Fiber-Optic Strength Member Components for Use in Outer Strength Member Layers

Abstract

A cable containing at least one optical fiber in a strength member and methods for manufacturing the strength member and cable are provided. A cable may include a cable core and armor wire strength members that surround the cable core. One of the armor wire strength members that surround the cable core contains an optical fiber.

1 . A method comprising:
 inserting a first optical fiber into a space shaped into one or more wires;   enclosing the space to enclose the first optical fiber in an optical-fiber-containing structure; and   extruding a first polymer tube over the optical-fiber-containing structure.   
     
     
         2 . The method of  claim 1 , wherein inserting the first optical fiber into the space comprises:
 inserting the first optical fiber between two semi-circular shaped wires;   inserting the first optical fiber into a longitudinal channel of a grooved wire;   inserting the first optical fiber into a hollow region of a C-shaped wire; or   inserting the first optical fiber into one of a plurality of circumferentially spaced channels in a wire; or   some combination thereof.   
     
     
         3 . The method of  claim 1 , comprising filling the space with a material, wherein the material comprises air, a silicon polymer, or a UV-curable polymer, or some combination thereof. 
     
     
         4 . The method of  claim 1 , comprising extruding a second polymer tube over the first polymer tube to provide additional rigidity or wrapping a plurality of wires over the first polymer tube to provide additional rigidity, or a combination thereof. 
     
     
         5 . The method of  claim 1 , comprising cabling the optical-fiber-containing structure around a cable core in a cable suitable for use downhole in a wellbore.