Wireline Cable Polymer Jacket Void Prevention

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Solution Overview

Problem

Wireline cables used for well-logging tools often develop interstitial voids due to contact between armor wire layers, allowing gases and fluids to enter and reduce the cable's robustness and interfere with power and data transmission.

Innovation Solution

A wireline cable design featuring a core surrounded by a first armor wire layer, a first polymer layer with lower energy sensitivity, and a second armor wire layer and polymer layer with higher energy sensitivity, where the second polymer layer melts faster to prevent contact between armor wire layers, using different pigment colors or concentrations to achieve varying sensitivities to energy sources.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If armor wire layers are placed in close proximity to reduce cable volume, then cable compactness is improved, but interstitial voids form between the armor wires allowing gas and fluid infiltration

Engineering Contradiction:

Improvecable volumeVSAvoidcable robustness

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent applies local quality by using different polymer materials with different melting characteristics in different locations within the cable structure. The first polymer layer has a first melting point and the second polymer layer has a second melting point, creating localized functional zones that prevent void formation while maintaining cable compactness.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the melting point parameter of the polymer layers to resolve the contradiction. By selecting polymers with different melting points (first polymer layer with lower melting point, second polymer layer with higher melting point), the system prevents void formation during the extrusion and cooling process while maintaining a compact cable structure.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If polymer layers with different melting points are used to prevent void formation, then cable robustness is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecable robustnessVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-selecting polymer materials with specific melting points before the extrusion process. The first polymer layer is chosen to melt at a lower temperature and the second polymer layer at a higher temperature, so that during the extrusion and cooling process, the first layer melts and flows to fill voids before solidifying, while the second layer maintains structural integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses composite materials by combining different polymer layers with different melting characteristics. This composite structure allows the first polymer layer to provide void-filling functionality while the second polymer layer provides structural support, achieving robustness without excessive manufacturing complexity.

Inventive Principle:

Principle #40Composite materials

3Reliability

If multiple polymer layers with different sensitivities to energy sources are used, then void formation is prevented, but device complexity increases

Engineering Contradiction:

Improvevoid preventionVSAvoidcable structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent exploits phase transitions by using polymer layers with different melting points. During the cable manufacturing process, energy is applied to melt the first polymer layer (lower melting point), which then flows to fill interstitial voids between armor wires. The second polymer layer (higher melting point) remains solid during this process, providing structural support. This phase transition mechanism prevents void formation without requiring complex active control systems.

Inventive Principle:

Principle #36Phase transitions

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design effectively reduces the formation of voids within the cable, enhancing its robustness by preventing gas and fluid infiltration and maintaining reliable power and data transmission.

Implementation Method 1

the second polymer layer has a second sensitivity to the energy emitted from energy source, and the second sensitivity is greater than the first sensitivity

Methodology Applied

Scientific EffectDifferential melting: Melting

Implementation Method 2

different pigment colors or concentrations to achieve varying sensitivities to energy sources

Methodology Applied

Scientific EffectEnergy absorption: Absorption (EM radiation)

Data Source

PatentUS10468156B2Cables with polymeric jacket layers

Publication Date: 2019.11.05 SCHLUMBERGER TECH CORP

AI summary

The present disclosure relates to a cable that includes a core, a first armor wire layer surrounding the core, a first polymer layer disposed around the first armor wire layer, where the first polymer layer has a first sensitivity to energy emitted from an energy source, a second armor wire layer that may be disposed at least partially in the first polymer layer, and a second polymer layer disposed around the second armor wire layer, where the second polymer layer has a second sensitivity to the energy emitted from energy source, and the second sensitivity is greater than the first sensitivity.