team photo

Figure 1
project photo

Materials Science and Engineering
Team 12

Team Members

Advisor

Eric Krementowski
Katelyn Whyte

Bryan Huey

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Optimization of adhesion between Kapton Tape and EPR in Motor Lead Extension cables for use in Electric Submersible Pump cables

Marmon is a leading company in high-performance, engineered electrical cables, especially for operating in harsh environments. For example, Marmon’s Kerite® electrical submersible pump cables must endure high temperatures and extreme environmental conditions when buried up to a mile deep. A high-reliability adhesive layer between cable components is therefore critical. In particular, the copper core is wrapped by two layers of Kapton® film and coated with industrial adhesive before applying a layer of ethylene propylene diene monomer rubber (EPDM). Failure of this adhesive bond can lead to ingress of corrosive species, and thus accelerated degradation of this crucial electrical system.
The goal of this project is to assess the adhesion between Kapton® tape and EPDM rubber of Chemlok® 250, Chemlok® 6150, 3M® 4799, and 3M® Primer 94 with 3M® 9485PC adhesive tape with a T-peel test. Samples are fabricated by pressure heating strips of adhesive coated Kapton® tape with a layer of EPDM rubber at 350 F for 30 minutes, replicating the continuous manufacturing process. Multiple layers of adhesive coatings, as well as high temperature exposure to mimic in-service conditions, are also considered. Ultimately this work aims to identify the optimal adhesive, prioritizing adhesion strength while considering ease of use and safety issues.