Corrosion-Resistant Wireline Cable Structure for Jacket Bonding
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Solution Overview
Problem
The manufacturing process of wireline cables using short carbon fiber reinforced polymer faces challenges in bonding the outer jacket to the inner layer and degradation due to infrared radiation absorption, which contaminates IR heaters and affects bonding efficiency.
Innovation Solution
A multi-layered wireline cable structure is developed with embedded armor wires and polymer layers, utilizing different material deposition and consolidation techniques to ensure effective bonding and corrosion resistance, including a final jacket layer to protect the underlying layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If short carbon fiber reinforced polymer is used for wireline cable construction, then mechanical strength and corrosion resistance are improved, but bonding between outer jacket and inner layer becomes difficult
Solution Approach 1:
A release paper is introduced as an intermediary layer between the inner carbon fiber reinforced polymer layer and the outer jacket. The release paper facilitates bonding during manufacturing by providing a temporary surface that allows the outer jacket to adhere properly, then is removed after bonding is complete, resolving the bonding difficulty while maintaining the strength benefits of carbon fiber reinforced polymer
Solution Approach 2:
The patent modifies the surface properties and chemical composition of the carbon fiber reinforced polymer layers to improve bondability. By changing parameters such as surface energy, roughness, or chemical functionality of the polymer layers, the material becomes more receptive to bonding with the outer jacket while retaining its high strength characteristics
2Ease of manufacture
If short carbon fiber reinforced polymer is heated with IR heater, then bonding process is enabled, but polymer degradation occurs due to IR radiation absorption
Solution Approach 1:
A release paper with specific infrared transmission properties is used as a mediator between the IR heater and the polymer. The release paper allows IR radiation to pass through to enable heating and bonding of the polymer layers, while protecting the polymer from excessive IR absorption that would cause degradation
Solution Approach 2:
The patent modifies the infrared absorption characteristics of the polymer composite by adjusting carbon fiber content, polymer matrix composition, or additive packages. This parameter change reduces the polymer's absorption of IR radiation, enabling the bonding process to proceed without causing thermal degradation of the material
3Temperature
If IR heater is used for heating, then bonding temperature is achieved, but mirrors are contaminated reducing heating efficiency
Solution Approach 1:
A release paper with low adhesion properties and specific surface characteristics is positioned between the IR heater mirrors and the polymer composite. This intermediary prevents polymer material from adhering to the mirrors during the heating process, maintaining mirror reflectivity and heating efficiency throughout production while still achieving the required bonding temperature
Solution Approach 2:
The release paper is pre-positioned on the IR heater mirrors before the bonding process begins. This preliminary action prevents contamination from occurring during heating, eliminating the need for mirror cleaning or replacement and maintaining consistent heating efficiency across multiple production cycles
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 resulting cable provides enhanced mechanical strength, corrosion resistance, and environmental sealing, suitable for harsh environments like downhole oil and gas operations, with improved durability and operational life.
Implementation Method 1
short carbon fiber reinforced polymer absorbs infrared (IR) radiation when heating with IR heater, which causes degradation of the polymer
Data Source
AI summary
A method of manufacturing a corrosion-resistant wireline cable includes embedding a first layer of armor wires onto a core cable using a heated carbon fiber reinforced polymer. A second layer of carbon fiber reinforced polymer is then extruded to envelop the first layer of armor wires. In one method, a layer of virgin or colored polymer is extruded over the second layer, and a second layer of armor wires is embedded through the virgin or colored polymer, displacing it to envelop the outer armor wires. In another method, each wire in the second armor layer is coated with virgin polymer before being embedded into the second carbon fiber reinforced polymer layer. The assembly is then heated to cause the virgin polymer to migrate outward, forming an outermost layer. In both methods, a final jacket layer is applied over the exterior to complete the cable. The resulting cable provides corrosion resistance and mechanical reinforcement.