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In some embodiments, an insulation shield layer is extruded over an insulation layer. For example, a lead (Pb) based mostly barrier layer is usually a metallic shield layer that also can serve as a floor plane. For example, a technique can embody extruding polyethylene a couple of lead (Pb) barrier layer disposed about a conductor to type an meeting; and armoring no less than one of the assemblies with metallic armor to type a cable. For example, a further cushion layer could also be applied that surrounds assemblies the place the extra cushion layer is substantially circular in its cross-sectional shape (e.g., an annular wall about a group of assemblies). In the instance of FIG. 10, the top assemblies form considerably "D" shapes (e.g., one being a backward "D") whereas the middle or intermediate meeting kinds a somewhat elongated "0" shape. As proven in FIG. 6, the cable 610 includes a circular cross-sectional form while the cable 630 includes an oblong cross-sectional shape. In some embodiments, a barrier layer could also be formed as an extruded layer whereas in different embodiments a barrier layer could also be formed as a taped layer. The third material 2416 can type a cushion layer concerning the second materials 2414. The third material 2416 can have a hoop stress such that it helps to retain shape, which can, in flip, assist to retain shape of the second materials 2414. The third materials 2416 might be formulated for at the very least some amount of crosslinking after extrusion by the extruder 2417. For example, crosslinking can occur at the least in part in situ while the meeting formed via the extruder 2417 is waiting to be armored and/or in any other case processed.

In such an instance, an extruded cushion layer can obtain a desired hoop stress, which can assist the extruded cushion layer to retain its form. Such a form may be outlined by one or more parameters comparable to, for example, an arc angle. For example, in some flat energy cable embodiments, two or extra individual coated conductors may be arranged in a facet-by-facet configuration (e.g., consider configurations corresponding to 2×1, 3×1, 4×1, and so on.) and, for instance, a number of armor layers could be applied over a jacket. In some embodiments, a mix of extruded and taped layers may be used to form the barrier layer. For instance, a cushion layer can embrace a colorant (e.g., for coloration coding phases of a multiphase power cable). For example, a layer 762 may be a further cushion layer 762 that surrounds the three cushion layers 760 of the grouped assemblies, which might further help to protect the metallic shields 750 from an armoring course of. As shown in FIG. 12, the cable seven hundred with the cushion layer 760 lacks the sharp, lower-like indentations of the cable 1200 with the braided fibers 1260. In the photographs related to the cable 700, a comparatively straight, longitudinal line is an artefact from a knife used to cut the cushion layer 760 for its elimination to expose the lead (Pb) barrier layer.

In different embodiments, an insulation shield layer could also be adhered to an insulation layer using an acceptable adhesive or adhesives based mostly on a number of of the respective supplies of the insulation layer and insulation shield layer. In the example of FIG. 8, the formulation block 812 can formulate the fabric by means of use of one or more polymeric materials (e.g., polyethylene and optionally, additionally polypropylene) and one or more further materials similar to, for example, a number of fillers and/or one or more curatives. In some embodiments, a barrier layer could also be formed from a number of fluoropolymers, lead, or another material resistant to downhole gases and fluids. For example, a barrier layer could be a layer exterior to a shield (e.g., an insulation shield layer) that will purpose to supply extra safety from corrosive downhole gases and fluids. Where a cable contains EPDM insulation adjacent to a copper conductor, a lead (Pb) layer may be placed over the EPDM insulation and a fabric tape or a braid (e.g., a braided fiber) could also be positioned over the lead (Pb) layer as a producing support to attenuate distortion of the lead (Pb) layer during armoring. For example, insulation and shield could also be strippable as a unit, for instance, where substantially cross-linked at an interface between the insulation and the shield.

As an example, a metallic shield layer may be applied over an insulation shield layer. For example, consider a fast production process that includes extrusion the place the excessive speed of the melt extrusion of an XLPE layer can speed up crosslinking by allowing for fast quenching of the melt extruded XLPE layer in sizzling water, which, consequently, can achieve a high crosslink response fee. The crosslink density (ve) of S1054A/PP/Talc composites might be decided from the rubbery moduli using the next equation, based on the kinetic theory of rubber elasticity (Eqn. In some embodiments, an insulation layer and insulation shield layer might be co-extruded via strain extrusion and cured utilizing compatible cure systems with substantially similar cure rates. As an example, a substantially circular formed cushion layer could also be extruded about a plurality of considerably pie shaped cushion layers which are grouped. Such one or more cushion layers may also help to preserve integrity of a number of metallic shields from a producing process akin to, for instance, an armoring course of. As defined, conductor and/or meeting geometries can be grouped where geometry of a number of cushion layers could also be appropriately shaped to help preserve integrity of one or more metallic shields, which may perform as gasoline obstacles that will help to hinder permeation of gasoline (e.g., H2S, and so forth.) towards a conductor of a power cable.

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