Fiber-Reinforced Resin Cable for Deep Drilling
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Solution Overview
Problem
High-temperature cables used in deep drilling operations, such as oil drilling, face deformation and inefficiency due to weight and heat exposure, with conventional materials like PFA failing to maintain insulation resistance above 250°C.
Innovation Solution
A high-temperature cable design featuring a fiber-reinforced resin layer applied radially around an elongated conductor portion, which can withstand temperatures up to 550°C, replacing traditional armor shells and providing thermal protection without bulkiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal casing is used to protect the cable from heat and physical damage, then the cable's protection and sealing are improved, but the cable's weight increases causing structural distortion
Solution Approach 1:
The patent applies composite materials by combining fiber-reinforced resin with the cable structure. The resin impregnated with reinforcing fibers creates a lightweight yet strong protective layer that replaces traditional metal casings, providing mechanical protection without the excessive weight that causes cable distortion in deep drilling applications
Solution Approach 2:
The fiber-reinforced resin forms a flexible protective shell around the cable conductors. This thin-film-like reinforcement provides adequate protection against physical damage and heat while maintaining flexibility and minimizing weight, allowing the cable to withstand drilling conditions without structural distortion
2Ease of manufacture
If conventional insulating materials like PFA are used, then the cable can be manufactured with standard materials, but the insulation resistance drops when temperatures exceed 250°C
Solution Approach 1:
The patent changes the thermal parameter of the insulating material by using fiber-reinforced resin that can withstand temperatures up to 550°C, compared to conventional PFA materials that fail above 250°C. This parameter change in temperature resistance maintains insulation resistance under high-temperature drilling conditions while still allowing for practical manufacturing
3Strength
If a heavy metal armor shell is used to protect the cable, then the cable's mechanical strength is improved, but the cable becomes bulkier and more prone to deformation
Solution Approach 1:
The patent uses composite materials consisting of fibers impregnated with resin to create a lightweight armor layer. This composite structure provides the necessary mechanical strength to protect the cable while being significantly lighter than metal armor, preventing the cable from becoming bulky and reducing deformation under its own weight in vertical drilling applications
Data Source
AI summary
A high-temperature cable and method of making the same is provided. The high-temperature cable includes at least one elongated conductor portion. A fiber-reinforced resin is positioned radially about at least a portion of an exterior surface of the at least one elongated conductor portion. The high-temperature may optionally include a thin metal layer and/or an armor shell.