Cables and wires in downhole equipment are often exposed to severe conditions that can easily compromise their performance — from vibration and abrasion to high temperatures, aggressive chemicals, and harsh fluids. So, they need to be much stronger, perform reliably and last longer to survive deep drilling. At the same time, cables and wires need to be smaller and more flexible to fit inside cramped spaces of smaller tools.

Constructed with uniquely engineered fluoropolymers, GORE Insulated Wires are designed specifically to withstand extreme oil and gas downhole environments. They provide superior mechanical protection against harsh chemicals and hydrolysis in high temperatures typically found in downhole environments. They also withstand repeated mechanical stress such as vibration and abrasion caused by deep drilling. These high-strength insulated wires also deliver outstanding electrical performance with dependable signal integrity for high-speed data transmission over longer distances, eliminating the need for additional signal amplification.

GORE Insulated Wires withstand continuous exposure to hazardous environmental contaminants such as acid, water, steam, synthetic oil, methane, and hydrogen sulfide at extreme temperatures while delivering consistent power and critical real-time data to operators. That’s because our unique thin-wall insulation improves signal integrity and provides higher signal density, which means smaller, more durable solutions in your application.

We compared our insulated wires to standard PTFE-PI-PTFE insulated wires using test method ASTM D2307. Results showed that GORE Insulated Wires provided enhanced tensile strength up to 39,530 psi (272 MPa). Ultimately, our wires are much stronger and more flexible so that they won’t break as easily during winding and handling operations, like the other insulated wires. Also, our wires performed reliability in wide temperatures, achieving a thermal class rating of 300° C (572° F).

Typical applications for GORE Insulated Wires are in any down hole environment where the existence of water, temperature or chemicals can cause a negative impact to the life and or performance of the electronics, Downhole motors/windings:

• Generators
• Electric Motors
• Solenoids
• Transformers

Or as in non-winding applications like high-temperature cable systems:

• EPS or downhole pre-heating power cables
• Sensor cables
• High-temperature hook-up wires
• Thermocouple wires

If you have any questions or to discuss your specific application needs, please contact a Gore representative.

GORE Insulated Wires provide manufacturers with many benefits that improve electrical and mechanical performance such as:

• high-speed data transmission over longer distances eliminating the need for additional signal amplification
• increased power density at high temperatures due to high-strength wire insulation
• exceptional resistance to chemicals and hydrolysis in extreme environments with temperatures up to 300° C
• enhanced tensile strength for less wire breakage
• longer tool life with abrasion-resistant wire insulation
• increased design options with smaller diameters and more durable construction
• simple routing in confined spaces due to smaller wires with greater flexibility

Gore’s tests were modified to achieve better accuracy in comparing GORE Insulated Wires to conventional PTFE and PTFE-PI-PTFE wire insulation.  Results are based on bare copper wires insulated with 6-millimeter wall insulation material. Results for tensile strength and dielectric constant are based on film material.