A system and process for enhanced magnet wire insulation is clarified. The technique comprises a sequence of operations to create an improved magnet wire insulation acceptable for use in temperatures of approximately 550. degree. Fahrenheit. A magnet aluminum cable is wrapped using a polyimide wrap and subsequently wrapped using a natural polymer thermoplastic (e.g., PEEK). The polyimide wrap is implemented while the magnet aluminum cable is around a spool to create a wrapped magnet cable. The wrapped magnet cable can be heated with an induction coil in a metallic tube bolted to an extruder to eliminate moisture and also to enable including the layer of natural polymer thermoplastic. The metallic tube can be held in a partial vacuum to fortify moisture removal of this wrapped magnet wire prior to running the wrapped magnet cable through the extruder which adds the natural polymer thermoplastic layer. This method creates an improved magnet cable acceptable for a wide range of temperatures.


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1. Field of the Invention

Embodiments of this invention described herein pertain to the area of magnet wire. More particularly, but not by way of limitation, one or more embodiments of this invention enable a system and process for enhanced magnet wire insulation forelectric submersible pump software.

2. Description of the Related Art

Currently available magnet wire is not suitable for some motor software. Particularly, magnet wire used in motors for oil or gas pumping software ought to be exceptionally dependable. When a motor is utilized in a petroleum or gas well, a wirefailure or short is especially costly as the engine is heavy in the floor. If the insulating material of the magnet wire in the engine forms fractures, these fractures can cause premature failure of the engine.

In the instance of an electrical submersible pump (ESP), a failure of the engine can be catastrophic as it implies having to remove the unit in the well for repairs. ESP assemblies particularly require the magnet wire used be able ofsurviving the high temperatures deep below ground. Additionally, ESP pumps can sometimes leak, allowing some water to go into the motor. A magnet wire that’s appropriately waterproof so as to prevent a short when exposed to these leakage could be anadvantage in all kinds of pumping applications. At length, magnet wires often are damaged when they are transported, incurring fractures, nicks or pinholes. This damage reduces the life expectancy of this wire. A magnet wire with greater durabilityduring transport would be an advantage in all kinds of magnet wire software.

Currently available magnet cable is occasionally insulated with polyimide film, such as Kapton.RTM. (a signature of E. I. Du Pont De Nemours and Company) tape. Polyimide film is a sort of synthetic polymeric resin of a course resistant to hightemperatures, wear, and corrosion, utilized primarily as a coating or film on a parasite material. While for brevity this description uses Kapton.RTM. As an example of polyimide film, nothing herein restricts the creation to using a particularpolyimide movie like Kapton.RTM. tape. While Kapton.RTM. Gets the greatest dielectric strength of any cable insulating material now available, it does have inherent weaknesses. Kapton.RTM. Easily takes on water (is hydroscopic) and then degradesrapidly. The adhesive used to attach Kapton.RTM. Tape into the cable may also delaminate at the extreme high temperatures of deep wells. Magnet cable wrapped with Kapton tape can also be likely to damage during transport.

Another currently available insulation for magnet wire is organic polymer thermoplastic insulation, for example PEEK (polyetheretherketone). While PEEK has sufficient dielectric strength at room temperature, it drops off quickly when utilized above500.degree. F. Motor temperatures at high temperature wells may reach in excess of 550. degree. F. Therefore, PEEK is also not perfect wire insulation for use in ESP motors.

Therefore, there is a demand for a system and method to make enhanced magnet wire insulation that is more waterproof, durable during shipping and also reliable in the high temperatures for ESP applications.

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