Field application of polymer-based electrical insulation

Abstract

Methods are disclosed for producing an insulated electrical conductor. Electrically uninsulated portions of respective electrical conductors are connected. A joint between the electrically uninsulated portions is coated with a preceramic resin, which is heated to cure the preceramic resin into a green-state insulator that substantially covers the joint.

1 . A method of producing an insulated electrical conductor, the method comprising: 
 connecting a first electrically uninsulated portion of a first electrical conductor with a second electrically uninsulated portion of a second electrical conductor;    coating a joint between the first and second electrically uninsulated portions with a preceramic resin; and    heating the preceramic resin to cure the preceramic resin into a green-state insulator that substantially covers the joint.    
   
   
       2 . The method recited in  claim 1  further comprising applying a compressive force to the preceramic resin while curing the preceramic resin into the green-state insulator to consolidate the preceramic resin.  
   
   
       3 . The method recited in  claim 2  wherein applying the compressive force comprises disposing a sleeve around the preceramic resin, the sleeve being made of a material having a volumetric thermal-expansion coefficient between about 10 −4  and 10−2 K −1  and a Young's modulus between about 10 5  and 10 8  N/m 2 .  
   
   
       4 . The method recited in  claim 3  wherein the material comprises silicone rubber.  
   
   
       5 . The method recited in  claim 2  wherein applying the compressive force comprises applying pressure to the preceramic resin with a pressurized containment system.  
   
   
       6 . The method recited in  claim 2  wherein applying the compressive force to the preceramic resin comprises: 
 applying a resin containment film to the preceramic resin; and    disposing a sleeve around the resin containment film,    the method further comprising removing the sleeve and the resin containment film.    
   
   
       7 . The method recited in  claim 1  wherein each of the first and second electrical conductors comprises an electrically insulated portion.  
   
   
       8 . The method recited in  claim 1  wherein each of the first and second electrical conductors comprises a solid electrically conductive rod.  
   
   
       9 . The method recited in  claim 1  wherein each of the first and second electrical conductors comprises a stranded electrical conductor.  
   
   
       10 . The method recited in  claim 1  wherein curing the preceramic resin into the green-state insulator comprises passing an electrical current through the first and second electrical conductors.  
   
   
       11 . The method recited in  claim 1  wherein curing the preceramic resin comprises curing the preceramic resin in a field location with locally mounted heaters.  
   
   
       12 . A method of assisting an oil-recovery process, the method comprising: 
 deploying a first electrical conductor into an oil-recovery environment, the first electrical conductor comprising a first electrically uninsulated portion;    connecting the first electrically uninsulated portion with a second electrically uninsulated portion of a second electrical conductor;    coating a first joint between the first and second electrically uninsulated portions with a preceramic resin;    curing the preceramic resin to convert the preceramic resin into a green-state insulator that substantially covers the first joint to form a continuous conductor;    applying a compressive force to the preceramic resin while curing the preceramic resin to consolidate the preceramic resin; and    deploying at least a portion of the continuous conductor corresponding to the second electrical conductor into the oil-recovery environment.    
   
   
       13 . The method recited in  claim 12  further comprising: 
 coating a portion of the first electrical conductor with the preceramic resin before deploying the first electrical conductor into the oil-recovery environment; and    pyrolyzing the preceramic resin of the coated portion to convert the preceramic resin of the coated portion into a ceramic insulator that electrically insulates the portion, wherein pyrolyzing the preceramic resin of the coated portion is performed before connecting the first electrically uninsulated portion with the second electrically uninsulated portion.    
   
   
       14 . The method recited in  claim 12  further comprising: 
 connecting a third electrically uninsulated portion of the second electrical conductor with a fourth electrically uninsulated portion of a third electrical conductor;    coating a second joint between the third and fourth electrically uninsulated portions with the preceramic resin;    curing the preceramic resin coating the second joint to convert the preceramic resin into a green-state insulator that substantially covers the second joint to form the continuous conductor;    applying a second compressive force to the preceramic resin coating the second joint while curing the preceramic resin coating the second joint to consolidate the preceramic resin; and    deploying a portion of the continuous conductor corresponding to the third electrical conductor into the oil-recovery environment.    
   
   
       15 . The method recited in  claim 12  wherein applying the compressive force comprises disposing a sleeve around the preceramic resin, the sleeve being made of a material having a volumetric thermal-expansion coefficient between about 10 −4  and 10 −2  K −1  and a Young's modulus between about 10 5  and 10 8  N/m 2 .  
   
   
       16 . The method recited in  claim 15  wherein the material comprises silicone rubber.  
   
   
       17 . The method recited in  claim 15  wherein applying the compressive force comprises applying pressure to the preceramic resin with a pressurized containment system.  
   
   
       18 . The method recited in  claim 15  wherein applying the compressive force to the preceramic resin comprises: 
 applying a resin containment film to the preceramic resin; and    disposing a sleeve around the resin containment film,    the method further comprising removing the sleeve and the resin containment film.    
   
   
       19 . The method recited in  claim 12  wherein pyrolyzing the preceramic resin comprises passing an electrical current through the first and second electrical conductors.