Patent Description:
A rope socket assembly is one example by which the wireline tool string is mechanically and electrically connected to the wireline. Making the electrical connections from the wireline to the wireline tool string is time consuming, and the mechanical and electrical connections are prone to failure if armored layers of the wireline are not uniformly loaded.

<CIT> describes a cable having at least one electrical signal conductor extending through the core of the cable, an elongated housing having an interior passageway of a predetermined diameter at one end and tapering to a predetermined smaller diameter at an opposite end, the smaller diameter being in excess of the diameter of the cable. Means secured to the cable for defining a protuberance thereon, the protuberance means having a diameter intermediate the diameter of the opposed ends of the housing passageway. The cable and protuberance means are received within the lower part of the housing means with the protuberance means securely seating against the tapered sidewalls of the housing passageway thereby to provide effective securance of the cable to the housing means. The upper part of the housing passageway defines a splicing cavity for the at least one electrical signal conductor, with a closure cap secured to the housing and sealing the splicing cavity. <CIT> describes a method for attaching non-displaceable connections to tensioned cables, characterized in that a closed mold is placed around the connection point of the cable, the individual wires of the cable are spread apart by a clamping device inside the mold and a casting compound which solidifies is introduced into the mold. <CIT> describes a synthetic fiber rope with intermediate spaces between components inside the rope and with a power transmission element. The cable has a widening in at least one cable area to provide free space between cable components that have a larger cross-sectional and which are filled with a filling compound.

This summary is not intended to identify indispensable features of the claimed subject matter, nor is it intended for use as an aid in limiting the scope of the claimed subject matter.

In a first aspect, the present invention resides in an apparatus as defined in claim <NUM>.

In a further aspect, the present invention resides in a method as defined in claim <NUM>.

The present disclosure is understood from the following detailed description when read with the accompanying figures.

It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. This repetition is for simplicity and clarity, and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact.

<FIG> is a sectional view of at least a portion of an example implementation of a composite or "armored" cable rope socket <NUM> according to one or more aspects of the present disclosure. The rope socket <NUM> may be utilized for mechanically and communicably connecting an armored cable <NUM> to a downhole tool string <NUM> (depicted in <FIG> by phantom lines).

<FIG> is a sectional view of at least a portion of an example implementation of the armored cable <NUM> shown in <FIG>. The armored cable <NUM> comprises a conductor core <NUM> that comprises one or more conductors and/or other cables <NUM> for transmitting electrical and/or optical signals, such as for delivering electrical power to the downhole tool string <NUM> and/or communicating electrical and/or optical signals between the downhole tool string <NUM> and surface equipment disposed at a wellsite surface (e.g., see <FIG>). Although the conductor core <NUM> is for a wireline cable that includes seven cables <NUM> in the example implementation shown in <FIG>, other implementations also within the scope of the present disclosure may include a conductor core <NUM> having more or fewer than seven cables <NUM>, including implementations in which the conductor core <NUM> is for a slickline cable that comprises just one cable <NUM>.

The armored cable <NUM> also comprises an inner armor layer <NUM> comprising a plurality of inner armor wires <NUM> wound around the conductor core <NUM>. Although the inner armor layer <NUM> includes twelve inner armor wires <NUM> in the example implementation shown in <FIG>, other implementations also within the scope of the present disclosure may include an inner armor layer <NUM> having more or fewer than twelve inner armor wires <NUM>. The inner armor wires <NUM> may be wound around the conductor core <NUM> in a helical, braided, and/or other manner.

The armored cable <NUM> also comprises an outer armor layer <NUM> comprising a plurality of outer armor wires <NUM> wound around the conductor core <NUM>. Although the outer armor layer <NUM> includes eighteen outer armor wires <NUM> in the example implementation shown in <FIG>, other implementations also within the scope of the present disclosure may include an outer armor layer <NUM> having more or fewer than eighteen outer armor wires <NUM>. The outer armor wires <NUM> may be wound around the inner armor layer <NUM> in a helical, braided, and/or other manner. For example, the inner armor wires <NUM> and the outer armor wires <NUM> may be helically wound in opposite directions (e.g., clockwise and counterclockwise).

The inner and/or outer armor wires <NUM>/<NUM> permit protection of the conductor core <NUM> and have a carrying effect of the conductor core <NUM>. The inner and/or outer armor wires <NUM>/<NUM> may be metallic. One or more of the inner and/or outer armor wires <NUM>/<NUM> may comprise a reinforcement element including a bundle of reinforcement fibers comprising at least one fiber and a thermoset (or thermoplastic) matrix impregnating the bundle of fibers. Such reinforcement element may be encased with a thermoplastic coating. Examples of cables according to such implementation are detailed in PCT Patent Application No. <CIT>, the entire disclosure of which is hereby incorporated herein by reference.

The armored cable <NUM> may also comprise an outer layer <NUM>, such as may comprise a friction reducing material to reduce friction between the armored cable <NUM> and inner surfaces of the wellbore. The armored cable <NUM> may also comprise intermediate layers <NUM> for various mechanical and electrical protection (e.g., shielding). Further, although not explicitly illustrated in <FIG>, the conductor core, <NUM>, the cables <NUM>, the inner armor wires <NUM>, and/or the outer armor wires <NUM> may individually comprise protective coatings, such as for insulative purposes.

<FIG> describes an example implementation of an armored cable <NUM> but other types of armored cables having at least a conductor core <NUM> and a layer of armor wires <NUM>/<NUM> may be considered as part of the disclosure, including armored cables with more or less than two layers of armored wires <NUM>/<NUM>. In such implementations, among others within the scope of the present disclosure, the armor wires may be made of various materials, such as composite material or metallic material.

Returning to <FIG>, the rope socket <NUM> comprises a housing <NUM> having an uphole end <NUM> and a downhole end <NUM>. The armored cable <NUM> extends into the housing <NUM> through the uphole end <NUM>. The conductor core <NUM> extends from the housing <NUM> through the downhole end <NUM>. The housing <NUM> may be formed from metallic and/or plastic materials.

Within the housing <NUM>, a first (or "lower" or "inner") spacer <NUM> radially interposes the conductor core <NUM> and the plurality of inner armor wires <NUM>. <FIG> is a perspective view of an example implementation of the first spacer <NUM> according to one or more aspects of the present disclosure. The first spacer <NUM> may be annular, thus comprising a longitudinal inner passage <NUM> having a diameter <NUM> not smaller than a diameter <NUM> of the conductor core <NUM>. For example, the diameter <NUM> of the passage <NUM> may be about <NUM>% to <NUM>% larger than the diameter <NUM> of the conductor core <NUM>. The radial thickness (i.e., half the difference between the outer and inner diameters) <NUM> of the first spacer <NUM> may be equal to about <NUM>% to <NUM>% of the individual diameter of one or more (or each) of the inner armor wires <NUM> and/or the outer armor wires <NUM>. The axial length <NUM> of the first spacer <NUM> may be about <NUM>-<NUM> centimeters. As shown in <FIG>, the first spacer <NUM> surrounds the conductor core <NUM>, and the inner armor wires <NUM> wrap around the first spacer <NUM> and the portions of the conductor core <NUM> that are not covered by the first spacer <NUM>. Accordingly, the outer armor wires <NUM> wrap around the inner armor wires <NUM>, including the portions of the inner armor wires <NUM> wrapped around the first spacer <NUM>.

As also shown in <FIG>, a second (or "upper" or "outer") spacer <NUM> radially interposes the plurality of inner armor wires <NUM> and the plurality of outer armor wires <NUM>. <FIG> is a perspective view of an example implementation of the second spacer <NUM> according to one or more aspects of the present disclosure. The second spacer <NUM> may be annular, thus comprising a longitudinal inner passage <NUM> having a diameter <NUM> not smaller than the sum of the outer diameter <NUM> of the first spacer <NUM> and twice the diameter of the individual inner armor wires <NUM>. For example, the diameter <NUM> of the passage <NUM> may be about <NUM>% to <NUM>% larger than this sum. The radial thickness <NUM> of the second spacer <NUM> may be equal to about <NUM>% to <NUM>% of the individual diameter of one or more (or each) of the inner armor wires <NUM> and/or the outer armor wires <NUM>. The axial length <NUM> of the second spacer <NUM> may be about <NUM>-<NUM> centimeters. As shown in <FIG>, the second spacer <NUM> surrounds a portion of the conductor core <NUM> that is wrapped by the inner armor wires <NUM> but axially offset from the first spacer <NUM> by a predetermined distance <NUM> such that the second spacer <NUM> does not radially overlap any portion of the first spacer <NUM>. The predetermined distance <NUM> may be not less than the axial length <NUM> of the first spacer <NUM> or the axial length <NUM> of the second spacer <NUM>.

Accordingly, within an axial portion <NUM> of the rope socket <NUM> delineated by axial ends of the second spacer <NUM>, the inner armor wires <NUM> wrap (e.g., loosely or tightly) around the conductor core <NUM>, the second spacer <NUM> extends around the inner armor wires <NUM>, and the outer armor wires <NUM> wrap (e.g., loosely or tightly) around second spacer <NUM>. Within an axial portion <NUM> of the rope socket <NUM> delineated by axial ends of the first spacer <NUM>, the first spacer <NUM> extends around the conductor core <NUM>, the inner armor wires <NUM> wrap (e.g., loosely or tightly) around the first spacer <NUM>, and the outer armor wires <NUM> wrap (e.g., loosely or tightly) around the inner armor wires <NUM>. Within the axial portion of the rope socket <NUM> defined by the predetermined distance <NUM> separating the first spacer <NUM> from the second spacer <NUM>, as well as an axial portion uphole of the portion <NUM> and an axial portion downhole of the portion <NUM>, inner armor wires <NUM> wrap (e.g., loosely or tightly) around the conductor core <NUM>, and the outer armor wires <NUM> wrap (e.g., loosely or tightly) around the inner armor wires <NUM>.

The example rope socket <NUM> shown in <FIG> is depicted as including two spacers, namely the upper spacer <NUM> and the lower spacer <NUM>. However, other implementations also within the scope of the present disclosure may include the spacers <NUM>/<NUM> in a different relative orientation, or spacers other than those depicted in <FIG>, or more/fewer spacers. For example, <FIG> depicts another example implementation in which the inner and outer armor wires <NUM>/<NUM> have been unwrapped and then loosely rewrapped around the conductor core <NUM> without including either spacer <NUM>/<NUM>. Thus, the following description relative to <FIG> is also applicable (or readily adaptable) to <FIG>.

A thermoset or other plastic material <NUM> is disposed within the housing <NUM> to fill each interstice defined by one or more surfaces of one or more of the conductor core <NUM>, the first spacer <NUM>, one or more of the inner armor wires <NUM>, the second spacer <NUM>, one or more of the outer armor wires <NUM>, and internal surfaces of the housing <NUM>. The thermoset material <NUM> may be or comprise a (for example, rigid dielectric) polyurethane and/or epoxy. Although not limited as such within the scope of the present disclosure, commercial examples may include HAPCO's DI-PAK R-series epoxies and MASTER BOND's EP110F8-<NUM> epoxy, among myriad others. The thermoset or other plastic material <NUM> may instead be a thermoplastic material, such as may be installed within the housing <NUM> via thermoplastic injection. Thus, further reference herein to the thermoset material <NUM> is deemed to refer to either thermoset or thermoplastic material, although other injectable plastic materials are also contemplated. In an example implementation, when the armor wire includes a reinforcement element as described above, with a plastic matrix, the plastic material <NUM> may be of the same type (i.e., thermoplastic or thermoset) as the plastic matrix or compatible in term of bonding with the plastic matrix. In such case, the plastic material may comprise a common material with the plastic matrix of the reinforcement element of the armor wire or be of the same composition as the plastic matrix, to facilitate mechanical attachment of both materials.

The thermoset material <NUM> may be a polymer matrix embedded with fibrous, particulate, or spherical glass, carbon, aramid, or basalt reinforcement members. The thermoset material <NUM> may also comprise, instead of or in addition to the polymer matrix embedded with the reinforcement members, a polymer matrix not embedded with reinforcement members.

<FIG> also illustrates that the uphole end <NUM> of the housing <NUM> is defined by a truncated conical surface <NUM> that narrows to an opening <NUM> through which the armored cable <NUM> extends. The opening <NUM> may have a diameter that is not more than about <NUM>% larger than an outer diameter <NUM> of the armored cable <NUM>. The second spacer <NUM> may be axially (longitudinally) disposed in a frustum-shaped volume defined by the conical surface <NUM>. That is, the second spacer <NUM> may be axially positioned between the longitudinally opposing edges of the conical surface <NUM>. The conical surface <NUM> may widen to a maximum diameter <NUM> that is not less than the sum of the outer diameter <NUM> of the second spacer <NUM> and twice the diameter of each outer armor wire <NUM>.

The housing <NUM> may comprise a cylindrical member <NUM> and an upper cap <NUM> coupled with the cylindrical member <NUM>, wherein the upper cap <NUM> comprises the conical surface <NUM>. The upper cap <NUM> and the thermoset material <NUM> may cooperatively seal a volume containing the first and second spacers <NUM>, <NUM> within the housing <NUM>. For example, such sealing may prevent the incursion of wellbore fluid into the rope socket <NUM>. However, such sealing, if existent, may be accomplished via other means.

As depicted in the example implementation of <FIG>, the upper cap <NUM> may be a single discrete member that extends into the cylindrical member <NUM> such that a shoulder <NUM> of the upper cap <NUM> abuts the upper end <NUM> of the cylindrical member <NUM>. However, the upper cap <NUM> may take other forms in other implementations also within the scope of the present disclosure. Furthermore, the upper cap <NUM> and the cylindrical member <NUM> may be integral in the form of a single discrete member, such as depicted in <FIG> described below.

The housing <NUM> may further comprise a lower cap <NUM> coupled with the cylindrical member <NUM> opposite the upper cap <NUM>. The lower cap <NUM> may aid the thermoset material <NUM> to fully fill the interstices within the housing <NUM> (i.e., the interstices between the conductor core <NUM>, the spacers <NUM>, <NUM>, and the inner and outer armor wires <NUM>, <NUM>) during injection of the uncured thermoset material <NUM> into the housing <NUM>. However, this may also be accomplished via other means/processes in implementations lacking the lower cap <NUM>, such as depicted in <FIG> described below. The lower cap <NUM> may form the downhole end <NUM> and comprise an opening <NUM> through which the conductor core <NUM> extends from the housing <NUM>. As with the upper cap <NUM>, the lower cap <NUM> may be a single discrete member that extends into the cylindrical member <NUM> such that a shoulder <NUM> of the lower cap <NUM> abuts the lower end <NUM> of the cylindrical member <NUM>. However, the lower cap <NUM> may take other forms in other implementations also within the scope of the present disclosure.

The upper cap <NUM>, the lower cap <NUM>, and the thermoset material <NUM> may cooperatively seal a volume containing the first and second spacers <NUM>, <NUM> within the housing <NUM>, such as may prevent the incursion of wellbore fluid into the rope socket <NUM>. However, such sealing, if existent, may be accomplished via other means.

The housing <NUM> may comprise a fill port <NUM> through which the uncured thermoset material <NUM> may be injected into the housing <NUM> before the thermoset material is thermally cured. When the material <NUM> is a thermoplastic material, it is injected in a melted state and there is no curing of the thermoplastic material. After the injection, a plug, cover, and/or other means <NUM> may seal the port <NUM>, such as to prevent incursion of wellbore fluid into the rope socket <NUM> via the port <NUM>.

<FIG> sequentially depict an example implementation of a composite cable rope socket <NUM> during stages of manufacture according to one or more aspects of the present disclosure. The rope socket <NUM> comprises same or similar features of the rope socket <NUM> depicted in <FIG>, including where indicated by the same reference numerals.

In <FIG>, the armored cable <NUM> is inserted through an upper end <NUM> of a rope socket housing <NUM>. As described above, the armored cable <NUM> may include an outer layer <NUM>. In such implementations, a portion of the outer layer <NUM> is removed to expose the outer armor wires <NUM>.

The housing <NUM> is similar to the housing <NUM> shown in <FIG> and <FIG>. The housing <NUM> is depicted in <FIG> as a single, discrete member, although in other implementations the housing <NUM> may comprise a plurality of components coupled together. The housing <NUM> may be formed from metallic and/or plastic materials.

An internal volume of the housing <NUM> includes an upper frustum-shaped volume <NUM> defined by an internal conical surface <NUM>, a lower frustum-shaped volume <NUM> defined by another internal conical surface <NUM>, and a cylindrical volume <NUM> interposing the upper and lower frustum-shaped volumes <NUM>, <NUM>. The upper volume <NUM> tapers downward from the upper housing end <NUM> to the cylindrical volume <NUM>, and the lower volume <NUM> tapers downward from the cylindrical volume to a lower end <NUM> of the housing <NUM>. Other aspects of the housing <NUM> may be as or similar to the above-described aspects of the housing <NUM> shown in <FIG> and <FIG>. For example, the housing <NUM> may also include a fill port <NUM> at least functionally similar to the fill port <NUM> depicted in <FIG> and <FIG>.

<FIG> depicts a manufacturing stage subsequent to the stage depicted in <FIG>, in which portions of the outer armor wires <NUM> have been unwound from around the inner armor wires <NUM> and the second spacer <NUM> has been positioned over the inner armor wires <NUM>. Below the second spacer <NUM>, portions of the inner armor wires <NUM> have been unwound from the conductor core <NUM> and the first spacer <NUM> has been positioned around the conductor core <NUM>. The predetermined distance <NUM> between the first and second spacers <NUM>, <NUM> is as described above with respect to <FIG>. <FIG> also depicts two of the inner armor wires <NUM> partially rewrapped around the first spacer <NUM>.

<FIG> depicts a manufacturing stage subsequent to the stage depicted in <FIG> in which the inner armor wires <NUM> have been fully rewrapped (e.g., tightly or loosely) around the first spacer <NUM> and the conductor core <NUM>. <FIG> depicts a manufacturing stage subsequent to the stage depicted in <FIG> in which the outer armor wires <NUM> have been fully rewrapped (e.g., tightly or loosely) around the second spacer <NUM> and the inner armor wires <NUM> that were rewrapped around the first spacer <NUM>. Thus, as described above, the first spacer <NUM> interposes the conductor core <NUM> and the rewrapped inner armor wires <NUM>, the second spacer <NUM> interposes the originally wrapped inner armor wires <NUM> and the rewrapped outer armor wires <NUM>, and the first and second spacers <NUM>, <NUM> are axially offset by the predetermined distance <NUM>.

<FIG> depicts a manufacturing stage subsequent to the stage depicted in <FIG> in which the housing <NUM> has been repositioned relative to the armored cable <NUM> such that the first spacer <NUM> (depicted by phantom lines) and the second spacer <NUM>, having been rewrapped within the inner and outer armor wires <NUM>, <NUM>, respectively, are now positioned within the upper frustum-shaped volume <NUM> within the housing <NUM>. Such repositioning, along with uniform azimuthal and/or longitudinal spacing of the outer armor wires <NUM> when rewrapping around the second spacer <NUM>, may result in one, several, or each rewrapped outer armor wire <NUM> having a contact point <NUM> where that rewrapped outer armor wire <NUM> is in abutment with (i.e., radially sandwiched between) both the second spacer <NUM> and the conical surface <NUM>.

The conical surface <NUM> may also present one or more advantages. For example, when the housing <NUM> is being repositioned by applying opposing tension forces to the housing <NUM> and the armored cable <NUM>, the conical surface <NUM> may aid in compressing the armor wires <NUM>/<NUM> around the spacers <NUM>/<NUM>. Such compression of the armor wires <NUM>/<NUM> around the spacers <NUM>/<NUM> may be advantageous when performed prior to the thermoset material <NUM> being injected into the volumes <NUM>/<NUM> or prior to the curing and/or other setting of the material <NUM> within the volumes <NUM>/<NUM> as it improves the mechanical properties of the rope socket.

<FIG> also depicts the thermoset material <NUM> filling the lower frustum-shaped volume <NUM> and a portion of the cylindrical volume <NUM>, although it will be understood that such depiction is merely for the sake of clarity and ease of understanding the illustration, and that the entireties of the upper frustum-shaped volume <NUM>, the cylindrical volume <NUM>, and the lower frustum-shaped volume <NUM> will be filled by the thermoset material <NUM>, thus completing this example implantation of the composite cable rope socket <NUM>.

<FIG> is a schematic view of at least a portion of an example implementation of a system <NUM> incorporating the armored cable <NUM> and a composite cable rope socket <NUM> according to one or more aspects of the present disclosure. The armored cable <NUM> is as described above and is mechanically, electrically, and/or optically connected with a logging tool string and/or other downhole equipment <NUM> in a wellbore <NUM> via the rope socket <NUM>. The wellbore <NUM> may extend from a wellsite surface <NUM> into one or more subterranean formations <NUM>. Within the downhole equipment <NUM>, one or more conductors/cables <NUM> (see <FIG>) of the conductor core <NUM> are connected to one or more components <NUM> of the downhole equipment <NUM>. At the wellsite surface <NUM>, the armored cable <NUM> is sheaved on a cable reel <NUM>, and one or more conductors/cables <NUM> of the conductor core <NUM> are connected to a collector and/or other electrical and/or optical connector(s) <NUM> of the cable reel <NUM>. The cable reel <NUM> may be supported by a rig <NUM> and/or other means (e.g., a wireline services truck). Electronic surface equipment <NUM> is connected to the connector(s) <NUM> via one or more connections <NUM>. Accordingly, the conductor core <NUM> may be utilized to transmit electrical and/or optical signals between the surface equipment <NUM> and the downhole equipment <NUM> suspended by the armored cable <NUM> in the wellbore <NUM>.

A rope socket according to one or more aspects of the present disclosure may aid in distributing (e.g., spreading) tensile load of the armored cable to each of the armor wires, contrary to conventional rope sockets. This is of particular interest when the armor wires are made of composite material. For example, in such implementations, the armored cable is anisotropic and exhibits low radial strength, such that distributing the axial load aids in permitting the cable to carry heavier downhole equipment. Moreover, utilizing the same thermoset (or thermoplastic) material as both the matrix forming the armor wires and the socket-filling material may also aid in evenly transferring tensile load to the armor wires. These and/or other aspects of the present disclosure may result in a rope socket having a high strength, perhaps as high as the breaking strength of the armored cable. Furthermore, a rope socket according to one or more aspects of the present disclosure may also be simpler and cheaper to manufacture because the rope socket includes just a few simple components, namely, a simple machined housing (which may be a single machined component) and the above-described thermoset (or thermoplastic) material, and perhaps one or more spacers. Additionally, the metallic component(s) of the rope socket may be re-usable (e.g., after removing the thermoset material filling the rope socket by, for example, baking at high temperature).

In view of the entirety of the present disclosure, including the figures and the claims, a person having ordinary skill in the art will readily recognize that the present disclosure introduces an apparatus comprising a rope socket coupled with an armored cable, wherein the armored cable comprises a conductor core comprising one or more cables for transmitting electrical and/or optical signals and at least one layer comprising a plurality of armor wires wound around the conductor core, and wherein the rope socket comprises: a housing having an uphole end through which the armored cable extends into the housing and a downhole end through which the conductor core extends from the housing, wherein the armor wires are arranged inside of the housing so that they are spaced apart at least locally from the conductor core; and a plastic material disposed within the housing and filling interstices each defined by one or more surfaces of one or more of the conductor core, one or more of the armor wires, and the housing.

The rope socket may comprise at least one spacer radially interposing the conductor core and the plurality of armor wires within the housing, and the plastic material disposed within the housing may fill interstices each defined by one or more surfaces of one or more of the conductor core, the at least one spacer, one or more of the armor wires, and the housing. The at least one spacer may comprise a first spacer and a second spacer. The first spacer may be axially offset from the second spacer such that no portion of the second spacer radially overlaps any portion of the first spacer. The at least one layer may comprise: an inner layer comprising a plurality of inner armor wires wound around the conductor core; and an outer layer comprising a plurality of outer armor wires wound around the plurality of inner armor wires. The first spacer may radially interpose the conductor core and the plurality of inner armor wires within the housing. The second spacer may radially interpose the plurality of inner armor wires and the plurality of outer armor wires within the housing. The plastic material may fill interstices each defined by one or more surfaces of one or more of the conductor core, the first spacer, one or more of the inner armor wires, the second spacer, one or more of the outer armor wires, and the housing.

The plastic material may be one of a thermoset material, comprising at least one of polyurethane and epoxy, and a thermoplastic material.

The plastic material may be a polymer matrix embedded with fibrous, particulate, or spherical glass, carbon, aramid, or basalt reinforcement members.

The uphole end of the housing may be defined by a conical surface that narrows to an opening through which the armored cable extends. The at least one spacer may be longitudinally disposed in a volume defined by the conical surface. The housing may comprise a cylindrical member and an upper cap coupled with the cylindrical member, and the upper cap may comprise the conical surface.

The housing may comprise a lower cap coupled with the cylindrical member, and the lower cap may form the downhole end and comprise an opening through which the conductor core extends from the housing.

The housing may comprise a fill port for installing the plastic material within the housing.

The present disclosure also introduces a system comprising and armored cable and an armored cable rope socket. The armored cable comprises: a conductor core comprising one or more conductors for transmitting electrical and/or optical signals between surface equipment at a wellsite surface and downhole equipment suspended by the armored cable in a wellbore that extends between the wellsite surface and a subterranean formation; and at least one layer comprising a plurality of armor wires wound around the conductor core. The armored cable rope socket comprises: a housing having first and second ends, wherein the armored cable extends into the housing through the first end, wherein the conductor core extends from the housing through the second end to a component of the downhole equipment, and wherein the armor wires are arranged inside of the housing so that they are spaced apart at least locally from the conductor core; and a plastic material disposed within the housing and filling interstices each defined by one or more surfaces of one or more of the conductor core, one or more of the armor wires, and the housing.

Each armor wire may comprise a reinforcement element including a bundle of reinforcement fibers comprising at least one fiber and a plastic matrix impregnating the bundle of fibers, wherein the plastic material filling the housing is selected to bond with the plastic matrix of the reinforcement element.

The present disclosure also introduces a method comprising passing an end of an armored cable through an uphole end of a housing, wherein the armored cable comprises: a conductor core comprising one or more cables for transmitting electrical and/or optical signals; and at least one layer comprising a plurality of armor wires collectively extending around the conductor core. Portions of each armor wire of the at least one layer are then unwrapped to expose the conductor core. The unwrapped portions of the armor wires are then rewrapped around the exposed conductor core so that the armor wires are at least locally spaced apart from the conductor core. The housing is then positioned so that the rewrapped portions of the armor wires are located inside the housing. A plastic material is then injected into the housing to fill interstices each defined by one or more surfaces of one or more of the conductor core, one or more of the rewrapped portions of the armor wires, and the housing.

The method may further comprise: after unwrapping portions of each armor wire, positioning at least one spacer to radially interpose the conductor core and the unwrapped portions of armor wires, such that the rewrapping of the unwrapped portions of the armor wires includes wrapping the unwrapped portions of the armor wires around the at least one spacer, and such that the repositioning of the housing positions the at least one spacer within the housing; and affixing a lower cap to the housing after the positioning of the housing and before the injecting of the plastic material.

Claim 1:
An apparatus comprising:
a rope socket (<NUM>) coupled with an armored cable (<NUM>), wherein the armored cable (<NUM>) comprises a conductor core (<NUM>) comprising one or more cables (<NUM>) for transmitting electrical and/or optical signals and at least one layer (<NUM>, <NUM>) comprising a plurality of armor wires (<NUM>, <NUM>) wound around the conductor core (<NUM>), and wherein the rope socket (<NUM>) comprises:
a housing (<NUM>) having:
an uphole end (<NUM>) through which the armored cable (<NUM>) extends into the housing (<NUM>); and
a downhole end (<NUM>) through which the conductor core (<NUM>) extends from the housing (<NUM>), wherein the armor wires (<NUM>, <NUM>) are arranged inside of the housing (<NUM>) so that they are spaced apart at least locally from the conductor core (<NUM>); and
characterized in further comprising
a first spacer (<NUM>) and a second spacer (<NUM>) radially interposing the conductor core (<NUM>) and the plurality of armor wires (<NUM>, <NUM>) within the housing (<NUM>), wherein the first spacer (<NUM>) is axially offset from the second spacer (<NUM>) such that no portion of the second spacer (<NUM>) radially overlaps any portion of the first spacer (<NUM>); and
a plastic material (<NUM>) disposed within the housing (<NUM>) and filling interstices each defined by one or more surfaces of one or more of the conductor core (<NUM>), the first and second spacers (<NUM>,<NUM>), one or more of the armor wires (<NUM>, <NUM>), and the housing <NUM>).