Sealing Layer Cable Structure for Fluid and Gas Blocking
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Solution Overview
Problem
Current electromechanical cables used in subterranean applications face challenges in preventing fluid and gas migration due to the shifting of the cable jacket under elevated temperatures and pressures, leading to inconsistencies and potential leaks between the armor wires and polymer jacket layer.
Innovation Solution
The development of a gas and fluid blocked electromechanical cable featuring a cable core, a jacket layer, and an armor layer, with a sealing layer composed of a gel or resin material that hardens or a thermoplastic elastomer, which is applied in a deformable state to uniformly surround the cable core and fill gaps between armor wires, providing a stable seal against fluid and gas migration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If armor wires are embedded into a solid non-deformable polymer jacket layer using heating and compressive force, then fluid/gas migration is prevented, but the manufacturing process becomes complex and lengthy with potential leaks due to inconsistencies
Solution Approach 1:
The patent changes the physical state parameter of the sealing material from solid non-deformable to deformable (such as thermoplastic elastomer or silicone-based material). This allows the material to be applied in a deformable state that automatically conforms to the cable core and armor wires without requiring complex heating and compressive force processes, while still providing effective fluid/gas migration prevention when set
Solution Approach 2:
The deformable sealing material has self-sealing properties that allow it to automatically conform to the cable core and fill gaps between armor wires without external intervention. The material self-adjusts to the cable geometry and provides consistent sealing along the entire cable length without requiring manual positioning or adjustment
2Reliability
If armor wires are embedded into a solid non-deformable polymer jacket layer using heating and compressive force, then fluid/gas migration is prevented, but the production time increases and inconsistencies occur along the cable length
Solution Approach 1:
The patent changes the physical state parameter of the sealing material from solid non-deformable to deformable, enabling application at ambient temperatures without compressive force. This simplifies the manufacturing process to a single step of applying the deformable material, which then sets to provide consistent sealing, thereby increasing production speed while maintaining sealing consistency
Solution Approach 2:
The deformable sealing material provides continuous sealing action along the entire cable length as it is applied in a continuous process. The material maintains its sealing properties uniformly along the cable without the interruptions or variations that occur in discrete heating and compression zones, ensuring consistent fluid/gas migration prevention throughout production
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
This solution effectively prevents fluid and gas migration by embedding armor wires into the sealing layer, eliminating gaps and voids, and can be implemented without the need for heating or pressure, resulting in a more consistent and efficient cable production method.
Implementation Method 1
The material used for the sealing layer has at least a first material state where the material is viscous or deformable, and at least a second material state where the material has hardened or set into a non-viscous, non-deformable state
Implementation Method 2
The sealing layer can comprise a fluid-protecting gel- or resin-based material that is applied while in a liquid, semi-liquid, deformable, viscous, or gel-like consistency so that it can uniformly surround the extruded cable core and then fill and migrate through all the gaps and spaces between the armor wires
Data Source
Figure 1A~1E
Figure 2A~2E
Figure 3~4
AI summary
An electromechanical cable that has fluid/gas migration protection is provided as well as a method for manufacturing a fluid/gas migration protected electromechanical cable. The cable can include a core having at least one conductor or fiber optic, a first jacket layer surrounding the core, a sealing layer surrounding the first jacket layer, and a first armor layer surrounding the sealing layer. In one embodiment, the sealing layer can be applied to the cable in a viscous material state and may be a two-part epoxy or synthetic filler material to form a seal between one or more spaces between the armor wire layer and the first jacket layer. In one embodiment, the sealing layer can be applied to the cable in a solid material state and may be a thermoplastic elastomer or silicone-based material or a combination of both.