FR2920059A1 - Method of forming portion of cable e.g. wellbore cable, involves embedding several conductors into inner layer of cable conductor core by heating inner layer and conductors prior to embedding conductors into inner layer - Google Patents

Abstract

An inner layer of polymeric insulation (104) is extruded over a conductor to form a cable conductor core (105). Several conductors (106) are embedded into the inner layer of the cable conductor core by heating one of the inner layer and the conductors prior to embedding the conductors into the inner layer. An outer layer of the polymeric insulation (118) is extruded over the cable conductor core and the conductors, and the inner layer is bonded to the outer layer to form the cable and provide a contiguous bond between the inner layer, the conductors, and the outer layer.

Description

METHOD OF MANUFACTURING ELECTRIC CABLES BACKGROUND OF THE INVENTION

  exposed in this section only provide background information related to this description and may not represent the prior art. Embodiments of the present invention generally relate to wellbore cables.

  In high pressure wells, the wireline is unwound on one or more lengths of grease filled pipe to seal the gas pressure in the well while allowing the drill bit to move into and out of the well.

  Isolated stranded conductors typically consist of several wires (typically copper) wired at a margin angle around a core wire, with one or more polymeric insulation layers extruded onto the strand bundles. The insulation can not penetrate the spaces between the conductor strands. Additional space is typically left between the center strand and the next layer of stranded wires, and between the insulator and the outer surface of the conductor wires, creating a potential path for the high pressure bottom gases. When the cable is pulled out of the wellbore at a high speed, these gases can decompress, leading to swelling of the insulation. If the gases decompress quickly, this can even cause the bursting of the insulation, by the phenomenon of explosive decompression.

  Problems with gas migration through interstitial spaces are also observed in coaxial cables and individual insulated conductors. In coaxial cables, a central insulated conductor is covered with a shielded shield consisting of individual wires having a diameter in the range of about 8 mm to about 14 mm. An additional sheath is placed on the wrapped shield, followed by two layers of wrapped weave wire. Since these wires do not "anchor" sufficiently in the central conductor insulation, the individual wires can become raised over the other wires and "stripped" during the manufacturing process, thereby damaging the cable. The individual threads can also cross each other, causing localized thickenings in the rolled armor, which can lead to similar damage. As the coiled wires are not firmly attached to the conductor, compression extrusion of the outer jacket layer would displace the shield wires. Tubular extrusion processes that are compatible with unstable wound shield wires leave gaps between the coiled shield and the outer jacket, which form a path for the pressurized bottom gas. The cable can be damaged when this pressurized gas is released through the points of weakness in the sheath through explosive decompression. It also compromises the separation between the wound shield and the armor wires.

  Since the layers of weave wire have unfilled annulus spaces, gas from the well can migrate in and move through these gaps upwardly toward a lower pressure. This gas tends to stay in place as the wire rope moves through the grease-filled pipe. When the drill bit passes over the top pulley at the top of the pipe, the armor wires tend to spread slightly, and the pressurized gas is released, which is disadvantageous. In seismic cables used in offshore exploration, armor is typically placed around the circumference of the cable at a coverage of 50 to 60% at a high angle of view (ie, angle). close to the perpendicular to the cable than other cables). Because of the space between the armor, the armor tends to strip (milk) or cross each other during manufacture, and are not evenly spaced. Non-uniform armor spacing may lead to weakened points in finished cables. In gun cables, which carry air under extremely high pressure, this is particularly disadvantageous. A potential strategy for sealing armor wires and preventing gas migration through the cable is known as "caging." In encapsulation designs, a polymeric sheath is applied to the outer armor wire. A sheath applied directly to a standard outer layer of armor wire would be essentially a sleeve; this would be unacceptable under load conditions. To create a better connection with the inner layers, a gap is created in the outer armor wire layer by reducing the armor wire coverage from 98% to between 50 and 70. This type of design has several problems. When the cladding has a cut, potentially hazardous well fluids enter and become trapped between the sheath and the armor wire, causing it to rust very rapidly, which can cause failure if it is not noted and, even if it is noted, is not easy to repair. Some well fluids may soften the sheath material and cause it to swell. This swelling weakens the connection of the sheath with the layer of outer weave wire. The sheath can then be peeled off the cable when the cable is pulled through packers, or seals, or if it reaches downhole obstructions. The sheath does not provide adequate protection against breakage. Breakage allows corrosive well fluids to accumulate in the annular spaces between the core and the first layer of armor wires. To improve the bond between the sheath and the outer armor wires, the armor wire coverage must be significantly reduced. This means the use of fewer or smaller outer armor wires. As a result, the resistance of the cable is also significantly reduced.

  Due to the above problems, encircled armor designs can currently only be used in coiled pipe / tube systems. Even in these applications, encircled armor designs will present many of the problems mentioned above. A current manufacturing strategy for maintaining uniform weave spacing in flutes is to place filler bars (made of polymeric bars or embedded wires in an extruded polymer) between the polymer-coated weave wires. While this helps keep the armor wires in place and maintains spacing during the manufacturing process, this also creates more interstitial spaces between the armor wires and the spacer bars.

  SUMMARY OF THE INVENTION A method for forming at least a portion of a cable comprises the steps of providing at least one conductor, extruding at least one inner layer of polymeric insulation on the at least one conductor to form a cable conductive core, to embed a plurality of conductors in the inner layer of the cable conductive core, and to extrude an outer layer of polymeric insulation on the cable conductive core and the plurality of conductors and to bond the inner layer to the outer layer to form the cable and make a contiguous connection between the inner layer, the conductors, and the outer layer, wherein the embedding comprises heating one of the inner layer and the conductors before embedding the conductors in the inner layer. Alternatively, the heating comprises extruding the inner layer over the at least one conductor and, almost immediately after, embedding the plurality of conductors in the freshly extruded inner layer. Alternatively, the heating comprises heating the inner layer almost immediately before embedding. The heating of the inner layer may include exposing the inner layer to a source of electromagnetic radiation. Alternatively, the method further comprises cooling the inner layer prior to embedding. Alternatively, the heating comprises heating the plurality of conductors prior to embedding. The heating of the plurality of conductors may include the use of a heat induction / shaping device. Alternatively, the at least one conductor comprises a single uninsulated strand. Alternatively, the at least one conductor comprises a plurality of conductors. Alternatively, the plurality of leads comprises one of uninsulated electrical conductors, shield layers, and layers of armor wire.

  In one embodiment, a method for forming a cable comprises the steps of providing at least one conductive cable core having at least one inner layer of polymeric insulation disposed on at least one conductor, having a plurality of of conductors, to heat one of the inner layer and the plurality of conductors, to embed the plurality of conductors in the inner layer of the cable conductive core almost immediately after heating, and to extrude an outer layer of polymeric insulation on the conducting core of the cable and the plurality of conductors and bonding the inner layer to the outer layer to form the cable and making a contiguous connection between the inner layer, the conductors, and the outer layer. Alternatively, the heating comprises exposing the inner layer to a source of electromagnetic radiation. Alternatively, the heating comprises heating the plurality of conductors prior to embedding. The heating of the plurality of conductors may include the use of a heat shaping / inducing device. Alternatively, the plurality of leads comprises one of uninsulated electrical conductors, shield layers, and layers of armor wire. Alternatively, the method further comprises cooling the inner layer prior to embedding. Alternatively, the method further comprises the steps of disposing a second plurality of conductors, heating one of the outer layer and the second plurality of conductors, embedding the second plurality of conductors in the outer layer of the cable immediately after heating, and extruding a second outer layer of polymeric insulation on the cable and the second plurality of conductors and bonding the outer layer to the second outer layer to form the cable and making a contiguous connection between the inner layer , the conductors, and the outer layer, the second conductors, and the second outer layer.

  In one embodiment, a method for forming a cable includes the steps of disposing a conductive strand, extruding a first layer of polymeric insulation on the conductive strand to form a cable conductive core, embedding a first plurality of conductors in the first layer of the cable conducting core almost immediately after extrusion of the first layer, extruding a second layer of polymeric insulation on the cable conductive core and the plurality of conductors and bonding the inner layer to the second layer to make a contiguous connection between the inner layer, the conductors, and the second layer, to have a second plurality of conductors, to heat one of the second layer and the second plurality of conductors, to embed the second plurality of conductors in the second layer almost immediately after heating, to extrude a third couch e of polymer insulator on the second layer and the second plurality of conductors, and to bond the third layer to the second layer to make a contiguous connection between the second layer, the second conductors, and the third layer, to have a third plurality of conductors, heating one of the third and third plurality of conductors, embedding the third plurality of conductors in the third layer almost immediately after heating, and extruding a fourth layer of polymeric insulation on the third layer and the third plurality of conductors and to bond the fourth layer to the third layer to form the cable and make a contiguous connection between each of the layers and the conductors. Alternatively, the heating comprises extruding the second and third layers on the second and third conductors and almost immediately after embedding the conductors in the freshly extruded second and third layers. Alternatively, the heating comprises exposing the second and third layers to a source of electromagnetic radiation. Alternatively, the heating comprises heating the second and third pluralities of conductors prior to embedding. Heating of the second and third conductors may include the use of a heat shaping / inducing device. Alternatively, the conductive strand comprises a single uninsulated strand. Alternatively, the first plurality of conductors comprise uninsulated electrical conductors. In a variant, the first plurality of conductors comprises shielding layers. Alternatively, the second plurality of conductors comprise shielding layers. Alternatively, the second and third pluralities of conductors comprise layers of armor wire. Alternatively, the method further comprises cooling the second and third layers prior to heating.

  In one embodiment, a method for forming a cable comprises the steps of providing at least one conductive cable core, extruding an inner layer of polymeric insulation on the conductive cable core, having a plurality of of conductors, to heat one of the inner layer and the plurality of conductors, to embed the plurality of conductors in the inner layer of the cable conductive core almost immediately after heating, and to extrude an outer layer of polymeric insulation on the inner layer and the plurality of conductors and bonding the inner layer to the outer layer to form the cable and making a contiguous connection between the inner layer, the conductors, and the outer layer. Alternatively, the heating comprises exposing the inner layer to a source of electromagnetic radiation. Alternatively, the heating comprises heating the plurality of conductors prior to embedding. The heating of the plurality of conductors may include the use of a heat shaping / inducing device. Alternatively, the plurality of leads comprises one of insulated electrical conductors, shield layers, and layers of armor wire. Alternatively, the at least one conductive core comprises one of a monocable, a coaxial cable, a triple cable, a quadruple cable, a seven-fold cable, and a flute. Alternatively, the at least one conductive core comprises a strip layer disposed on an outer portion thereof.

  Alternatively, the method further comprises the steps of providing a second plurality of conductors, heating one of the outer layer and the second plurality of conductors, embedding the second plurality of conductors in the outer layer of the cable almost immediately after heating, and extruding a second outer layer of polymeric insulation on the outer layer and the second plurality of conductors and adhering the outer layer to the second outer layer to form the cable and bonding adjacent the inner layer , the conductors, and the outer layer, the second conductors, and the second outer layer.

  Process embodiments provide cables with continuously bonded polymer layers, substantially free of interstitial spaces, for applications ranging from stranded conductors to wound shield conductors, to single-cable weave systems, coaxial cables , seven-fold cables and flutes. With the weave wire systems, this can consist of a continuous sheath, extending from the cable core to the outside diameter of the cable, while maintaining a high percentage of coverage by the layers of armor wire. The sheath system encapsulates the armor wires and substantially eliminates the interstitial spaces between the armor wires and the sheath (or between the conductive strands and the insulation) that could serve as conduits for gas migration. Embodiments of the methods allow wired metallic components (such as conductive strands or armor wires) to be applied to and partially embedded in lightly melted polymers. The methods include cabling the components to a freshly extruded and / or extruded semi-cooled polymer and / or passing the polymer through a heat source such as infrared (IR) almost immediately prior to wiring, and / or using a heat induction to heat the metal components sufficiently to allow them to melt the polymer and to be partially embedded in the polymer surface, and / or the use of an electromagnetic heat source (for example infrared) to partially melt the cladding material very shortly after each conductive strand or layer of weave wire has been applied to a cladding layer. This allows conductive strands or armor wires to be embedded in polymeric insulation or sheath materials, to lock armor wires in place, and virtually eliminates interstitial spaces. Embodiments also include machines for practicing embodiments of the methods, including, but not limited to, an armor machine comprising an armor machine casing having a driver input and output of cable and at least one coil disposed inside the housing and having a supply of armor wire wound thereon for delivering the armor wire for the wiring, the coil being adapted to rotate with respect to the housing for allow the cable conductor to pass through it. The method for forming a cable can be used for drilling ropes, such as, but not limited to, monocables, coaxial cables, seven, quad, triple or five cables and all the different flutes, slickline cables which incorporate wound or stranded metal elements, and any other cables. The method can also be applied to insulated conductors to provide gas blocking capabilities.

  BRIEF DESCRIPTION OF THE DRAWINGS These features and advantages of the present invention, as well as others, will be better understood with reference to the following detailed description, taken in conjunction with the accompanying drawings, in which: Figure 1 is a schematic drawing of a method for forming a cable; Figures 2a-2e are cross-sectional radial views, respectively, of a cable during various formation stages in the process of Figure 1; Figure 3 is a schematic view of a method for forming a cable; Figures 4a-4d are cross-sectional radial views, respectively, of a cable during various stages of formation during the process of Figure 3; Figure 5 is a schematic view of a method for forming a cable; Figures 6a-6e are cross-sectional radial views, respectively, of a cable during various formation stages in the process of Figure; Figure 6f shows a pair of rollers usable in this process; Figure 7 is a schematic view of a method for forming a cable; Figures 8a-8e are cross-sectional radial views, respectively, of a cable during various stages of formation during the process of Figure 7; and Figure 9 is a schematic view of a method for forming a cable; Figure 10 is a schematic view of a method for forming a cable; Figure 11 is a schematic view of an armor machine of the prior art; and Fig. 12 is a schematic view of an armor machine operable with the method of Fig. 10.

  DETAILED DESCRIPTION OF THE INVENTION First of all, it should be noted that, in the development of any such real embodiment, many decisions, specific to the implementation, must be made to achieve the specific goals of the invention. developer, as a conformation with system-related and economy-related constraints, which will vary from one implementation to another. In addition, it will be appreciated that this development effort could be complex and time consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art benefiting from this description. Referring now to FIGS. 1 and 2a-2e, a method for forming a cable 101 is indicated generally at 100. The method 100 begins with the provision, for example, of a copper-coated central strand 102, and extruding (for example by compression extrusion or tubular extrusion through an extruder 103) a layer of polymeric insulation 104 on the center strand 102 to form a cable conductive core 105. Those skilled in the art will appreciate the fact that that the central strand 102 may be, but not limited to, a coated strand, uncoated strand, or a preformed cable core comprising a plurality of conductors (such as, but not limited to, a single cable, a coaxial cable, triple cable, quad cable, sevenfold cable, flute, or combinations thereof) and coated with a tape layer (not shown) while remaining within the scope of the present invention. The process 100 may be carried out on a separate production line, the central strand 102 being wound for use in at least one second production line which completes the process, which is discussed in more detail below. Preferably, almost immediately before a plurality of preferably helical conductors or copper strands 106 are applied to continue formation of the cable 101, the cable conductive core 105 passes through a heat source 108, which melts or softens slightly. insulation 104. The heating of the insulation 104 before application of the strands or conductors 106 is thermodynamically more effective than the heating of the combined central strand assembly 102, insulation 104, and strands or conductors 106. Then, the strands preferably uninsulated copper wires 106 are wired on and partially embedded in the insulator 104 of the center strand 102 at a predetermined margin angle to form a conductor 110 comprising the central strand 102, the insulator 104, and the strands 106. the strands 106 are wired, the conductor 110 passes through a closure eyelet 112 to provide a circular profile for the cable 101. Immediately before entering an extruder 114, the conductor 110 is exposed to a heat source 116, which slightly melts the insulator 104 to facilitate subsequent bonding with the insulator 104. Then, a final insulator layer 118 is preferably extruded by compression on the helical strands 106, being bonded through the spaces between the strands 106, the insulator 104 beneath. The mechanical connection between the inner insulation layer 104 and the outer strands 106 allows the outer insulation layer 118 to be extruded by compression without causing any damage to the outer strands 106 or stripping them. Referring now to FIGS. 3 and 4a-d, a process for forming a cable 201 is indicated generally at 200. The method 200 begins with the provision, for example, of a copper central coated strand 202, and extruding (for example by compression extrusion or tubular extrusion through an extruder 203) a layer of polymeric insulation 204 on the center strand 202 to form a conductor 208.

  Those skilled in the art will appreciate that the center strand 202 may be, but is not limited to, a coated strand, uncoated strand, or a preformed cable core comprising a plurality of conductors and coated with a layer of band (not shown) while remaining within the scope of the present invention. Then, shortly after the extruder 203, a plurality of preferably uninsulated copper strands 206 are wired on and at least partially embedded in the freshly extruded, still hot and soft, polymer of the conductor 204 insulation 208 a predetermined margin angle, which forms a conductor comprising the central strand 202, the insulator 204, and the strands 206. Preferably, the strands 206 are wired onto the central strand 202 at a short predetermined distance from the extruder 203 to allow the freshly extruded polymer insulation 204 to retain the heat of the extrusion process and therefore facilitate the embedding of the strands 206 in the insulation 204. When the strands 206 are wired, the conductor passes through a closure eyecup 212 to provide a circular profile for the cable 201. Immediately before entering an extruder 214, the driver can be exposed to a heat source 216, which melts slightly insulating 204 to facilitate subsequent bonding with insulation 204. Thereafter, a final layer of insulation 218 is preferably extruded by compression on the helical strands 206, being bonded through the spaces between the strands 206 , the insulation 204 lying below. The mechanical connection between the inner insulation layer 204 and the outer strands 206 allows the outer insulation layer 218 to be extruded by compression without causing any damage to the outer strands 206 or stripping them.

  Referring now to FIGS. 5 and 6a-6f, a method for forming a cable 301 is indicated generally at 300. The method 300 begins with the provision, for example, of a copper-coated central strand 302, and extruding (for example by compression extrusion or tubular extrusion through an extruder 303) a layer of polymeric insulation 304 onto the center strand 302. Those skilled in the art will appreciate that the center strand 302 can be, but not limited to, a coated strand, an uncoated strand, or a preformed cable core comprising a plurality of conductors and coated with a tape layer (not shown) while remaining within the scope of the present invention. Then, after the extruder 303, a plurality of preferably uninsulated copper strands 306 are wired onto the center strand 302 at a predetermined margin angle to form a conductor 310 comprising the center strand 302, the insulator 304, and the 306. Preferably, immediately after the strands or helical metal components 306 have been applied, they pass through a heat shaping / inducing device 312. For example, electromagnetic heat induction may be applied via a pair of paired copper rollers 314. The induction of heat rapidly heats the strands or metal components 306.

  The heated components 306 slightly melt the polymeric surface or insulator 304 and partially fit into the insulator 304. The paired wheels 314 press the heated metal components 306 into the polymer 304 and maintain a circular cable profile. When the metal components 306 are pressed into the polymer 304, the diameter around which they are wired decreases slightly. The length of excess metal components created by this diameter change is transferred back to the process feed coils with the metal components, which are described in more detail below in excess length and coverage length equations. hypothetical monocable. Immediately before entering an extruder 316, the conductor 310 may be exposed to a heat source 318, which gently melts the insulator 304 to facilitate subsequent bonding with the insulation 304. Next, a final layer of insulation 320 is preferably extruded by compression on the helical strands 306, being bonded through the spaces between the strands 306, with the insulation 304 underneath. The mechanical connection between the inner insulation layer 304 and the outer strands 306 allows the outer insulation layer 320 to be extruded by compression without causing any damage to the outer strands 306 or stripping them.

  Referring now to Figures 7 and 8a-8e, a method for forming a cable 401 is indicated generally at 400. The method 400 begins with an insulative conductor or cable 402, such as cable 101, 201 or 301 shown in Figures 1-6 and formed by methods 100, 200 or 300, respectively, and having an insulator layer 403 thereon. Those skilled in the art will appreciate that cable 402 may be, but is not limited to, a coated strand, uncoated strand, or a preformed cable core comprising a plurality of conductors and coated with a strand layer. (not shown) while remaining within the scope of the present invention. Preferably, almost immediately before a plurality of shielding wires 404 is applied, the conductor 402 passes through a heat source 406 for gently melting or softening the insulator 403. The shielded shield wires 404 are then wired on and slightly embedded in the insulator 403 of the conductor 402, forming a cable or conductor 408. When the shielding wires 404 are applied, the conductor 408 passes through a closure eyelet 410 so that a circular profile is maintained. Immediately before an extruder 412, the cable 408 passes through a heat source 414, which melts and slightly softens the insulator 403, so as to facilitate subsequent bonding with the insulator 403. The extruder 412 extrudes the polymer 416 on the partially recessed coiled wires 404 (and preferably the adhesive to the insulator 403) to complete the cable core or coaxial cable 401. The completed cable core 401 preferably has substantially no interstitial spaces not filled. The polymer or cladding material 416 can be glued from the center 402 to the outer diameter of the insulator 416, if necessary, which advantageously provides reliable insulation of the wound wires 404 with respect to the armor wires (not shown) , which can not normally be obtained in coaxial cables of smaller diameter. Alternatively, shortly after an extruder (not shown) extruding the insulator layer 403 to form the cable or conductor 402, the plurality of shield wires 404 are wired on and at least partially embedded in the freshly extruded polymer, still hot and soft, of the cable insulation 404 or conductor 402 at a predetermined margin angle to form the conductor 408 before the rest of the process steps 400 are used to form the cable or core cable 401. Alternatively, Preferably, immediately after the shielding wires 404 have been applied, the conductor 408 passes through a heat shaping / inducing device (not shown), such as the heat shaping / inducing device 312 and the pair of rollers. paired copper 314, shown in Figure 5. Heat induction of the heat shaping / inducing device quickly heats the shield wires 404 and the wires 404 cha The mating wheels press the heated 404 shielding wires 404 into the polymer 403 to maintain a circular cable profile and, when the shielding wires are in place, to melt the insulator 403's polymeric surface. 404 are pressed into the polymer 403, the diameter around which they are wired decreases slightly, in a manner similar to the method 300 indicated above, before the rest of the process steps 400 are used to form the cable or core The excess length of wire created by this diameter change is transferred back to the coils feeding the process with the yarns, which are described in more detail below in excess length and coverage equations. for a hypothetical monocable. Alternatively, the methods 100, 200, 300 or 400 are used to form a cable having a plurality of layers of armor wire (not shown) disposed around a cable core, such as the cable 401 shown in FIGS. 7-8e, by replacing, for example, the shielding wires 404 shown in FIGS. 7-8e by armor wires, and embedding the armor wires in the polymer by passing the polymer through a heat source, by embedding the armor wires in the freshly extruded polymer, or by passing the conductor through a heat shaping / inducing device, to form a conductor, such as the conductor 408, as will be appreciated by the skilled man. job. In addition, additional extruders can be used to form multiple layers of armor and insulation wire and embed the armor wire in the insulation using at least one of the heat source, the polymer freshly extruded and the shaping device / heat induction. The cable or cables, for example, may be formed for use in the outer cladding of a projection cable used in seismic exploration.

  Referring now to FIG. 9, a method for forming a cable 501 is indicated generally at 500. The method 500 begins with the provision, for example, of a copper central strand 502, and the extrusion ( for example by compression extrusion or tubular extrusion through an extruder 503) of a polymeric insulation layer 504 on the center strand 502. Those skilled in the art will appreciate that the center strand 502 may be, but without limiting thereto, a coated strand, an uncoated strand, or a preformed cable core comprising a plurality of conductors and coated with a tape layer (not shown) while remaining within the scope of the present invention. Then, shortly after the extruder 503, a plurality of preferably uninsulated copper strands 506 are wired on and at least partially embedded in the freshly extruded, still hot and soft polymer, of the central insulated strand insulation 504. 502 at a predetermined margin angle, which forms a conductor 508 comprising the center strand 502, the insulator 504, and the strands 506. Preferably, the strands 506 are wired on the center strand 502 for a short predetermined distance from each other. at the extruder 503 to allow the freshly extruded polymer of the insulation 504 to retain the heat of the extrusion process and therefore facilitate the embedding of the strands 506 in the insulation 504. When the strands 506 are wired, the strand 502, the insulator 504, and the strands 506 pass through a closure eyelet 510 to provide a circular profile for the cable 501. Immediately before entering an extruder 512, the lead 508 is exposed to a heat source 514, which gently melts the insulator 504 to facilitate subsequent bonding with the insulator 504. Next, another insulating layer 516 is preferably extruded by compression onto the helical strands 506, by being bonded through the spaces between the strands 506, the insulator 504 lying below to form a conductor 520. The mechanical connection between the inner insulation layer 504 and the outer strands 506 allows the insulation layer 516 to be extruded by compression without causing any damage to the outer strands 506 or skinning them. Then, preferably immediately before a plurality of preferably helical armor wires 522 are applied to continue formation of the cable 501, the conductor 520 passes through a heat source 524, which gently melts or softens the insulation 516. Then, the armor wires 522 are wired on or partially embedded in the insulator 516 of the conductor 520 at a predetermined margin angle to form a conductor 526 comprising the conductor 520 and the armor wires 522. When the wires 522 522 are wired, the conductor 526 passes through a closure eyelet 528 to provide a circular profile for the cable 501. Immediately before entering an extruder 530, the conductor 526 is exposed to a heat source 532, which melts slightly insulating 516 to facilitate subsequent bonding with insulation 516. Next, another insulating layer 534 is preferably extruded by compression from the extruder 530 on the armor wires 522, being bonded through gaps between the wires 522, the insulation 516 underneath, to form a conductor 536. Then, preferably immediately before a plurality of preferably helical wire son 538 is applied so that the formation of the cable 501 continues, the conductor 536 passes through a heat source 520, which melts or slightly softens the insulation 534. Then the armor wires 538 are wired on or partially embedded in the conductor 534 insulation 536 at a predetermined margin angle to form a conductor 542 comprising the conductor 536 and the armor wires 538. When the armor wires 538 are wired, the conductor 542 passes through a Closure eyelet 544 for providing a circular profile for the cable 501. Immediately before entering an extruder 544, the lead 542 is exposed to a heat source 546, which is lightly melted. the insulation 534 to facilitate subsequent bonding with the insulation 534. Then, another insulation layer 548 is preferably extruded by compression from the extruder 544 onto the armor wires 538, being bonded by via gaps between the wires 548, the insulation 534 underneath, to form a cable 501.

  Referring now to Figure 10, a method of forming a cable 601 is indicated generally at 600. The method 600 begins with the provision of a prefabricated cable core 602 that is placed or wound on a coil 604. The cable core 602 is delivered from the coil 604 and passes through a cable dancer 606 intended to facilitate the maintenance of a voltage of the wire method or method immediately prior to entering a an armor machine shown in Figure 10), passes through an extruder 610 where a preferably carbon fiber reinforced 612 is applied to the cable core 602. Those skilled in the art will appreciate that the layer 612 can be made of other materials such as, but not limited to, reinforced or unreinforced fluorinated polymers such as MFA, PFA, FEP, ETFE or the like, or modified polyethylenes, PPEK, PEDS, PPS or PPS, or their combinations. Layer 612 can be briefly air-cooled or water-cooled prior to entering armor machine 608 or a tubular armor machine 640, shown in FIG. 12. Method 600 can utilize tubular armor machine 640 which comprises a plurality of coils 605 which each contain a strand or armor wire 614 or 626 wound or disposed thereon and are disposed within the armor machine 640 being preferably adapted such that the coils 605 can be rotated or rotated about ninety degrees per constant during sheathed armor. planetary weave machine 608 cable core 602 Tefzel layer compared to the casing of the 640 armor machine to allow the 602/612 cable core to pass through the center of the 605 coils, as shown in Figure 12, allowing thus the use of the machine 640 in a number of different methods or methods of forming cable. A prior art tubular weave machine 609, shown in FIG. 11, comprises a plurality of strand or armor coils 605, each oriented approximately at right angles to the length of a housing of the machine. 609, which requires that the cable core 602/612 be directed to an outer portion or to the outside of the machine 609 away from the coils, as will be appreciated by those skilled in the art. The armor machine 640 can be used in a manner similar to the armor machine 609, whereby the cable core 602/612 passes outside the machine 640, or through which the cable core 602/612 passes through the center of the coil or coils 605.

  The layer 612 can pass through an infrared or induction heat source 613 for softening the layer 612. While the layer 612 is still soft, the first layer of weave wire 614 is applied to and slightly embedded in the polymer layer 612. forming the conductor 616. After the interior weave wires 614 have been applied, the conductor 616 passes through a closure eyelet 618 so that the weave wires 614 are firmly embedded in the layer 612. To further embed the wires 614 in the polymer 612 and maintain a circular profile for the cable 601, the conductor 616 passes through a pair of forming wheels 619. Immediately before entering a second planetary armor machine 620 (or a second tubular armor machine such as the armor machine 640 shown in Figure 12), the conductor 616 passes through an extruder 622 where is applied a layer 624 of Tefzel preferably reinforced by carbon fibers. The layer 624 may be briefly air-cooled and / or water-cooled prior to entering the second tubular weave machine 620 so that it may pass through a tubular weave machine, such as tubular weave 609 shown in Figure 11, to allow the layer 624 to remain stable enough to pass through the outside of the rotating tube on the tubular weave machine 609. The polymeric layer 624 can pass through a heat source to infrared or induction 625 for softening the layer 624. While the Tefzel layer preferably reinforced with carbon fiber 624 is still soft, a second layer of weave wire 626 is applied to and slightly embedded in the polymer 624 to 628 After the outer armor wires 626 have been applied, the conductor 628 passes through a closure eyelet 630 so that the armor wires 626 are firmly embedded. in the carbon-fiber-reinforced Tefzel 624. To further embed the outer armor wires 626 in the polymer 624 and maintain a circular profile for the cable 601, the lead 628 passes through an infrared or induction heat source ( not shown), such as heat sources 108, 116, 216, 318, 406, 414, 503, 514, 524, 532, 540, or 546, before passing through a pair of forming wheels 634. The conductor 628 then passes into a final extruder 636 where an outer sheath 638 made of pure Tefzel or Tefzel reinforced with carbon fibers is applied to complete the cable 601. Alternatively, the conductor 628 may be collected on a reel (not shown) after passing through the forming wheels 634 and the final cladding layer 638 can be applied in a separate production operation. Therefore, Figure 10 illustrates a process 600 that can be used to manufacture, for example, a gas-tight single cable cable in a single production line. The methods 100, 200, 300, 400, 500 and 600 can be used to produce cables, such as cables 101, 201, 301, 401, 501 or 601 for filling interstitial spaces in metal elements of petroleum exploration and other cables. The methods 100, 200, 300, 400, 500 and 600 can be used to fill interstitial spaces between stranded conductors, wound shielded conductors, or armor wire reinforcing elements in monocables, coaxial cables, seven-fold cables, flutes, or other cables. The insulation for the layers 104, 204, 304 or 504 for the center strands 102, 202, 302 or 502 may be formed from any suitable insulating material including, but not limited to, a polyolefin (such as an ethylene-polypropylene copolymer) or fluorinated polymers (such as MFA, PFA, Tefzel). Insulation for layers 118, 218, 320, 416 or 516 on the helical stranded conductors may be formed, but not limited to, from one or more of the following: PEEK, PEK, Parmax B, PPS Modified PPS, polyolefin (such as an ethylene-polypropylene copolymer), fluoropolymer (such as MFA, PFA, Tefzel), and the like. Similarly, for coiled coiled cables, the insulation material for layer 403 under the coiled shield may be any of those specified for the helical stranded conductors above. Similarly, the layer 416 for the sheath on the wound shield may be of the same material used for the insulation or may be of any other compatible material selected from the listed materials for the coaxial cables. Depending on the materials chosen, the insulation and the sheath may or may not be glued. For flutes, layers 104, 204, 304 or 504 and layers 118, 218, 320, 416 or 516 may be formed of nylon 11 or 12, or any other nylon, polyurethane, hytrel, santoprene, polysulfide phenylene) (PPS), polypropylene (PP), or ethylene-polypropylene copolymer (EPC) or a combination of one or more polymers bonded by means of a tie layer.

  For sevenfold cables, the sheath materials can be glued continuously from the core cable 104, 204, 304 or 504 to the outermost sheath 118, 218, 320, 416 or 548 for tear strength. Starting with the optional band around the cable core 105, 205, 305 or 505, all materials can be selected to chemically bond to one another. Short carbon fibers, glass fibers, or other synthetic fibers may be added to the sheath materials 118, 218, 320, 416, 516, 534, 548, 601, 612 or 624 to reinforce the thermoplastic or the thermoplastic elastomer and provide protection against cuts. In addition, graphite, ceramic or other particles may be added to the outer sheath polymer matrix 118, 218, 320, 416, 516, 534, 548, 601, 612 or 624 to increase the resistance to the outer sheath. 'abrasion. A protective polymeric coating may be applied to each strand of armor wire 522, 538, 614 and 626 for corrosion protection. The following coatings may be used, but not limited to: fluoropolymer coating FEP, Tefzel, PFA, PTFE, MFA; combination of PEEK or PEK with a fluoropolymer; combination of PPS and PTFE; latex or rubber coating. Each weave wire strand 522, 538, 614, and 626 may also be plated (for example) with a metal cladding of 0.5 mm to 3.0 mm which may enhance bonding of the weave wires to the polymeric materials. sheath. Veneer materials may include, but are not limited to: ToughMet (a high strength copper-nickel-tin alloy manufactured by Brush Wellman); brass; the copper ; a copper alloy, zinc, nickel, their combinations; and the like. The sheath material 118, 218, 320, 416, or 516 and the armor wire coating material 522, 538, 614, or 626 may be selected so that the armor wires 522, 538, 614, or 626 are not bonded to and can move in the sheath material 118, 218, 320, 416 or 516. The sheath materials 118, 218, 320, 516 or 516 may comprise polyolefins (such as EPC or polypropylene), fluorinated polymers (such as Tefzel, PFA, or MFA), PEEK or PEK, Parmax, and PPS. In some cases, the virgin polymers do not have sufficient mechanical properties to withstand 25,000 pounds (11340 kg) of tensile or compressive force when the drilling cable 101, 201, 301, 401, 401, 501 or 601 is pulled on pulleys. The materials may be virgin polymers with short fibers added. The fibers may be carbon, glass, ceramic, Kevlar, Vectran, quartz, nanocarbon, or any other suitable synthetic material. The friction for the short fiber-added polymers can be significantly greater than that of the virgin polymer. To achieve lower friction, a layer of virgin polymer material of about 1.0 mm to about 15.0 mm may be added to the outside of the fiber-reinforced sheath. Particles can be added to fluoropolymers or other polymers to improve wear resistance and other mechanical properties. These may be in the form of a sheath of about 1.0 mm to about 15.0 mm applied to the outside of the sheath or throughout the polymer matrix of the sheath. The particles may include: CeramerTM; boron nitride; PTFE; graphite; or any combination of the previous ones. As an alternative to CeramerTM, fluoropolymers or other polymers may be reinforced by nanoparticles to improve wear resistance and other mechanical properties, such as, but not limited to, a sheath of about 1.0 mm to about 10.0 mm applied to the outside of the sheath or throughout the polymer matrix of the sheath. The nanoparticles may include nano-clays, nano-silica, nano-carbon beams, or nano-carbon fibers. The materials and material properties for the layers and armor yarns can be selected from the materials disclosed in commonly assigned U.S. Patents Nos. 6,600,108, 7,170,007 and 7,188,406. The heat sources 108, 116 , 216, 318, 406, 414, 503, 514, 524, 532, 540, or 546 may be one of or a combination of exposure to a source of electromagnetic radiation or electromagnetic heating, which may be realized by use of any one or any combination of infrared heaters emitting short, medium or long infrared waves, ultrasonic waves, microwaves, lasers, and other suitable electromagnetic waves, as will be appreciated by skilled person.

  Armor wires 522, 538, 614, or 626 or leads 106, 206, 306, 505, or 506 may be heated prior to embedding in the layers, for example, and not limited to, by induction heating of metal , ultrasonic heating, or thermal heating using radiation or conduction, as will be appreciated by those skilled in the art. The aforementioned methods 100, 200, 300, 400, 500, and 600 are examples of certain approaches, which may be used alone, or in combination, for metallic elements embedded in cable sheaths or insulating layers or for an insulator as described above. In the aforementioned methods 100, 200, 300, 400, 500, and 600, wire elements (such as helical conductor strands, wound shield wires, or armor wires) are wired to core elements incorporated in a polymer (such as central conductor strands, insulated conductors or cable cores) at a given coverage rate in a slightly melted or softened insulator, allowing the wired wires to be embedded themselves in the insulation. When the wired wires are recessed, they reach a larger coverage with a smaller circumference. Correspondingly, a shorter length of wired wire elements is required to cover a smaller circumference. For example, on a single cable, coiled shield wires could be wired to a central insulated conductor with a coverage of about 80 to about 85 Over a distance of a few inches (1 inch = 2.54 cm) or feet (1 foot) = 30.48 cm), the cable passes through an electromagnetic heat source for softening the insulation, and the coiled wires fit themselves into the insulation.

  As the wires are now distributed around a smaller circumference, the coverage increases to between 93 and 98. Along the length of a drill string, wiring at the smaller diameter also requires significantly less length.

  A single-cable assembly is assumed to be applied by applying 0.0323 inch (0.082 cm) weave wires at a 22 degree margin angle over a 0.112 inch (0.315 cm) initial diameter sheath, as shown by the equations and calculations shown below.

  The total initial diameter is 0.1866 inches (0.474 cm). The sheath is then softened so that the armor wire can be partially embedded in the sheath, so that the resulting total diameter is 0.1733 inches (0.4402 cm). As described in the calculations below, the length of armor wire needed to surround the core with a 22 degree margin angle is 10.16% shorter at the smaller diameter. On a 24,000-foot (7,300-m) monocable, there is a difference of about 2440 feet (745 meters) for each armor wire, as shown by the equations and calculations shown below. The excess length and coverage equations for a hypothetical monocable are given below.

  For calculations, 1 in (1 inch) = 2.54 cm and 1 ft (1 foot) = 30.48 cm. 36 D = diameter of the pitch D = D, + dW D, = diameter of the core dw = diameter of the armor wire

  CI = total circumference at pitch diameter =, r (D, + dW) =, rD

  = circumference of total metal at step diameter

  m = number of metallic elements

C2 = mx cos a

  C% = metal cover at step diameter

md C% = x100 n-Dcosa

  DQ = initial diameter Da = 0.124 in. + 0.0323 in. = 0.1563 in. = length of a coil of Da armor wire

rr x 0.1563 in. tan 22 = 1.22 Db = final diameter Db = 0.109 in. + 0.0323 in. = 0.141 in.

  = length of a winding of armor wire at Db

  rrx 0.141 in. = tan 22 = 1,096 in.2920059 = length of a coil of armor wire at Db

rr x 0.141 in.

tan 22 = 1.096 in.

  42 difference in margin length as a fraction of 2a 42 0.124

AQ 1.22 = 10.16%

  The = 24 000 ft. Lb = (0.1016 x 24,000 μm) + 24,000 ft. = 26439 ft.

AL = Lb ù The

  AL = 26,439 ft. ù 24,000 ft. = 2439 ft. AQ = This length could of course not be removed from a 24,000 foot (7300 m) cable after the armor wire has been completed. The methods or processes described herein are possible only because the excess length is recovered by tension at the armor wire coils when the diameter is reduced. The unwinding speed of the armor yarn from the reels is decreased to take into account the excess length "returning" to the reels.

  The foregoing description has been presented with reference to presently preferred embodiments of the invention. Those with a good knowledge of the technology and technology to which this invention belongs will appreciate that modifications and changes in the described operating structures and methods can be practiced without departing significantly from the principle and the framework. of this invention. Therefore, the foregoing description should not be read in such a way as to relate only to the specific structures described and shown in the accompanying drawings, but rather should be read in agreement with and in support of the following claims, which must have the most complete and most just.

Claims (12)

  A method for forming at least a portion of a cable, characterized in that it comprises the steps of. having at least one driver; extruding at least one inner layer of polymeric insulation on the at least one conductor to form a cable conductive core; 10 to embed a plurality of conductors in the inner layer of the cable conductive core; and extruding an outer layer of polymeric insulation on the cable conductive core and the plurality of conductors and bonding the inner layer to the outer layer to form the cable and making a contiguous connection between the inner layer, the conductors, and the outer layer, wherein the recess comprises heating one of the inner layer and the conductors prior to embedding the conductors in the inner layer.   The method of claim 1, wherein the heating comprises extruding the inner layer on the at least one conductor and, almost immediately after, embedding the plurality of conductors in the freshly extruded inner layer. 30   A method as claimed in any one of the preceding claims, wherein the heating comprises heating one of the inner layer and the plurality of conductors almost immediately prior to embedding.   The method of any of the preceding claims, further comprising cooling the inner layer prior to embedding.   The method of any one of the preceding claims, wherein the at least one conductor comprises one of a single non-insulated strand and a plurality of conductors.   The method of any of the preceding claims, wherein the plurality of conductors comprise one of uninsulated electrical conductors, shield layers, and layers of armor wire.   7. A method for forming a cable, characterized in that it comprises the steps of: disposing at least one conducting cable core having at least one inner layer of polymeric insulation disposed on at least one conductor; having a plurality of conductors; heating one of the inner layer and the plurality of conductors; embedding the plurality of conductors in the inner layer of the cable conductive core almost immediately after heating; andextruding an outer layer of polymeric insulation on the cable conductive core and the plurality of conductors and adhering the inner layer to the outer layer to form the cable and making a contiguous connection between the inner layer, the conductors, and the layer outdoor; having a second plurality of conductors; heating one of the outer layer and the second plurality of conductors; embedding the second plurality of conductors in the outer layer of the cable almost immediately after heating; and extruding a second outer polymer insulator layer 15 over the cable and the second plurality of conductors and bonding the outer layer to the second outer layer to form the cable and making a contiguous connection between the inner layer, the conductors, and the outer layer, the second conductors, and the second outer layer.   8. A method of forming a cable, characterized in that it comprises the steps of: disposing of a conductive strand; extruding a first polymer insulator layer on the conductive strand to form a cable conductive core; embedding a first plurality of conductors 30 in the first layer of the cable conducting core immediately after extrusion of the first layer; extruding a second layer of polymeric insulation on the cable conductive core and the plurality of conductors and bonding the inner layer to the second layer to provide a contiguous connection between the inner layer, the conductors, and the second layer; providing a second plurality of leads; heating one of the second layer and the second plurality of conductors; embedding the second plurality of conductors in the second layer almost immediately after heating; extruding a third layer of polymeric insulation on the second layer and the second plurality of conductors, and bonding the third layer to the second layer to effect a contiguous connection between the second layer, the second conductors, and the third layer; providing a third plurality of conductors; heating one of the third layer and the third plurality of conductors; embedding the third plurality of conductors in the third layer almost immediately after heating; and extruding a fourth layer of polymeric insulation 30 over the third and third plurality of conductors and bonding the fourth layer to the third layer to form the cable and making a contiguous connection between each of the layers and conductors.   The method of claim 8, further comprising cooling the second and third layers prior to heating.   A method of forming a cable, characterized in that it comprises the steps of: providing at least one conductive cable core; extruding an inner layer of polymeric insulation on the conductive cable core; Providing a plurality of conductors; heating one of the inner layer and the plurality of conductors; embedding the plurality of conductors in the inner layer of the cable conductive core almost immediately after heating; and extruding an outer layer of polymeric insulation on the inner layer and the plurality of conductors and adhering the inner layer to the outer layer to form the cable and making a contiguous bond between the inner layer, the conductors, and the layer exterior.   The method of claim 10, wherein the at least one conductive core comprises one of a single cable, a coaxial cable, a triple cable, a quadruple cable, a seven-fold cable, and a flute.   The method of claim 10, wherein the at least one conductive core comprises a band layer disposed on an outer portion thereof.