Inductive coupler for downhole components and method for making same
First Claim
1. A method of making an inductive coupler for downhole components, comprising the steps of:
- providing an annular housing having a recess;
a conductor; and
a plurality of generally U-shaped MCEI segments;
forming an assembly by placing the plurality of MCEI segments within the recess in the annular housing, wherein said segments are aligned to form a generally circular trough and placing a first portion of the conductor within the circular trough;
consolidating the assembly with a meltable polymer to thereby fill spaces between the segments, annular housing and the first portion of the conductor.
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Accused Products
Abstract
The present invention includes a method of making an inductive coupler for downhole components. The method includes providing an annular housing, preferably made of steel, the housing having a recess. A conductor, preferably an insulated wire, is also provided along with a plurality of generally U-shaped magnetically conducting, electrically insulating (MCEI) segments. Preferably, the MCEI segments comprise ferrite. An assembly is formed by placing the plurality of MCEI segments within the recess in the annular housing. The segments are aligned to form a generally circular trough. A first portion of the conductor is placed within the circular trough. This assembly is consolidated with a meltable polymer which fills spaces between the segments, annular housing and the first portion of the conductor. The invention also includes an inductive coupler including an annular housing having a recess defined by a bottom portion and two opposing side wall portions. At least one side wall portion includes a lip extending toward but not reaching the other side wall portion. A plurality of generally U-shaped MCEI segments, preferably comprised of ferrite, are disposed in the recess and aligned so as to form a circular trough. The coupler further includes a conductor disposed within the circular trough and a polymer filling spaces between the segments, the annular housing and the conductor.
156 Citations
29 Claims
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1. A method of making an inductive coupler for downhole components, comprising the steps of:
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providing an annular housing having a recess;
a conductor; and
a plurality of generally U-shaped MCEI segments;forming an assembly by placing the plurality of MCEI segments within the recess in the annular housing, wherein said segments are aligned to form a generally circular trough and placing a first portion of the conductor within the circular trough; consolidating the assembly with a meltable polymer to thereby fill spaces between the segments, annular housing and the first portion of the conductor. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 26, 27, 28, 29)
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25. A method of making an inductive coupler for downhole components, comprising the steps of:
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providing an annular housing having a recess, an insulated wire, a plurality of generally U-shaped MCEI segments, a meltable polymer liner and a circular, meltable polymer cap; forming an assembly by placing the liner within the recess, placing the plurality of MCEI segments on top of the liner, wherein said segments are aligned to form a circular trough, placing a first portion of the insulated wire within the circular trough, and placing the cap on top of the MCEI segments; and consolidating the assembly by applying sufficient heat to at least partially melt the liner and the cap, to thereby fill spaces between the segments, annular housing and the first portion of the insulated wire.
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Specification