Manufacturing techniques for a jacketed metal line

Patent metadata

Field	Value
Publication number	US-11158442-B2
Application number	US-201816034639-A
Country	US
Kind code	B2
Filing date	Jul 13, 2018
Priority date	Apr 3, 2015
Publication date	Oct 26, 2021
Grant date	Oct 26, 2021

Abstract

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.

First claim

We claim:

1. A method of manufacturing a jacketed metal line, the method comprising:
roughening an outer surface of a metal core of the line;
applying an insulating polymer layer to the roughened metal core, wherein the insulating polymer layer is a first polymer layer of between about 0.001 inches and about 0.010 inches in thickness and comprises a reinforcing additive comprising: graphite, carbon, glass, aramid, short-fiber filled PolyEtherEtherKetone, mircron-sized polytetrafluoroethylene, or combinations thereof;
exposing the insulated roughened metal core to a heat source for at least partially melting the first polymer layer;
running the insulated roughened metal core with the partially melted polymer layer through a set of shaping rollers;
providing a tie layer between the roughened metal core and the insulating polymer layer to promote bonding between the roughened metal core and the insulating polymer layer;
applying a second polymer layer over the first polymer layer; and
running the first and second polymer layered core through another set of shaping rollers.

2. The method of claim 1 , further comprising exposing the first polymer layered core to a heat source prior to the applying of the second polymer layer.

3. The method of claim 1 , wherein the applying of the second polymer layer is achieved by compression extrusion.

4. The method of claim 1 , further comprising providing a tie layer between the first polymer layer and the second polymer layer.

5. The method of claim 1 , wherein applying an insulating polymer layer to the roughened metal core comprises using a non-compression technique.

6. The method of claim 1 , wherein the insulating polymer layer is a short-fiber filled PolyEtherEtherKetone comprising short fiber material, wherein the short fiber material is from about 0.5% to about 30% of the total volume of the short-fiber filled PolyEtherEtherKetone.

7. The method of claim 1 , wherein the roughening of the outer of the metal core surface is achieved by one of arc spraying, abrasive blasting, and electrolytic plasma coating.

8. The method of claim 7 , wherein the arc spraying comprises:
charging wires of metal based material; and
spraying molten droplets of the charged metal based material onto the heated core for the roughening.

9. The method of claim 7 , wherein the abrasive blasting comprises:
heating the metal core; and
sandblasting the heated metal core with a fine-grit medium for the roughening.

10. The method of claim 7 , wherein the electrolytic plasma coating comprises:
charging the metal core; and
running the core through a liquid bath of oppositely charged metals for bonding to the outer surface of the charged core for the roughening.

11. A method of manufacturing a jacketed metal line, the method comprising:
roughening an outer surface of a metal core of the line;
charging the metal core of the line;
powder coating the charged line with a charged insulating polymer, where a charge of the charged insulating polymer is opposite a charge of the metal core;
exposing the insulated metal core to a heat source for at least partially melting the polymer forming a first polymer layer;
running the insulated metal core with the partially melted polymer through a set of shaping rollers;
applying a second polymer layer over the first polymer layer; and
running the first and second polymer layered core through another set of shaping rollers; and
providing a tie layer between the metal core and the first polymer layer to promote bonding between the metal core and the polymer.

12. The method of claim 11 , wherein the melted insulating polymer is the first polymer layer of between about 0.001 inches and about 0.010 inches on the core, the method further comprising:
heating the first polymer layer;
applying the second polymer layer over the first polymer layer via compression extrusion; and
running the insulated metal core with the two polymer layers through the another set of shaping rollers.

13. A method of manufacturing a polymer jacketed metal line comprising:
roughening an outer surface of a metal core of the line;
charging the metal core of the line;
running the core through a liquid bath of oppositely charged metals for bonding to the surface of the charged core for the roughening;
placing a short-fiber filled PolyEtherEtherKetone layer about the roughened metal core;
heating the short-fiber filled PolyEtherEtherKetone layer;
placing a polymer alloy layer about the short-fiber filled PolyEtherEtherKetone layer, wherein the polymer alloy layer comprises fluoropolymer particles in a matrix of PolyEtherEtherKetone forming a bonded fluoropolymer outer jacket with the fluoropolymer particles diffused to a surface of the polymer alloy layer;
heating the bonded fluoropolymer outer jacket; and
extruding a layer of pure fluoropolymer about the bonded fluoropolymer outer jacket.

14. The method of claim 13 , wherein the short-fiber filled PolyEtherEtherKetone layer is heated before the polymer alloy layer is disposed thereabout.

15. The method of claim 13 , wherein the short-fiber filled PolyEtherEtherKetone layer comprises short fiber material, and wherein the short fiber material is from about 0.5% to about 30% of the total volume of the short-fiber filled PolyEtherEtherKetone.

16. The method of claim 15 , wherein the short fiber material is carbon, glass, an inorganic fiber, a filler with a low coefficient of thermal expansion, or combinations thereof.

Assignees

• Schlumberger Technology Corp

Inventors

• Varkey Joseph
• Altintas Burcu Unal
• Yun Jushik
• Yang Dong
• Chang Sheng
• Singh Ramnik

Classifications

• B05D2401/00

  Form of the coating product, e.g. solution, water dispersion, powders or the like · CPC title

• H01B13/24 Primary

  by extrusion {(extrusion of cables with plastic material in general B29C48/15)} · CPC title

• B05D3/12

  by mechanical means · CPC title

• B05D2202/00

  Metallic substrate · CPC title

• B05D7/52

  Two layers · CPC title