Systems for thermally insulating sensitive downhole equipment
A downhole electronics enclosure system may include a tool body, a carrier body, a phase change media, and a support mechanism. The tool body defines an interior cavity. The carrier body may be removably provided within the interior cavity, and the carrier body may define an interior compartment for receiving electronics. The phase change media may be sealed within the interior compartment of the carrier body. The support mechanism may suspend the carrier body within the interior cavity of the tool body, such that a space is defined between an outer surface of the carrier body and an inner surface of the tool body.
1 . A downhole electronics enclosure system, comprising:
a tool body defining an interior cavity providing an inner surface with a first diameter;
a carrier body removably provided within the interior cavity, the carrier body providing an outer surface along an entire length of the carrier body with a second diameter and defining an interior compartment for receiving electronics;
a phase change media sealed within the interior compartment of the carrier body; and
a support mechanism that suspends the carrier body within the interior cavity of the tool body,
wherein the first diameter is greater than the second diameter such that the outer surface of the carrier body does not contact the inner surface of the tool body.
2 . The downhole electronics enclosure system of claim 1 , wherein the phase change media comprises a paraffin wax.
3 . The downhole electronics enclosure system of claim 1 , wherein the support mechanism comprises an upper end cap arranged around an open top end of the carrier body and a lower end cap arranged around an open bottom end of the carrier body, such that the carrier body is suspended within the interior cavity of the tool body via the upper end cap and the lower end cap.
4 . The downhole electronics enclosure system of claim 3 , wherein the upper end cap and the lower end cap each include a base, a shaft extending axially from the base, and a plurality of spokes extending radially outward from an end of the shaft, wherein the plurality of spokes contact the inner surface of the tool body and the base contacts the carrier body such that heat is conducted to the carrier body through the plurality of spokes, the shaft, and the base.
5 . The downhole electronics enclosure system of claim 3 , wherein the upper end cap and/or the lower end cap comprises an interior bracket extending into the interior cavity for supporting electronics contained within the carrier body.
6 . The downhole electronics enclosure system of claim 3 , wherein the upper and lower end caps are made of a polymer selected from the group consisting of polyether ether ketone (PEEK), polytetrafluoroethylene (PTEF), and nylon.
7 . The downhole electronics enclosure system of claim 3 , wherein an exterior surface of the upper end cap and an exterior surface of the lower end cap are polished, and/or the exterior surface of the upper end cap and the exterior surface of the lower end cap comprise a low-emissivity plating and/or a low-emissivity paint.
8 . The downhole electronics enclosure system of claim 3 , wherein the upper end cap and/or the lower end cap comprises a hole through which the interior compartment of the carrier body may be accessed.
9 . The downhole electronics enclosure system of claim 1 , further comprising:
an upper bulkhead provided at an upper end of the tool body; and
a lower bulkhead provided at a lower end of the tool body.
10 . The downhole electronics enclosure system of claim 1 , wherein
the outer surface of the carrier body is polished, and/or the outer surface of the carrier body comprises a low-emissivity plating and/or a low-emissivity paint; and/or
the inner surface of the tool body which at least partially defines the interior cavity is polished, and/or the inner surface comprises a low-emissivity plating and/or a low-emissivity paint.
11 . The downhole electronics enclosure system of claim 1 , wherein the tool body includes a vacuum port extending into the interior cavity for pressurizing the interior cavity, the downhole electronics enclosure system further comprising a sealing plug removably provided over an opening to the vacuum port, wherein the vacuum port comprises a check valve; and
wherein the tool body includes opposing upper and lower ends, and the vacuum port is provided at the upper end, the downhole electronics enclosure system further including an upper bulkhead removably provided at the upper end of the tool body such that the upper bulkhead covers the vacuum port when installed on the tool body.
12 . The downhole electronics enclosure system of claim 1 , wherein either:
a gas is injected into a space defined between the carrier body and the interior cavity of the tool body, wherein the gas has lower heat transfer properties than air and comprises Nitrogen, Argon, or dry air; or
an aerogel and/or an open cell foam is injected into the space defined between the outer surface of the carrier body and the inner surface of the tool body.
13 . The downhole electronics enclosure system of claim 1 , wherein the outer surface of the carrier body provides at least one of slots, ribs, and/or fins for reducing convection.
14 . The downhole electronics enclosure system of claim 1 , wherein the phase change media is a conductive material in intimate contact with the electronics and the phase change media liquefies upon phase change, and, when the electronics are contacted by liquefied media, the electronics are automatically switched into a hibernation mode.
15 . The downhole electronics enclosure system of claim 1 , further comprising a sensor configured to detect temperature change and/or pressure change, wherein the electronics are configured to automatically switch into a hibernation mode upon detecting a threshold temperature and/or a threshold pressure.
16 . A carrier for housing electronics within a downhole tool, comprising:
a carrier body defining an open top end, an interior compartment, and an open bottom end, wherein the open top end and the open bottom end are in communication with the interior compartment;
an upper end cap provided at the open top end of the carrier body and generating a sealed interface with the open top end;
a lower end cap provided at the open bottom end of the carrier body and generating a sealed interface at the open bottom end; and
a phase change media sealed within the interior compartment of the carrier body via the upper end cap and the lower end cap,
wherein:
the upper end cap and the lower end cap each include a shaft, a plurality of spokes extending from a first end of the shaft, and a base extending from a second end of the shaft,
the base is disposed within either the open top end or the open bottom end of the carrier body, and
the plurality of spokes radially extend from the shaft for suspending the carrier body such that heat is conducted to the carrier body through the plurality of spokes, the shaft, and the base.
17 . The carrier of claim 16 , wherein an outer surface of the carrier body comprises a geometry for reducing convection, the geometry being selected from the group consisting of slots, ribs, and fins.
18 . The carrier of claim 16 , wherein
an exterior surface of the upper end cap and an exterior surface of the lower end cap are polished, and/or the exterior surface of the upper end cap and the exterior surface of the lower end cap are covered with a low-emissivity plating and/or a low-emissivity paint; and/or
an outer surface of the carrier body is polished, and/or the outer surface of the carrier body is covered with a low-emissivity plating and/or a low-emissivity paint.
19 . A method, comprising:
providing electronics within an interior compartment of a carrier body;
sealing a phase change media within the interior compartment via at least one end cap, wherein the carrier body having the at least one end cap sealed thereon defines a carrier;
suspending the carrier within an interior cavity of a tool body such that an outer surface defined along an entire length of the carrier body does not contact an inner surface of the tool body; and
at least partially evacuating air or gas from a space defined between the carrier body and the tool body.
20 . The carrier of claim 16 , wherein an outer diameter of each of the upper and lower end caps at the plurality of spokes is greater than an outer diameter of the carrier body.