In some embodiments, an insulation shield layer is extruded over an insulation layer. For instance, a lead (Pb) based barrier layer is usually a metallic shield layer that may also function a ground aircraft. For example, a way can embrace extruding polyethylene a few lead (Pb) barrier layer disposed a couple of conductor to type an assembly; and armoring a minimum of one of the assemblies with metallic armor to form a cable. As an example, a further cushion layer could also be utilized that surrounds assemblies where the additional cushion layer is considerably circular in its cross-sectional shape (e.g., an annular wall about a bunch of assemblies). In the instance of FIG. 10, the end assemblies kind somewhat "D" shapes (e.g., one being a backward "D") whereas the center or intermediate assembly types a considerably elongated "0" shape. As proven in FIG. 6, the cable 610 features a circular cross-sectional shape whereas the cable 630 consists of 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 may be formed as a taped layer. The third materials 2416 can form a cushion layer about the second materials 2414. The third material 2416 can have a hoop stress such that it helps to retain form, which can, in turn, help to retain form of the second material 2414. The third material 2416 will be formulated for a minimum of some quantity of crosslinking after extrusion by the extruder 2417. As an example, crosslinking can occur a minimum of partly in situ whereas the meeting formed by way of the extruder 2417 is waiting to be armored and/or in any other case processed.

In such an example, an extruded cushion layer can achieve a desired hoop stress, which may help the extruded cushion layer to retain its shape. Such a form could also be defined by one or more parameters similar to, for instance, an arc angle. For instance, in some flat power cable embodiments, two or more individual coated conductors may be organized in a side-by-facet configuration (e.g., consider configurations resembling 2×1, 3×1, 4×1, and so on.) and, for example, one or more armor layers will be applied over a jacket. In some embodiments, a combination of extruded and taped layers could also be used to form the barrier layer. For instance, a cushion layer can include a colorant (e.g., for colour coding phases of a multiphase energy cable). For example, a layer 762 could also be an additional cushion layer 762 that surrounds the three cushion layers 760 of the grouped assemblies, which might further assist to guard the metallic shields 750 from an armoring course of. As shown in FIG. 12, the cable 700 with the cushion layer 760 lacks the sharp, lower-like indentations of the cable 1200 with the braided fibers 1260. In the images associated with the cable 700, a relatively 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 other embodiments, an insulation shield layer could also be adhered to an insulation layer utilizing an applicable adhesive or adhesives based mostly on one or more of the respective materials of the insulation layer and insulation shield layer. In the instance of FIG. 8, the formulation block 812 can formulate the material through use of a number of polymeric materials (e.g., polyethylene and optionally, additionally polypropylene) and a number of extra materials reminiscent of, for example, a number of fillers and/or a number of curatives. In some embodiments, a barrier layer may be formed from a number of fluoropolymers, lead, or another material resistant to downhole gases and fluids. For instance, a barrier layer is usually a layer exterior to a shield (e.g., an insulation shield layer) that will purpose to offer extra protection from corrosive downhole gases and fluids. Where a cable consists of EPDM insulation adjoining to a copper conductor, a lead (Pb) layer could also be positioned over the EPDM insulation and a fabric tape or a braid (e.g., a braided fiber) could also be placed over the lead (Pb) layer as a producing help to minimize distortion of the lead (Pb) layer throughout armoring. For example, insulation and shield may be strippable as a unit, for instance, the place substantially cross-linked at an interface between the insulation and the shield.

For example, a metallic shield layer could also be utilized over an insulation shield layer. As an example, consider a rapid production course of that features extrusion the place the excessive pace of the melt extrusion of an XLPE layer can speed up crosslinking by permitting for speedy quenching of the melt extruded XLPE layer in hot water, which, consequently, can obtain a excessive crosslink response rate. The crosslink density (ve) of S1054A/PP/Talc composites will be determined from the rubbery moduli utilizing the following equation, in response to the kinetic principle of rubber elasticity (Eqn. In some embodiments, an insulation layer and insulation shield layer might be co-extruded by way of stress extrusion and cured utilizing appropriate cure methods with substantially similar cure rates. For instance, a substantially circular formed cushion layer could also be extruded about a plurality of substantially pie formed cushion layers which might be grouped. Such one or more cushion layers might help to preserve integrity of one or more metallic shields from a producing process akin to, for instance, an armoring process. As explained, conductor and/or assembly geometries may be grouped the place geometry of a number of cushion layers could also be appropriately formed to assist preserve integrity of a number of metallic shields, which may operate as gas barriers that can assist to hinder permeation of gasoline (e.g., H2S, etc.) towards a conductor of a power cable.

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