CN201229797Y - Armored component system for electric cable assembly - Google Patents

Abstract

The utility model relates to an armored assembly system for cable assemblies. The armored assembly system includes: a polymer composite material suitable for surrounding the cable core; a first strength element surrounding the polymer composite material; A first polymer layer; a second strength member surrounding the first polymer layer; and a second polymer layer surrounding the second strength member.

Description

Armor Assembly System for Cable Assemblies

The utility model is a divisional application of the utility model application filed on April 22, 2008, with the application number 200820112435.5 and the name "Optical-Electrical Cable with Bending Insensitivity with Improved Fatigue Life".

technical field

The utility model generally relates to an optical-electrical cable, and more particularly relates to a hybrid optical-electrical cable used for oil field logging cables and seismic exploration and a manufacturing method thereof.

Background technique

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

When an oil well is being drilled, a probe is typically lowered periodically into the wellbore to measure characteristics of the formation it traverses. Typically, the logging wireline supports and moves the probe while drilling, carries power to the probe, and relays control commands and data between the probe and instrumentation and control facilities at the surface. As measuring and measuring instruments have become more sophisticated, data transmission speeds have increased to the point where existing cables may become saturated.

As demonstrated by fiber optic telephone cables, fiber optic technology can increase data transmission rates by orders of magnitude. However, due to the requirements of using well logging cables, telephone fiber optic cables would not be acceptable. Telephone cables are designed to remain stationary in use and not experience the temperature and pressure extremes found in oil wells.

Instead, the logging cable is repeatedly pulled around the pulley and winds up and down the winch drum as it descends into and out of the well. Therefore, the cable must withstand repeated bending around several feet in diameter, and thousands of pounds of tension. Once in the well, the cable encounters pressures that may exceed 20,000 pounds per square inch and temperatures that may exceed 175°C. However, optical fibers are extremely sensitive to deformation (especially point loading), which greatly increases the attenuation of the optical signal within the fiber. They are also sensitive to moisture, which attacks tiny cracks in the fiber, reducing its strength. In addition, they are sensitive to atomic and molecular hydrogen, which reacts with silica (Silica), increasing the attenuation of the fiber. When the cable is manufactured, and subsequently when in use, stresses (bending and stretching) on the cable components (electrical conductors, strength members, etc.) cause them to move relative to each other within the cable. This can lead to local deformation of the fiber. Stretching the cables stretches the fibers, increasing their stress, increasing their attenuation, and sometimes causing them to break. The high pressure and temperature inside the well facilitates the intrusion of moisture and hydrogen into cables and fiber optics. As indicated, typical optical telephone communication cables are not designed for these operating conditions.

In view of the foregoing, an optical-to-electrical cable contemplated for use in oil well and seismic exploration applications is disclosed in U.S. 4,375,313 to Anderson et al., which is commonly assigned with this application, the contents of which patent is incorporated by reference in its entirety Incorporated here. The U.S. 4,375,313 patent discloses a buffer structure for protecting optical fibers from moisture, hydrogen and uneven stress. While this buffer structure is suitable for repeated and demanding logging applications, there is still a need for better buffering of optical fibers against stress and moisture and in consideration of the application of cables in deeper oil and gas wells and the adoption of more sophisticated tools requiring increased data transmission. hydrogen protection.

Utility model content

Embodiments of the present invention provide fiber optic components, hybrid photo-electric conductors, hybrid photo-electric conductor assemblies, and photo-electric core assemblies with improved bend insensitivity, fatigue life, and protection from hydrogen attack. In one preferred form, the fiber optic component includes an optical fiber and a carbon layer surrounding the optical fiber.

In another form, the hybrid optical-electrical conductor comprises: at least one optical fiber element; at least one electrical conductor disposed around the at least one optical fiber element; and an anchoring layer disposed around the at least one electrical conductor for securing the at least one electrical conductor in place. The at least one fiber optic component includes an optical fiber and a carbon layer surrounding the fiber optic component.

In another form, a hybrid photo-electric conductor assembly includes: a plurality of photo-electric conductors arranged in a bundle; and a filler material for bonding the plurality of photo-electric conductors. The optical-electrical conductors each include an optical fiber element and an electrical conductor surrounding the optical fiber element. The fiber optic component has an optical fiber and a carbon layer surrounding the optical fiber.

In another form, a hybrid optical-electrical conductor includes: at least one fiber optic component; at least one electrical conductor disposed around the at least one fiber optic component; a first polymer; and a second polymer layer. The first polymer layer holds at least one electrical conductor in place. The second polymer layer surrounds the first polymer layer for increasing the mechanical strength of the photo-electric conductor.

In another form, a hybrid photo-electric conductor assembly includes: a plurality of photo-electric conductors arranged in a bundle; a fillet; and a filler material. A plurality of photo-electric conductors defines an outer contour and a plurality of gaps between adjacent photo-electric conductors. A plurality of fillets is disposed in the gap adjacent the outer profile. A filler material is filled in the gaps to join the plurality of conductors and fillets to form a core assembly.

In another form, a jacket system for a cable assembly includes: a polymer composite material adapted to surround a cable core; a first strength member surrounding the polymer composite material; a first polymer layer surrounding the first strength member; a second strength member surrounding the first polymer layer; and a second polymer layer surrounding the second strength member.

In another form, a method of making a photoconductor assembly includes: providing a plurality of photo-electric conductors; arranging a plurality of photo-electric conductors in bundles, the photo-electric conductors defining the outer contour and the distance between adjacent photo-electric conductors; placing multiple fillets in the gaps adjacent to the outer profile; filling the gaps with filler material; and placing a protective layer around the conductors and fillets.

Further areas of applicability will be apparent from the description provided here. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the invention.

Description of drawings

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present invention in any way.

Figure 1 is a cross-sectional view of a fiber optic component constructed in accordance with the teachings of the present invention.

2 is a cross-sectional view of an alternative fiber optic component constructed in accordance with the teachings of the present invention.

Figure 3 is a cross-sectional view of a hybrid optical-electrical conductor constructed in accordance with the teachings of the present invention.

Figure 4 is a cross-sectional view of an alternative hybrid optical-electrical conductor constructed in accordance with the teachings of the present invention.

5 is a cross-sectional view of a hybrid light-cell assembly constructed in accordance with the teachings of the present invention.

6 is a cross-sectional view of another alternative hybrid optical-electrical cable assembly constructed in accordance with the teachings of the present invention.

7 is a cross-sectional view of another alternative hybrid optical-electrical cable assembly constructed in accordance with the teachings of the present invention.

8 is a cross-sectional view of an alternative cable core assembly constructed in accordance with the teachings of the present invention, and

9, 10 and 11 are cross-sectional views of a core assembly of a hybrid optical-electrical conductor assembly showing sequential steps in the manufacture of the core assembly in accordance with the teachings of the present invention.

Corresponding numerals indicate corresponding parts throughout the several views of the drawings.

Detailed ways

The following description is merely illustrative in nature and is not intended to limit the invention, application or use. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

fiber optic components

Referring to FIG. 1 , a fiber optic component constructed in accordance with the teachings of the present invention is shown and generally indicated by the numeral 10 . The fiber optic component 10 includes: an optical fiber 12; a carbon layer 14 disposed around the optical fiber 12; a buffer layer 18 surrounding the carbon layer 14; and an outer silicon layer 24 surrounding the buffer layer 18. The optical fiber 12 includes a core 1 and a cladding 2 .

Optical fiber 12 and carbon layer 14 form a fiber optic assembly 16 . Carbon layer 14 is hermetic, high temperature resistant, and is placed over fiber 12 to provide a barrier to _H2O and H ⁺ , thereby protecting against hydrogen attack and hydrolysis. The carbon layer 14 also increases the test stress level of the fiber optic component 10, and resistance to static fatigue, thereby increasing the useful life of the fiber optic component 10.

Preferably, the optical fiber 12 has a high numerical aperture (Numerical Aperture) and a smaller core 1 than conventional telecommunication optical fibers. High numerical aperture fibers require smaller fiber core sizes to maintain a constant cutoff wavelength. High NA fibers reduce the fiber's susceptibility to optical signal attenuation caused by microbends and large bends.

The buffer layer 18 surrounds the fiber optic component 16 and closely contacts the fiber optic component 16 . Buffer layer 18 is referred to as a "tight buffer" because buffer layer 18 is in intimate contact with fiber optic assembly 16 , as opposed to a "loose buffer," which may take the form of a conduit and loosely contain fiber optic assembly 16 . The buffer layer 18 includes a silicon layer or other suitable soft polymer 20 extruded on the fiber optic assembly 16 and a PFA (perfluoroalkoxy) layer 22 extruded on the silicon layer 20 .

An outer layer of silicon or other suitable soft polymer 24 is extruded over the buffer layer 18 to buffer the fiber optic assembly 16 and spread any compressive loads on the fiber optic assembly 16 from the outside. With this configuration, the fiber optic component 10 is less susceptible to tensile and bending stresses, thereby reducing signal attenuation.

Referring to FIG. 2 , an optional fiber optic component is shown and generally indicated by the numeral 30 . The fiber optic component 30 has a similar structure to the fiber optic component 10 except that the fiber optic component 30 includes three fiber optic assemblies 16 .

It is to be understood and appreciated that the fiber optic component 10 or 30 may have any number of fiber optic assemblies 16 depending on the application. Additionally, the fiber optic assembly 16 may be arranged to define a cross-section other than a circular cross-section. Other configurations may be employed without departing from the spirit of the invention. Each fiber optic assembly 16 may be coated with silicon or other suitable soft polymer 3 before laying them to form a bundle.

hybrid photo-electric conductor

Referring to FIG. 3 , a hybrid photo-electric conductor is shown and generally indicated by the numeral 40 . The hybrid optical-electrical conductor 40 includes: the fiber optic component 10 ; a plurality of electrical conductors 42 surrounding the fiber optic component 10 ; a securing layer 44 surrounding the plurality of electrical conductors 42 ; and a strengthening layer 46 surrounding the securing layer 44 . As previously described, fiber optic component 10 includes: optical fiber 12 ; carbon layer 14 ; buffer layer 18 ; and outer silicon layer 24 surrounding buffer layer 18 .

In this illustrated example, the plurality of electrical conductors 42 takes the form of a plurality of copper wires or nickel-plated copper wires. A plurality of electrical conductors 42 are helically wound around the fiber optic component 10 and partially embedded in the outer silicone layer 24 of the fiber optic component 10 .

)；其它含氟聚合物；聚芳基醚醚酮聚合物(PEEK)；聚苯硫醚聚合物(PPS)；改性聚苯硫醚聚合物；聚醚酮聚合物(PEK)；顺丁烯二酸酐改性的聚合物；全氟烷氧基聚合物；氟化乙烯丙烯聚合物；聚四氟乙烯-全氟甲基乙烯基醚聚合物；聚酰胺聚合物；聚氨酯；热塑性聚氨酯；乙烯三氟氯乙烯聚合物聚合物(诸如

氯化乙烯丙烯聚合物； SRP聚合物(由密西西比聚合物技术公司(Mississippi Polymer Technologies，Inc)生产的自强化聚合物，其基于取代的聚(1，4-亚苯基)结构，其中每个亚苯基环具有从多种有机基团衍生的取代基R基团)；ECTFE；PAEK；Santoprene；硅(Silicon)；乙烯-四氟乙烯共聚物(Tefzel)；EPDM；Engage；Infuse；含氟热塑性弹性体等；及其任何混合物。A securing layer 44 is disposed about the plurality of electrical conductors 42 for securing the plurality of electrical conductors 42 in place. In some preferred embodiments, the anchoring layer is a polymer layer that may act as a first polymer layer that is extruded around the plurality of electrical conductors 42 to lock the electrical conductors 42 . The polymer layer 44 is preferably made of materials such as fluoropolymers, polyolefins, polyphenylenes, soft elastomers, thermoplastic elastomers, and the like. Some non-limiting examples of these materials include: polyolefins; polytetrafluoroethylene-perfluoromethyl vinyl ether polymer (MFA); perfluoroalkoxyalkane polymer (PFA); polytetrafluoroethylene polymer ethylene-tetrafluoroethylene polymer (ETFE); ethylene-propylene copolymer (EPC); poly(4-methyl-1-pentene) (available from Mitsui Chemicals, Inc.) acquired

); other fluoropolymers; polyaryl ether ether ketone polymers (PEEK); polyphenylene sulfide polymers (PPS); modified polyphenylene sulfide polymers; polyether ketone polymers (PEK); Polymers modified with olefinic anhydride; perfluoroalkoxy polymers; fluorinated ethylene propylene polymers; polytetrafluoroethylene-perfluoromethyl vinyl ether polymers; polyamide polymers; polyurethanes; thermoplastic polyurethanes; ethylene Chlorotrifluoroethylene polymer polymers (such as

Chlorinated ethylene propylene polymers; SRP polymers (self-reinforced polymers produced by Mississippi Polymer Technologies, Inc) based on substituted poly(1,4-phenylene) structures in which each phenylene ring has from ECTFE; PAEK; Santoprene; Silicon (Silicon); Ethylene-tetrafluoroethylene copolymer (Tefzel); EPDM; Engage; Infuse; Fluorothermoplastic elastomers, etc.; any mixture.

A strengthening layer 46 surrounds the securing layer 44 for protecting the fiber optic component 10 and electrical conductor 42 surrounding it. The reinforcement layer 46 includes: a second polymer layer 48 extruded on the anchor layer 44 ; and a third polymer layer 50 extruded on the second polymer layer 48 . Materials for the second polymer layer 48 and the third polymer layer 50 are suitably selected to increase the mechanical strength for the hybrid photo-electric conductor 40 and to provide the desired electrical properties.

For example, the second polymer layer 48 can be made of a harder material than the third polymer layer 50 to provide the desired mechanical strength. Suitable materials for the second polymer layer 48 include: polyaryl ether ketones like PEEK, PEK, PK, PAEK, etc.; Parmax; PPS or modified PPS; carbon fiber reinforced fluoropolymers like Tefzel, ECTFE, etc.; Reinforced and toughened PTFE; etc. The third polymer layer 50 is used to provide desired electrical properties, such as desired impedance and low electrical signal attenuation. Suitable materials for the third polymer layer 50 include: polyolefins such as PP, PE, EPC, TPX; fluoropolymers such as Tefzel, MFA, ECTFE, PFA, FEP, PTFE, and the like.

Although not shown in the figures, it is understood and appreciated that the third polymer layer 50 can be disposed adjacent to the anchor layer 44 and that the second polymer layer 48 can be disposed around the third polymer layer 50 . It is possible to avoid fixing layer 44 together with layers 48 and 50 , and only with layers 48 and 50 .

In some embodiments, first polymer layer 44 may be removed. The optical fiber will be protected by the second polymer layer 48 and the third polymer layer 50 . In some embodiments, the second polymer layer 44 may be on the outside of the third polymer layer 50 to make the package more resistant to shattering from external forces.

Referring to FIG. 4 , an optional photo-electric conductor is shown and generally indicated by the numeral 54 . The photo-electric conductor 54 differs from the photo-electric conductor 40 of FIG. 3 in that the photo-electric conductor 54 includes three fiber optic assemblies 16 . It is to be understood and appreciated that any number of fiber optic assemblies 16 can be included in the optical-electrical conductor without departing from the scope of the present invention.

Hybrid optical-electrical cable core assembly

Referring to FIG. 5 , a hybrid optical-electrical cable core assembly constructed in accordance with the teachings of the present invention is shown and generally indicated by the numeral 60 . The optical-electrical cable core assembly 60 includes: a plurality of optical-electrical conductors 40 arranged in bundles; a band 62 surrounding a plurality of optical-electrical conductors 40 for bundling the optical-electrical conductors 40 together; protective layer 64 . Since the photo-electric conductor 40 has been described with reference to FIG. 3, its description is omitted here for brevity.

It should be noted that while seven photo-electric conductors 40 are shown, it should be understood and appreciated that any number of photo-electric conductors 40 can be included in the hybrid photo-electric cable core assembly 60 depending on the application. Furthermore, the photo-electric conductor 40 enclosed therein could be completely or partially replaced by the photo-electric conductor 54 of FIG. 4 having three fiber optic assemblies 16 without departing from the scope of the present invention.

The plurality of photo-electric conductors 40 define an outer profile and a plurality of gaps 66 between adjacent photo-electric conductors 40 . A plurality of fillets 68 are disposed in the gap 66 surrounded by the tape 62 and two adjacent conductors 40 such that the conductors 40 and the fillets 68 define an outer contour that approximates the shape of the desired cross-section of the cable core assembly 60 . The fillet 68 includes a twisted fiberglass core 74 and a polymer layer 76 extruded around the twisted fiberglass core 74 .

A filler material 70 is filled in the gap 66 for bonding the conductor 40 and the fillet 68 together.

The protective layer 64 in this illustrative example is a polymer sheath 64 extruded over the belt 62 to provide mechanical stability and protection. Cable 40 , fillet 68 , ribbon 62 , filler material 70 and polymer jacket 64 form core assembly 60 . The polymer sheath 64 may be composed of one or more layers depending on the application, including short fiber reinforced polymer composites.

Referring to FIG. 6 , a hybrid optical-electrical cable assembly is shown and generally indicated by the numeral 90 . The cable assembly 90 includes a first wire assembly 92 and a second wire assembly 94 arranged helically with respect to the central axis of the core assembly 60 . The first wire assembly 92 is wound in a helical direction, and the second wire assembly 94 is wound in a reverse helical direction. The first layer of armor wire can be laid in the same direction as the helical opto-electrical conductor 40, or can be laid in the opposite direction.

Referring to FIG. 7 , another hybrid optical-electrical cable core assembly is shown and generally indicated by the numeral 100 . The fiber optic cable core assembly 100 has a structure similar to the previously described cable core assemblies 40, 60, 80, except for the structure of the protective layer.

More specifically, the cable assembly 100 has a jacket system 102 disposed about the cable core assembly 60 using short fiber reinforced composite material as the polymer jacket 64 . In order from the inside out, the armor package 102 includes: a first strength element 106 ; a first polymer layer 108 ; a second strength element 110 ; and a second polymer layer 112 .

A short fiber reinforced polymer composite material 64 is applied, preferably extruded, onto the belt 62 . The first strength element 106 takes the form of an armor wire wound at a lay angle and partially embedded in the short fiber reinforced polymer 64 . The first polymer layer 108 is also reinforced with staple fibers and is extruded over the first strength member 106 encasing it. First polymer layer 108 is bonded to polymer jacket 64 through the gaps between first strength elements 106 . The second strength element 110 takes the form of an armor wire and is helically wound in the opposite direction to the first strength element 106 . The second strength element 110 is partially embedded in the first polymer layer 108 .

The second polymer layer 112 is also reinforced with staple fibers and is extruded over the second strength member 106 encasing it. The second polymer layer 112 is bonded to the first polymer layer 108 through the gaps between the second strength members 110 .

An outer layer (not shown) of small thickness and made of virgin polymer material can be applied over the second polymer layer 112 to create a smooth low friction surface.

core assembly

Referring to FIG. 8 , an optional core assembly is shown and generally indicated by the numeral 120 . The core assembly 120 includes: a plurality of first photo-electric conductors 122 ; and a plurality of second photo-electric conductors 124 . In FIG. 8, four first photo-electric conductors 122 and five second photo-electric conductors 124 are shown. First conductor 122 and second conductor 124 have a structure similar to conductors 40 (FIG. 3), 90 (FIG. 6), 100 (and FIG. 7), but are not limited to the structure described in the specification and shown in the drawings. Depending on the application, the number of fiber optic elements 10, number of electrical conductors 42, buffer structures or protective layers, and winding arrangement may vary.

As shown, the first conductor 122 and the second conductor 124 are surrounded by a band 126 . The first conductor 122 has a larger diameter than the second conductor 124 . The first conductor 122 defines a plurality of gaps 125 . The second conductor 124 is disposed in the gap 125 adjacent the strip 126 . A plurality of fillets 68 is disposed in the gap 125 adjacent the strip 126 and between two adjacent first and second conductors 122 and 124 . A filler material 130 is filled in the gap 125 for bonding the conductors 122 , 124 and the fillet 68 together.

Although not shown in Figure 8, the polymer jacket 64 described in connection with Figures 5, 6 or 7 would be placed on top of 120 to complete the cable core assembly.

Some other embodiments of the present invention include: a hybrid optical-electrical cable core assembly comprising a plurality of optical-electrical cables arranged in bundles and defining an outer profile and a plurality of gaps between adjacent optical-electrical cable conductors; a plurality of fillets in gaps adjacent the outer profile; and filler material filled in the gaps to combine the plurality of cables and fillets to form a core assembly. A fiber optic component may include: an optical fiber; carbon coated on the fiber; a buffer layer surrounding the carbon coating; and a layer of silicon or any other soft elastomer or thermoplastic extruded around the buffer layer and helically wound around the fiber Multiple copper or nickel-plated copper wires around a component. A first polymer layer may surround the copper wire or nickel-plated copper wire for holding the copper wire in place, and a second polymer layer may surround the first polymer layer. Optionally, a third copolymer layer may surround the second copolymer layer.

In another embodiment, an optical-electrical cable core assembly includes: a plurality of optical-electrical conductors arranged in a bundle; the optical conductors each comprising: an optical fiber assembly having an optical fiber and a carbon layer surrounding the optical fiber; an electrical conductor surrounding the optical fiber element ; and a filler material for combining a plurality of photo-electric conductors. A plurality of photo-electric conductors define a plurality of gaps, and a filler material fills the gaps.

Manufacturing method

Referring to Figures 9 through 11 in conjunction with Figure 5, an exemplary method of manufacturing an optical-to-electrical cable assembly will now be described in greater detail.

First, a plurality of opto-electronic assemblies 40 are arranged in bundles to define a configuration that approximates the desired cross-section of the cable assembly. A plurality of photo-electric conductors 40 form an outer contour and define a plurality of gaps 66 between adjacent conductors 40 .

Next, as shown in FIG. 10, a plurality of fillets 68 are placed in the gap 66 adjacent to the outer contour defined by the plurality of conductors 40 so that: the contour defined by the bundle of conductors 40 and the fillet 68 approximates the desired transverse noodle. Filler material 70 is then filled in all gaps 66 to bond conductor 40 and fillet 68 together.

As shown in FIG. 11 , after filling material 70 into gap 66 , tape 62 is then wrapped around conductor 40 and fillet 68 , and polymer sheath 64 is applied on top to form core assembly 60 . Two layers of armor wires 92 and 94 ( FIG. 6 ) or armor assembly system 102 ( FIG. 7 ) are applied on top of cable core assembly 60 to form cable assembly 90 or 100 .

With the structure of fiber optic element 10, photoconductor 40, core assembly 60, and thus cable assembly 100, optical fiber 12 with carbon layer 14 has improved fatigue life and is less susceptible to bending stress. The carbon layer 14 also protects against hydrolysis. Furthermore, the optical fiber 12 is further protected against bending stress through the special arrangement of the optical-electrical cable, cable core assembly and protective layer according to the present invention. Therefore, the service life of optical fiber components, optical-electrical cables and optical-electrical cable assemblies can be improved.

Some embodiments of the present invention are methods of making an optical-electrical cable assembly, comprising: providing a plurality of optical-electrical cable conductors; Multiple gaps between the outer profile and adjacent optical-to-electrical cable conductors; multiple fillets are then placed in the gaps adjacent to the outer profile; filler material is filled into the gaps; and a protective layer is then placed around the cables and fillets . The method may also include placing a tape around the cable and fillet after filling the gap with filler material to form the core assembly. Additionally, the methods may include extruding the polymer composite over the cable and the fillet, wherein in some examples the first strength member is helically wound around the polymer composite in a helical direction. The laying direction can be the same as or opposite to the laying direction of the helical optical-electrical conductor.

The first strength element may comprise a plurality of armor wires. The first polymer layer may be extruded onto the first strength member, and the second strength member wrapped around the first polymer layer in an opposite helical direction. Additionally, a second polymer layer may be placed on the second strength member.

The protective layer may also include a polymer sheath with enclosed armor wires, and the protective layer may include at least two types of armor wires.

The above description of the utility model is actually only exemplary, so changes that do not deviate from the gist of the utility model should be within the scope of the utility model. Such changes should not be regarded as departing from the spirit and scope of the present invention.

Claims (10)

1. An armored assembly system for cable assembly, characterized in that said armored assembly system comprises: Polymer composite materials suitable for surrounding the cable core; enclosing a first strength member of the polymer composite; a first polymer layer surrounding the first strength member; a second strength member surrounding the first polymer layer; and A second polymer layer surrounding the second strength member. 2. The armor assembly system of claim 1, wherein at least one of the polymer composite, the first polymer layer, and the second polymer layer is reinforced with short fibers. 3. The armor assembly system of claim 1, wherein the first strength element is partially embedded in the polymer composite material. 4. The armor assembly system of claim 1, wherein the second strength element is partially embedded in the first polymer layer. 5. The armor assembly system of claim 1, wherein the first polymer layer encloses the first strength member. 6. The armor assembly system of claim 1, wherein the second polymer layer encloses the second strength member. 7. The armor assembly system of claim 1, wherein at least one of the polymer composite, the first polymer layer, and the second polymer layer is formed by extrusion and bonded from the cable core to the second polymer object layer. 8. The armor assembly system of claim 1, further comprising an outer layer disposed about the second polymer layer, the outer layer having a smooth low friction outer surface. 9. The armor assembly system of claim 1, wherein the first and second strength elements comprise armor wires. 10. The armor assembly system of claim 9, wherein the armor wires are helically wound in opposite directions.

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