WO2008132637A1

WO2008132637A1 - Bend insensitive opto-electrical cables with improved fatigue life

Info

Publication number: WO2008132637A1
Application number: PCT/IB2008/051177
Authority: WO
Inventors: Joseph Varkey; Vladimir Hernandez-Solis; Surya Simanjuntak; Dan Tabalan; Byong Jun Kim
Original assignee: Schlumberger Canada Limited; Services Petroliers Schlumberger; Schlumberger Holdings Limited; Schlumberger Technology B.V.; Prad Research And Development Limited
Priority date: 2007-04-25
Filing date: 2008-03-28
Publication date: 2008-11-06
Also published as: CN101295061A; CN201229797Y; CN201196694Y

Abstract

A hybrid opto-electrical cable assembly for oilfield wireline or seismic exploration applications includes an optical fiber element and an electrical conductor. The optical fiber element includes an optical fiber and a carbon layer surrounding the optical fiber. The optical fiber can have a high Numerical Aperture to reduce the fiber susceptibility to optical signal attenuation due to microbendings or macrobendings. The carbon layer increases the fatigue life of the optical fiber and protects the optical fiber against hydrogen attack and hydrolysis. Therefore, the optical fiber element and the opto-electrical cable assembly are less susceptible to bending stress and have increased service life. A jacketing system for protecting the opto-electrical cable assembly and a manufacturing method thereof are also disclosed.

Description

BEND INSENSITIVE OPTO-ELECTRICAL CABLES WITH IMPROVED

FATIGUE LIFE

FIELD

[0001] The present disclosure relates generally to opto-electrical cables, and more particularly to hybrid opto-electrical cables for oilfield wirelines, seismic exploration, and their manufacturing methods.

BACKGROUND

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] As an oil well is being drilled, a sonde is usually lowered periodically into the borehole to measure characteristics of the earth formations it traverses. Typically, a logging cable supports and moves the sonde within the borehole, carries electrical power for the sonde, and relays control instructions and data between the sonde and instrumentation and control facilities at the surface of the earth. As measurements and measuring instruments have become more sophisticated, data transmission rates have increased to the point where existing electrical cables can become saturated.

[0004] Fiber optic technology can increase data transmission rates several orders of magnitude, as has been demonstrated by fiber optic telephone cables. Due to the demanding conditions under which a well logging cable is used, however, telephonic fiber optic cables would not be acceptable. Telephone cables are designed to remain stationary in use and not to encounter the extremes of temperature and pressure found in an oil well.

[0005] In contrast, a well logging cable is repeatedly pulled around sheave wheels and wound onto and off a winch drum as it is lowered into and lifted out of wells. The cable must therefore withstand repeated bending around diameters of a few feet, and tensions of thousands of pounds. Once in the well, the cable encounters pressures which may exceed twenty thousand pounds per square inch and temperatures which may exceed 175^°C. Optical fibers, however, are extremely sensitive to deformation (especially point loads), which greatly increase the attenuation of the optical signals within the fiber. They are also sensitive to moisture, which attacks micro-cracks in the fibers reducing their strength. Moreover, they are sensitive to atomic and molecular hydrogen, which reacts with the Silica increasing the fiber attenuation. While the cable is being manufactured, and later when in use, the stresses (bending and stretching) on the cable components (electrical conductors, strength members, etc.) move them relative to one another within the cable. This can cause local deformations of the optical fibers. Stretching the cable stretches the fibers, thereby increasing their stress, aggravating their attenuation, and sometimes causing them to break. The high pressures and temperatures within the well assist moisture and hydrogen in invading the cable and the optical fibers. As indicated, typical optical telephonic communication cables are not designed for these operating conditions.

[0006] In view of the foregoing, one opto-electhcal cable intended for oil well and seismic exploration applications which is commonly assigned with the present application is disclosed in U.S. 4,375,313 to Anderson et al. The '313 patent discloses a buffering structure for protecting the optical fibers from moisture, hydrogen, and non-uniform stresses. While this buffering structure is suited for repetitive and demanding well logging applications, a need remains for better buffering the optical fibers against stresses and moisture and hydrogen protection in view of applications of the cables in deeper oil and gas wells and with more sophisticated tools requiring increased amount of data transmission.

SUMMARY

[0007] Embodiments of the present invention provide optical fiber elements, hybrid opto-electrical conductors, hybrid opto-electhcal conductors assemblies, and opto-electrical core assemblies with enhanced bend insensitivity, fatigue life and protection against hydrogen attack. In one preferred form, an optical fiber ensemble includes an optical fiber, and a carbon layer surrounding the optical fiber.

[0008] In another form, a hybrid opto-electrical conductor includes at least one optical fiber element, at least one electrical conductor disposed around the at least one optical fiber element, and a securing layer disposed around the at least one electrical conductor for securing the at least one electrical conductor in place. The at least one optical fiber element includes an optical fiber and a carbon layer surrounding the optical fiber element.

[0009] In still another form, a hybrid opto-electrical conductor assembly includes a plurality of opto-electrical conductors arranged in a bundle and a filler material for binding the plurality of opto-electhcal conductors. The opto-electhcal conductors each include an optical fiber element and an electrical conductor surrounding the optical fiber element. The optical fiber element has an optical fiber and a carbon layer surrounding the optical fiber.

[0010] In still another form, a hybrid opto-electrical conductor includes at least one optical fiber element, at least one electrical conductor disposed around the at least one optical fiber element, a first polymer, and a second polymer layer. The first polymer layer secures the at least one electrical conductor in place. The second polymer layer surrounds the first polymer layer for improving mechanical strength of the opto-electrical conductor.

[0011] In yet still another form, a hybrid opto-electrical conductor assembly includes a plurality of opto-electrical conductors arranged in a bundle, a filler rods, and a filler material. The plurality of opto-electrical conductors define an outer contour and a plurality of interstices between adjoining opto-electrical conductors. The plurality of filler rods are disposed in the interstices adjacent to the outer contour. The filler material fills in the interstices to interlock the plurality of conductors and the filler rod to form a core assembly.

[0012] In yet still another form, a jacketing system for a cable assembly includes a polymer composite adapted to enclose a cable core, a first strength element surrounding the polymer composite, a first polymer layer surrounding the first strength element, a second strength element surrounding the first polymer layer, and a second polymer layer surrounding the second strength element. [0013] In yet still another form, a method of manufacturing an opto- electrical conductor assembly includes: providing a plurality of opto-electrical conductors; arranging the plurality of opto-electrical conductors in a bundle, the opto-electrical conductors defining an outer contour and a plurality of interstices between the adjoining opto-electrical conductors; placing a plurality of filler rods in the interstices adjacent to the outer contour; filling a filler material in the interstices; and placing a protective layer around the conductors and the filler rods.

[0014] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

[0015] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0016] Figure 1 is a cross-sectional view of an optical fiber element constructed in accordance with the teachings of the present disclosure;

[0017] Figures 2 is a cross-sectional view of an alternative optical fiber element constructed in accordance with the teachings of the present disclosure;

[0018] Figure 3 is a cross-sectional view of a hybrid opto-electrical conductor constructed in accordance with the teachings of the present disclosure; [0019] Figure 4 is a cross-sectional view of an alternative hybrid opto- electhcal conductor constructed in accordance with the teachings of the present disclosure;

[0020] Figure 5 is a cross-sectional view of a hybrid opto-electhcal core assembly constructed in accordance with the teachings of the present disclosure;

[0021] Figure 7 is a cross-sectional view of another alternative hybrid opto-electrical cable assembly in accordance with the teachings of the present disclosure;

[0022] Figure 8 is a cross-sectional view of still another alternative hybrid opto-electrical cable assembly constructed in accordance with the teachings of the present disclosure;

[0023] Figure 9 is a cross-sectional view of an alternative cable core assembly constructed in accordance with the teachings of the present disclosure; and

[0024] Figures 10, 11 , and 12 are cross-sectional views of a core assembly of a hybrid opto-electrical conductor assembly, illustrating sequential steps of manufacturing the core assembly in accordance with the teachings of the present disclosure.

[0025] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION [0026] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

Optical Fiber Element

[0027] Referring to Figure 1 , an optical fiber element constructed in accordance with the teachings of the present disclosure is illustrated and generally indicated by reference numeral 10. The optical fiber element 10 comprises an optical fiber 12, a carbon layer 14 disposed around the optical fiber 12, a buffer layer 18 surrounding the carbon layer 14, and an outer silicon layer 24 surrounding the buffer layer 18. The optical fiber 12 comprises a core 1 and a cladding 2.

[0028] The optical fiber 12 and the carbon layer 14 form an optical fiber ensemble 16. The carbon layer 14 is hermetic, high-temperature and is placed over the optical fiber 12 to provide a barrier against H₂O and H⁺, thereby protecting against hydrogen attack and hydrolysis. The carbon layer 14 also increases the proof stress level of the optical fiber element 10 and resistance to static fatigue, thereby increasing the service life of the optical fiber element 10.

[0029] Preferably, the optical fiber 12 has a high numerical aperture and a smaller core 1 than conventional telecommunications fiber. A high numerical aperture fiber requires a smaller fiber core size to maintain a constant cutoff wavelength. High NA fibers reduce the fiber susceptibility to optical signal attenuation due to microbendings and macrobendings.

[0030] The buffer layer 18 surrounds the optical fiber ensemble 16 and is in intimate contact with the optical fiber ensemble 16. The buffer layer 18 is called a "tight buffer" because the buffer layer 18 is in intimate contact with the optical fiber ensemble 16, as opposed to a "loose buffer" which may take the form of a conduit and loosely contains the optical fiber ensemble 16. The buffer layer 18 includes a silicon layer or other suitable soft polymers 20 extruded over the optical fiber ensemble 16 and a PFA (perfluoroalkoxy) layer 22 extruded over the silicon layer 20.

[0031] The outer silicon layer or other suitable soft polymers 24 is extruded over the buffer layer 18 to cushion the optical fiber ensemble 16 and distribute any compressive load on the optical fiber ensemble 16 from outside. With this construction, the optical fiber element 10 is less susceptible to tensile stress and bending stress, thereby reducing signal attenuation.

[0032] Referring to Figure 2, an alternative optical fiber element is illustrated and generally indicated by reference numeral 30. The optical fiber element 30 has a construction similar to that of the optical fiber element 10, differing in that the optical fiber element 30 includes three optical fiber ensembles 16.

[0033] It should be understood and appreciated that the optical fiber element 10 or 30 may have any number of optical fiber ensembles 16 depending on applications. Moreover, the optical fiber ensembles 16 may be arranged to define a cross section other than a circular cross section. Other configurations are possible without departing from the spirit of the present disclosure. Each of the optical fiber ensembles 16 may be coated with silicon or other suitable soft polymers 3 before cabling them to form a bundle.

Hybrid Opto-Electhcal Conductor

[0034] Referring to Figure 3, a hybrid opto-electhcal conductor is illustrated and is generally indicated by reference numeral 40. The hybrid opto- electrical conductor 40 includes an optical fiber element 10, a plurality of electrical conductors 42 surrounding the optical fiber element 10, a securing layer 44 surrounding the plurality of electrical conductors 42, and a strengthening layer 46 surrounding the securing layer 44. As described earlier, the optical fiber element 10 includes an optical fiber 12, a carbon layer 14, a buffer layer 18, and an outer silicon layer 24 surrounding the buffer layer 18.

[0035] In this illustrative example, the plurality of electrical conductors 42 are in the form of a plurality of copper wires or nickel coated copper wires. The plurality of electrical conductors 42 are helically wrapped around the optical fiber element 10 and are partially embedded into the outer silicone layer 24 of the optical fiber element 10.

[0036] The securing layer 44 is disposed around the plurality of electrical conductors 42 for securing the plurality of electrical conductors 42 in place. In some preferred embodiments, the securing layer is a polymer layer, which may be a first polymer layer, the polymer layer extruded over the plurality of electrical conductors 42 to lock the electrical conductors 42. The polymer layer 44 is preferably made of a material such as a fluoropolymer, polyolefin, polyphenylene, soft elastomers, thermoplastic elastomers, and the like. Some nonlimiting examples of these materials include polyolefins, polytetrafluoroethylene-perfluoromethylvinylether polymer (MFA), perfluoro- alkoxyalkane polymer (PFA), polytetrafluoroethylene polymers (PTFE), ethylene- tetrafluoroethylene polymers (ETFE), ethylene-propylene copolymers (EPC), poly(4-methyl-1-pentene) (TPX® available from Mitsui Chemicals, Inc.), other fluoropolymers, polyaryletherether ketone polymers (PEEK), polyphenylene sulfide polymers (PPS), modified polyphenylene sulfide polymers, polyether ketone polymers (PEK), maleic anhydride modified polymers, perfluoroalkoxy polymers, fluohnated ethylene propylene polymers, polytetrafluoroethylene- perfluoromethylvinylether polymers, polyamide polymers, polyurethane, thermoplastic polyurethane, ethylene chloro-thfluoroethylene polymers (such as Halar®), chlorinated ethylene propylene polymers, Parmax® SRP polymers (self- reinforcing polymers manufactured by Mississippi Polymer Technologies, lnc based on a substituted poly (1 ,4-phenylene) structure where each phenylene ring has a substituent R group derived from a wide variety of organic groups), ECTFE, PAEK, Santoprene, Silicon, Tefzel, EPDM, Engage, Infuse, fluorothermoplastic elastomers or the like, and any mixtures thereof.

[0037] The strengthening layer 46 surrounds the securing layer 44 for protecting the optical fiber element 10 and the electrical conductors 42 enclosed therein. The strengthening layer 46 includes a second polymer layer 48 extruded over the securing layer 44 and a third polymer layer 50 extruded over the second polymer layer 48. The materials for the second polymer layer 48 and the third polymer layer 50 are properly chosen to increase mechanical strength for the hybrid opto-electhcal conductor 40 and provide the required electrical properties.

[0038] For example, the second polymer layer 48 can be made of a material harder than that of the third polymer layer 50 to provide the desired mechanical strength. Suitable materials for the second polymer layer 48 include: polyarylether ketone families like PEEK, PEK, PK, PAEK, etc; Parmax; PPS or modified PPS; carbonfiber reinforced fluoropolymers like Tefzel, ECTFE, etc; reinforced and toughened PTFE; and the like. The third polymer layer 50 is used to provide the desired electrical properties, such as the desired impedance and low electrical signal attenuation, Suitable materials for the third polymer layer 50 include: polyolefins such as PP, PE, EPC, TPX, etc; fluoropolymers such as Tefzel, MFA, ECTFE, PFA, FEP, PTFE, and the like.

[0039] While not shown in the figures, it should be understood and appreciated that the third polymer layer 50 can be disposed adjacent to the securing layer 44 and the second polymer layer 48 can be disposed around the third polymer layer 50. It is possible to avoid the securing layer 44 altogether and go only with layers 48 and 50.

[0040] In some embodiments the first polymer layer 44 may be removed. The optical fiber will be protected by the second polymer layer 48 and third polymer layer 50. In some embodiments the second polymer layer 44 may be on the outside of the third polymer layer 50 to give better crush resistance from external forces to the package.

[0041] Referring to Figure 4, an alternative opto-electrical conductor is illustrated and generally indicated by reference numeral 54. The opto-electrical conductor 54 differs from the opto-electrical conductor 40 of Figure 3 in that the opto-electrical conductor 54 includes three optical fiber ensembles 16. It should be understood and appreciated that any number of optical fiber ensembles 16 can be included in an opto-electrical conductor without departing from the scope of the present disclosure.

Hybrid Opto-Electhcal Cable Core Assembly

[0042] Referring to Figure 5, a hybrid opto-electrical cable core assembly constructed in accordance with the teachings of the present disclosure is shown and indicated generally by reference numeral 60. The opto-electrical cable core assembly 60 includes a plurality of opto-electrical conductors 40 arranged in a bundle, a tape 62 surrounding the plurality of opto-electrical conductors 40 for binding the opto-electrical conductors 40 together, and a protective layer 64 surrounding the tape 62. Since the opto-electrical conductors 40 have been described in connection with Figure 3, the description thereof is omitted herein for clarity.

[0043] It should be noted that while seven opto-electrical conductors 40 are shown, it is understood and appreciated that any number of opto-electrical conductors 40 can be included in the hybrid opto-electrical cable core assembly 60 depending on applications. Moreover, the opto-electhcal conductors 40 enclosed therein can be replaced completely or partially with the opto-electrical conductors 54 of Figure 4 having three optical fiber ensembles 16, without departing from the scope of the present disclosure

[0044] The plurality of opto-electrical conductors 40 define an outer contour and a plurality of interstices 66 between the adjoining opto-electrical conductors 40. A plurality of filler rods 68 are disposed in the interstices 66 enclosed by the tape 62 and the two adjoining conductors 40 so that the conductors 40 and the filler rods 68 define an outer contour close to the shape of the desired cross section of the cable core assembly 60. The filler rods 68 include a twisted glass fiber core 74 and a polymer layer 76 extruded around the twisted glass fiber core 74.

[0045] A filler material 70 fills in the interstices 66 for bonding the conductors 40 and the filler rods 68 together.

[0046] The protective layer 64 in this illustrative example is a polymer jacket 64 extruded over the tape 62 to provide mechanical stability and protection. The cables 40, the filler rod 68, the tape 62, the filler material 70, and the polymer jacket 64 form a core assembly 60. The polymer jacket 64 may consist of one or more layers depending on the application, including short fiber reinforced polymer composite.

[0047] Referring to Figure 7, a hybrid opto-electrical cable assembly is illustrated and generally indicated by reference numeral 90. The cable assembly 90 includes a first wire assembly 92 and a second wire assembly 94 arranged helically relative to the central axis of the core assembly 60. The first wire assembly 92 is wrapped in a helical direction and the second wire assembly 94 is wrapped in a counter-helical direction. The first layer of armor wire can be in the same lay direction as the helical opto-electric conductors 40 or can be laid in the opposite direction.

[0048] Referring to Figure 8, still another hybrid opto-electrical cable core assembly is illustrated and generally indicated by reference numeral 100. This cable core assembly 100 has a construction similar to that of the cable core assemblies 40, 60, 80 previously described except for the construction of the protective layer.

[0049] More specifically, the cable assembly 100 has a jacketing system 102 disposed around the cable core assembly 60, utilizing short fiber reinforced composite as polymer jacket 64. The armor package 102 includes, in the order from inside to outside, a first strength element 106, a first polymer layer 108, a second strength element 110 and a second polymer layer 112.

[0050] The short-fiber-reinforced polymer composite 64 is applied, preferably extruded, over the tape 62. The first strength element 106 is in the form of armor wires which are wrapped at a lay angle and are partially embedded into the short-fiber-reinforced polymer 64. The first polymer layer 108 is also short-fiber-reinforced and is extruded over the first strength element 106 encasing it. The first polymer layer 108 bonds to the polymer jacket 64 through gaps between the first strength element 106. The second strength element 110 is in the form of armor wires and is wrapped helically in a direction counter to the direction of the first strength element 106. The second strength element 110 is partially embedded into the first polymer layer 108.

[0051] The second polymer layer 112 is also short-fiber-reinforced and extruded over the second strength element 106 encasing it. The second polymer layer 112 bonds to the first polymer layer 108 through gaps between the second strength element 110.

[0052] An outer layer (not shown) having a small thickness and made of virgin polymer material can be applied cover the second polymer layer 112 to create a smooth low friction surface.

Core Assembly

[0053] Referring to Figure 9, an alternative core assembly is illustrated and generally indicated by reference numeral 120. The core assembly 120 includes a plurality of first opto-electrical conductors 122 and a plurality of second opto-electrical conductors 124. In Figure 9, four first opto-electrical conductors 122 and five second opto-electrical conductors 124 are shown. The first conductors 122 and the second conductors 124 have a construction similar to the construction of the conductors 40 (Figure 3), 90 (Figure 7), 100 (Figure 8), but are not limited to the construction described in the specification and shown in the drawings. The number of optical fiber elements 10, the number and wrapping arrangement of the electrical conductors 42, the buffering structures or protective layer can be varied depending on applications. [0054] As shown, the first conductors 122 and the second conductors 124 are enclosed by a tape 126. The first conductors122 have a diameter larger than that of the second conductors124. The first conductors122 define a plurality of interstices 125. The second conductors124 are disposed in the interstices 125 adjacent to the tape 126. A plurality of filler rods 68 are disposed in the interstices 125 adjacent to the tape 126 and between the adjoining first and second conductors122 and 124. A filler material 130 fills in the interstices 125 to bind the conductors122, 124 and the filler rods 68 together.

[0055] While not shown in Figure 9, the polymer jacket 64 described in connection with Figure 5, 7 or 8 will be provided on top of 120 to complete a cable core assembly.

[0056] Some other embodiments of the invention include hybrid opto- electrical cable core assemblies including a plurality of opto-electhcal cables conductors arranged in a bundle and defining an outer contour and a plurality of interstices between adjoining opto-electrical cablesconductors, a plurality of filler rods disposed in the interstices adjacent to the outer contour, and a filler material filling in the interstices to bond the plurality of cables and the filler rod to form a core assembly. The optical fiber element may include an optical fiber, a carbon cladding on the optical fiber, a buffer layer around the carbon cladding, and a silicon layer or any other soft elastomer or thermoplastic layer extruded around the buffer layer, as well as a plurality of copper wires or nickel coated copper wires helically wrapped around the optical fiber element. A first polymer layer may surround the copper wires or nickel coated copper wires for securing the copper wipers in place, and a second polymer layer may surround the first polymer layer. Optionally, a third polymer layer may surround the second polymer layer.

[0057] In another embodiment, the opto-electhcal cable core assembly includes a plurality of opto-electrical conductors arranged in a bundle, the opto- electrical conductors each including an optical fiber ensemble having an optical fiber and a carbon layer around the optical fiber, an electrical conductor surrounding the optical fiber element; and a filler material for binding the plurality of opto-electrical conductors. The plurality of opto-electrical conductors define a plurality of interstices and the filler material fills in the interstices.

Manufacturing Methods

[0058] Referring to Figures 10 to 12 in connection with Figure 5, an illustrative method of manufacturing an opto-electrical cable assembly is now described in more detail.

[0059] First, a plurality of opto-electrical conductors 40 are arranged in a bundle to define a construction close to a desired cross section of a cable assembly. The plurality of opto-electrical conductors 40 form an outer contour and define a plurality of interstices 66 between adjoining conductors 40.

[0060] Next, as shown in Figure 11 , a plurality of filler rods 68 are placed in the interstices 66 adjacent to the outer contour defined by the plurality of conductors 40 so that the contour defined by the bundled conductors 40 and the filler rods 68 is close to the desired cross section. A filler material 70 is then filled in all the interstices 66 to bind the conductors 40 and the filler rods 68 together.

[0061] As shown in Figure 12, after the filler material 70 fills in the interstices 66, a tape 62 is then wrapped around the conductors 40 and the filler rods 68, and a polymer jacket 64 is applied on top, thereby forming a core assembly 60. Two layers of armor wires 92 and 94 (Figure 7), or an armor package system 102 (Figure 8), are applied on top of cable core assembly 60, thereby forming a cable assembly 90 or 100.

[0062] With the construction of the optical fiber element 10, the opto- electrical conductors 40, the core assembly 60, and thereby the cable assembly 100, the optical fiber 12 with a carbon layer 14 has an improved fatigue life and is less susceptible to bending stress. The carbon layer 14 also protects against hydrolysis. Moreover, through the special arrangement of the opto-electrical cables, cable core assemblies and the protective layer according to the present disclosure, the optical fibers 12 are further protected against bending stress. Therefore, service life of the optical fiber element, the opto-electrical cable and the opto-electrical cable assembly can be improved.

[0063] Some embodiments of the invention are methods of manufacturing an opto-electrical cable assembly, including providing a plurality of opto-electrical cablesconductors; arranging the plurality of opto-electrical cables conductors in a bundle, the opto-electrical cables conductors to define an outer contour and a plurality of interstices between adjoining opto-electrical cablesconductors; then placing a plurality of filler rods in the interstices adjacent to the outer contour; filling a filler material in the interstices; and then placing a protective layer around the cables and the filler rods. Such methods may further include placing a tape around the cables and filler rods after filling the filler material in the interstices to form the core assembly. Also, methods may include extruding a polymer composite over the cables and the filler rods, where in some instances a first strength element is wrapped helically around the polymer composite in a helical direction. The lay direction can be the same or opposite to that of the helical opto-electric conductors.

[0064] The first strength element may include a plurality of armor wires. A first polymer layer may be extruded over the first strength element, and a second strength element wrapped around the first polymer layer in a counter- helical direction. Further, a second polymer layer may be placed over the second strength element.

[0065] The protective layer may also include a polymer jacket with encased armor wires, and the protective layer may include at least two armor wires.

[0066] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Claims

CLAIMS What is claimed is:

1. An optical fiber ensemble, comprising: an optical fiber; and a carbon layer surrounding the optical fiber to form an optical fiber ensemble.

2. The optical fiber ensemble of Claim 1 , wherein the carbon layer includes a carbon cladding on the optical fiber.

3. The optical fiber ensemble of Claim 1 , further comprising a buffer layer surrounding the carbon layer.

4. The optical fiber element of Claim 3, wherein the buffer layer is in intimate contact with the carbon layer.

5. The optical fiber element of Claims 3 or 4, further comprising a silicon layer surrounding the buffer layer.

6. The optical fiber element of Claim 3, 4, or 5 wherein the buffer layer includes a silicone layer, soft elastomer layer, or thermoplastic layer, and a perfluoroalkoxy (PFA) layer or fluoropolymer layer.

7. The optical fiber element of Claim 3, 4, 5, or 6, further comprising an outer silicon layer.

8. The optical fiber element of claim 1 , wherein the element has a high numerical Aperture, thereby reducing the susceptibility of the element to optical signal attenuation due to microbendings and macrobendings.

9. A hybrid opto-electrical conductor, comprising: at least one optical fiber element including an optical fiber and a carbon layer surrounding the optical fiber; at least one electrical conductor disposed around the at least one optical fiber element; and a securing layer disposed around the at least one electrical conductor for securing the at least one electrical conductor in place.

10. The hybrid opto-electrical conductor of Claim 9, wherein the securing layer includes a first polymer layer.

11. The hybrid opto-electrical conductor of Claim 9 or 10, further comprising a strengthening layer surrounding the securing layer for increasing the mechanical strength of the hybrid opto-electrical conductor.

12. The hybrid opto-electrical conductor of Claim 11 , wherein the strengthening layer includes a second polymer layer and a third polymer layer.

13. The hybrid opto-electrical conductor of Claim 12, wherein the second polymer layer is disposed adjacent to the securing layer and has a hardness greater than that of the third polymer layer.

14. The hybrid opto-electrical conductor of Claim 9 or 10, wherein the at least one electrical conductor includes a plurality of copper wires or nickel coated copper wires.

15. The hybrid opto-electrical conductor of Claim 14, wherein the plurality of copper wires or nickel coated copper wires are arranged helically around the at least one optical fiber element.

16. The hybrid opto-electrical conductor of Claim 9, wherein the at least one optical fiber element further includes a buffer layer in intimate contact with the carbon layer, the buffer layer including a silicon layer or any other soft elastomer or thermoplastic layer and a PFA layer or other suitable fluoropolymer, and an outer silicon layer or any other soft elastomer or thermoplastic layer extruded around the buffer layer.

17. An armor package system for a cable assembly, comprising: a polymer composite adapted to enclose a cable core; a first strength element surrounding the polymer composite; a first polymer layer surrounding the first strength element; a second strength element surrounding the first polymer layer; and a second polymer layer surrounding the second strength element.

18. The armor package system of Claim 17, wherein at least one of the polymer composite, the first polymer layer and the second polymer layer is short fiber-reinforced.

19. The armor package system of Claims 17 or 18, wherein the first strength element is partially embedded in the polymer composite.

20. The armor package system of any of Claims 17 through 19, wherein the second strength element is partially embedded in the first polymer layer.

21. The armor package system of any of Claims 17 through 20, wherein the first polymer layer encases the first strength element.

22. The armor package system of any of Claims 17 through 21 , wherein the second polymer layer encases the second strength element.

23. The armor package system of any of Claims 17 through 22, wherein at least one of the polymer composite, first polymer layer and the second polymer layer are formed by extrusion, and are bonded from the cable core to the second polymer layer.

24. The armor package system of any of Claims 17 through 23, further comprising an outer layer disposed around the second polymer layer, the outer layer having a smooth low friction outer surface.

25. The armor package system of any of Claims 17 through 24, wherein the first strength element and the second strength element include armor wires.

26. The armor package system of any of Claims 17 through 25, wherein the armor wires are wrapped helically in opposite directions.