A method of fabricating coated splices for oilfield applications

Abstract

A method is needed to make a critical splice for a downhole tool in the petroleum industry. The goal is to connect two wires, cover the connection with a protective coating, and then assess the integrity of the finished splice. This project investigates how ultrasonic welding and injection molding can be employed in making the splice. After equipment and a process are designed, splices are produced and testing proceeds. Then an overall assessment of the method is made: connecting the wires in manufacturing should be done by ultrasonic welding and coating the wires using injection molding is a viable option. Further testing should investigate the reliability and failure modes of the coating at high pressures and temperatures along with how the coating method can be improved for quality assurance. Using the system designed during this project and the information gleaned, the plastic injection method should be compared with different methods, such as shrink-tubing, in order to make a final decision on the best coating method to be optimized for employment in manufacturing.