimize the cross-sectional area of said first end of said body and maximize the surface area of said at least one conductor.  
     
     
       57. The electrical connector of claim  56  wherein said cross-sectional shape of said at least one conductor is wave-like. 
     
     
       58. The electrical connector of claim  56  wherein said cross-sectional shape of said at least one conductor comprises a plurality of fins. 
     
     
       59. The electrical connector of claim  56  wherein said cross-sectional shape of said at least one conductor is flat. 
     
     
       60. The electrical connector of claim  56  wherein said body comprises a ceramic material. 
     
     
       61. The electrical connector of claim  56  wherein said housing further comprises a back plate disposed on said second end of said body and having at least one opening, wherein said at least one conductor passes through said at least one opening of said back plate. 
     
     
       62. The electrical connector of claim  61  wherein a portion of said body surrounding said at least one conductor passes through said at least one opening of said back plate. 
     
     
       63. The electrical connector of claim  56  wherein said at least one conductor has at least one transverse hole in which a portion of the material of said body is disposed. 
     
     
       64. The electrical connector of claim  56  wherein said at least one conductor has at least one notch in which a portion of the material of said body is disposed. 
     
     
       65. The electrical connector of claim  56  further comprising a boot surrounding said at least one conductor on said first end of said body, said boot being sealably bonded to said body and said at least one conductor. 
     
     
       66. The electrical connector of claim  56  further comprising a boot surrounding said at least one conductor on said second end of said body, said boot being sealably bonded to said body and said at least one conductor. 
     
     
       67. The electrical connector of any one of claims  65  and  66  wherein said boot comprises a rubber material. 
     
     
       68. The electrical connector of claim  56  wherein said at least one conductor comprises a transition portion having a first end with a first cross-sectional shape and a second end with a second cross-sectional shape, said second cross-sectional shape being different from said first cross-sectional shape. 
     
     
       69. The electrical connector of claim  56  further comprising a pressure seal for sealing said electrical connector in a barrier structure having an opening for receiving said electrical connector. 
     
     
       70. The electrical connector of claim  69  wherein said pressure seal comprises an O-ring disposed between said housing and said barrier structure. 
     
     
       71. The electrical connector of claim  70  further comprising a retaining ring to hold said housing in place with respect to said barrier structure. 
     
     
       72. The electrical connector of claim  56  wherein said at least one conductor comprises two such conductors spaced apart from each other and wherein said body comprises a slot between said two conductors to prevent electrical arcing between said two conductors. 
     
     
       73. The electrical connector of claim  72  wherein said two conductors are substantially parallel. 
     
     
       74. The electrical connector of claim  72  wherein said two conductors have the same cross-sectional shape.