Abstract: Disclosed are high strength wellbore electric cables, which are formed from a plurality of strength members. The strength members are formed from several stranded filament wires which may be encased within a jacket of polymeric material. The strength members may be used as a central strength member, or even layered around a central axially positioned component or strength member, to form a layer of strength members. Cables of the invention may be of any practical design, including monocables, coaxial cables, quadcables, heptacables, slickline cables, multi-line cables, etc., and have improved resistant to corrosion, torque balancing, and gas migration from a wellbore to the surface.

Abstract: Disclosed are durable corrosion resistant wellbore electrical cables including a coated electrical conductor, a polymeric protective layer for trapping coating flakes, a first insulating jacket disposed adjacent to the polymeric protective layer and having a first relative permittivity. A second insulating jacket is disposed adjacent to the first insulating jacket and has a second relative permittivity that is less than the first relative permittivity. Another aspect of the invention is a method for manufacturing a cable that includes providing a coated electrical conductor, extruding a polymeric protective layer over the coated electrical conductor, extruding a first insulating jacket over the protective polymeric layer, and extruding a second insulating jacket thereon. Cables of the invention may further include armor wire layers or even current return conductors.

Abstract: Disclosed are electric cables with improved armor wires used with wellbore devices to analyze geologic formations adjacent a wellbore. The cables include at least one insulated conductor, and one or more armor wires surrounding the insulated conductor. The armor wires include a low density core surrounded by a corrosion resistant alloy clad, where the alloy clad includes such alloys as beryllium-copper based alloys, nickel-chromium based alloys, superaustenitic stainless steel alloys, nickel-cobalt based alloys, nickel-molybdenum-chromium based alloys, and the like. The low density core may be based upon titanium or titanium alloys. The cables of the invention may be any useful electric cable design, including monocables, quadcables, heptacables, quadcables, slickline cables, multiline cables, coaxial cables, or seismic cables.

Abstract: Compression, stretch, and crush resistant cables which are useful for welibores. The cables include insulated conductors, a compression and creep resistant jacket surrounding the insulated conductors, a filler material and compression resistant filler rods placed in interstitial spaces formed between the compression and creep resistant jacket and the insulated conductors, and at least one layer of armor wires surrounding the insulated conductor and compression and creep resistant jacket. The filler material may be a non-compressible filler material.

Abstract: Disclosed are methods of manufacturing electrical cables. In one embodiment of the invention, method for manufacturing a wellbore cable includes providing at least one insulated conductor, extruding a first polymeric material layer over the insulated conductor, serving a first layer of armor wires around the polymeric material and embedding the armor wires in the first polymeric material by exposure to an electromagnetic radiation source, followed by and extruding a second polymeric material layer over the first layer of armor wires embedded in the first polymeric material layer. Then, a second layer of armor wires may be served around the second polymeric material layer, and embedded therein by exposure to an electromagnetic radiation source. Finally, a third polymeric layer may be extruded around the second layer of armor wires to form a polymeric jacket.

Abstract: Electric cables used with wellbore devices to analyze geologic formations adjacent a wellbore including at least one insulated conductor, and one or more armor wires surrounding the insulated conductor, the armor wires formed of a high strength core surrounded by a corrosion resistant alloy clad. The alloy clad includes such alloys as beryllium-copper based alloys, nickel-chromium based alloys, superaustenitic stainless steel alloys, nickel-cobalt based alloys, nickel-molybdenum-chromium based alloys, and the like. The cables of the invention may be any useful electric cable, including monocables, quadcables, heptacables, quadcables, slickline cables, multiline cables, coaxial cables, or seismic cables.

Abstract: A cable includes a central insulated conductor with a plurality of outer insulated conductors disposed around the central conductor. Interstices formed between the central conductor and outer conductors are at least partially filled with a filler material. Filler materials suitable for high temperature use are included. A jacket encases the filler material and the central and outer conductors. In some embodiments a yarn strand is disposed in the interstices.

Abstract: An electrical cable includes a first layer, a second layer, and a tie layer, disposed between the first layer and the second layer, for bonding the first layer to the second layer. A method of making an electrical cable includes applying a tie layer to an inner layer, the tie layer being miscible with the inner layer, and bonding an outer layer to the tie layer via one of a chemical reaction therebetween and a physical bond therebetween. An electrical cable includes a first layer, a second layer immiscible with the first layer, and a tie layer disposed between the first layer and the second layer, wherein the tie layer is miscible with the first layer and is capable of bonding with the second layer.

Abstract: A dual stress member electrical cable includes an electrically conductive, load-bearing core, an insulating layer surrounding the core, and an electrically conductive, outer load-bearing member surrounding the insulating layer. The core may be formed of a solid wire of steel, aluminum, or titanium. The insulating layer may be formed of Teflon or PEEK. The outer load-bearing member may be a tube formed of Inconel, stainless steel, galvanized steel, or titanium.

Abstract: An electrical cable includes a conductor comprising a plurality of strands defining interstices therebetween and a first insulating layer comprising a polymer that is disposed on the conductor such that the first insulating layer substantially fills the interstices. Alternatively, an electrical cable includes a conductor comprising a plurality of strands defining interstices therebetween, a first insulating layer comprising a polymer that is disposed on the conductor such that the first insulating layer substantially fills the interstices, and an adhesion layer comprising a polymer that is disposed on the first insulating layer. The electrical cable further comprises a second insulating layer comprising a polymer that is disposed on the adhesion layer, wherein the adhesion layer is miscible with the polymer of the first insulating layer and the polymer of the second insulating layer.

Abstract: An electrical cable includes a central insulated conductor and a plurality of outer insulated conductors disposed around the central insulated conductor, the central insulated conductor and the plurality of outer insulated conductors forming interstices therebetween. Further, the electrical cable includes a filler material substantially filling at least a portion of the interstices and a jacket encasing the conductors and the filler material.

Abstract: A system for protecting the transmission of signals from and/or to a tool in a high pressure environment. The system includes a tool connected to a signal transmission line, such as an electrical cable or optical fiber. The signal transmission line is surrounded by a protective tube that is connected to the tool by a connector having a hollow chamber in communication with the interior of the tube. A fluid, such as a dielectric liquid, is disposed within the connector and the tubing at a pressure higher than the environmental pressure. In the event of a leak at, for instance, the connector, the high pressure fluid flows outwardly rather than allowing the inflow of deleterious fluid from the environment.

Abstract: A dual stress member electrical cable includes an electrically conductive, load-bearing core, an insulating layer surrounding the core, and an electrically conductive, outer load-bearing member surrounding the insulating layer. The core may be formed of a solid wire of steel, aluminum, or titanium. The insulating layer may be formed of Teflon or PEEK. The outer load-bearing member may be a tube formed of Inconel, stainless steel, galvanized steel, or titanium.

Abstract: An electrical cable includes a first layer, a second layer, and a tie layer, disposed between the first layer and the second layer, for bonding the first layer to the second layer. A method of making an electrical cable includes applying a tie layer to an inner layer, the tie layer being miscible with the inner layer, and bonding an outer layer to the tie layer via one of a chemical reaction therebetween and a physical bond therebetween. An electrical cable includes a first layer, a second layer immiscible with the first layer, and a tie layer disposed between the first layer and the second layer, wherein the tie layer is miscible with the first layer and is capable of bonding with the second layer.

Abstract: An electrical cable includes a conductor comprising a plurality of strands defining interstices therebetween and a first insulating layer comprising a polymer that is disposed on the conductor such that the first insulating layer substantially fills the interstices. Alternatively, an electrical cable includes a conductor comprising a plurality of strands defining interstices therebetween, a first insulating layer comprising a polymer that is disposed on the conductor such that the first insulating layer substantially fills the interstices, and an adhesion layer comprising a polymer that is disposed on the first insulating layer. The electrical cable further comprises a second insulating layer comprising a polymer that is disposed on the adhesion layer, wherein the adhesion layer is miscible with the polymer of the first insulating layer and the polymer of the second insulating layer.

Abstract: A cable includes an electrical conductor, a first insulating jacket disposed adjacent the electrical conductor and having a first relative permittivity, and a second insulating jacket disposed adjacent the first insulating jacket and having a second relative permittivity that is less than the first relative permittivity. A method includes providing an electrical conductor, extruding a first insulating jacket having a first relative permittivity over the electrical conductor, and extruding a second insulating jacket having a second relative permittivity over the electrical conductor, wherein the second relative permittivity is less than the first relative permittivity.