Jacketed Metal Line Bonding via Roughened Core and Silane Adhesion

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Solution Overview

Problem

Existing slickline manufacturing techniques face challenges in achieving reliable bonding between the polymer jacket and the metal wire, leading to potential failures due to loose points, cracks, or air pockets, which can result in lost time and expense during downhole applications.

Innovation Solution

A method involving roughening the metal core surface, applying a reinforcing polymer layer, and using a non-compression tubing extrusion process followed by heating and shaping rollers to enhance bonding without smoothing the wire surface, thereby improving the durability and reliability of the slickline.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heated compression extruding is used to bond polymer jacket to metal wire, then bonding strength is improved, but wire strength is reduced and air pockets form at the interface

Engineering Contradiction:

Improvebonding strengthVSAvoidwire strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the temperature parameter from high heating (several hundred degrees F) to mild heating (below the melting point of the polymer), and changes the pressure parameter from high compression to atmospheric or low pressure, thereby achieving bonding without compromising wire strength

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical compression extrusion system with a chemical bonding system using silane-based adhesion promoters that form covalent bonds between the polymer and metal wire, eliminating the need for high mechanical pressure and heat

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If heated compression extruding is used to bond polymer jacket to metal wire, then bonding strength is improved, but air pockets develop at the interface

Engineering Contradiction:

Improvebonding strengthVSAvoidair pockets

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces mechanical compression extrusion with a chemical bonding process using silane adhesion promoters that create strong covalent bonds without requiring high pressure and heat, thereby preventing air pocket formation at the polymer-metal interface

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the temperature parameter from high heating to mild heating below the polymer melting point, and changes the pressure parameter from high compression to atmospheric or low pressure, eliminating the conditions that cause air pockets while maintaining bonding strength

Inventive Principle:

Principle #35Parameter changes

3Reliability

If high heat is applied to bond polymer to wire, then bonding is improved, but wire strength is reduced

Engineering Contradiction:

ImprovebondingVSAvoidwire strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the temperature parameter from high heat (several hundred degrees F) to mild heat (below the melting point of the polymer), thereby achieving adequate bonding without thermally degrading the metal wire and reducing its strength

Inventive Principle:

Principle #35Parameter changes

4Reliability

If compression extruding is used to deliver polymer onto wire, then initial bonding is improved, but long term grip is adversely affected due to surface smoothing

Engineering Contradiction:

Improveinitial bondingVSAvoidlong term grip

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent replaces mechanical compression extrusion with a chemical bonding system using silane adhesion promoters that form covalent bonds without requiring high pressure, thereby avoiding surface smoothing while achieving strong initial and long-term bonding

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the pressure parameter from high compression to atmospheric or low pressure, eliminating the surface smoothing effect while maintaining bonding strength through chemical adhesion promoters

Inventive Principle:

Principle #35Parameter changes

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 enhanced bonding technique results in a more robust slickline with improved long-term grip and reduced risk of failure, ensuring effective power and telemetric capabilities in harsh downhole environments.

Implementation Method 1

exposed a heat source for at least partially melting the polymer layer

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

the partially melted polymer layer and insulated roughened metal core can be ran through a set of shaping rollers

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS11158442B2Manufacturing techniques for a jacketed metal line

Publication Date: 2021.10.26 SCHLUMBERGER TECH CORP

AI summary

A method of manufacturing a jacketed metal line is detailed herein. The method of manufacturing a jacketed metal line can include roughening an outer surface of a metal core of the line. An insulating polymer layer can be applied to the metal core, and the insulating polymer layer can include a reinforcing additive comprising: graphite, carbon, glass, aramid, short-fiber filled PolyEtherEtherKetone, mircron-sized polytetrafluoroethylene, or combinations thereof. The roughened metal core can then be exposed a heat source for at least partially melting the polymer layer; and the partially melted polymer layer and insulated roughened metal core can be ran through a set of shaping rollers.