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A thermoplastic extrusion may be performed at an almost unlimited velocity depending on the scale of the gear used and the specs of the method. In such an example, the crosslink response price could be decided by thickness of the XLPE layer, speed of extrusion of the XLPE layer and temperatures. FIG. 13 shows a plot 1300 of storage modulus obtained from DMA measurements at different temperatures for both uncured and absolutely cured XLPE samples. As to excessive temperature efficiency, the cable seven-hundred of FIG. 12 can exhibit improved excessive temperature efficiency when in comparison with the cable 1200 of FIG. 12. For instance, because the extruded cushion layer 760 may be thicker than the braided layer 1260, the extruded cushion layer 760 can allow for more room for thermal growth, which will help to stop lead (Pb) from deforming at high temperatures. As proven in FIG. 12, the cable seven hundred is flatter than the cable 1200 as a result of the cable 1200 has bulged in the middle due to drive that has distorted lead (Pb) barrier layers of the cable 1200. A flatter cable can sit better on a reel, in addition to, for instance, present a more commonplace and higher clearance during installation and as soon as put in.

Cable closer to a heart (e.g., rotational axis) of a reel could be below drive the place such drive may cause a number of edges of armor to dig-in. In some spherical cable embodiments, a power cable contains three conductors. In some spherical cable embodiments, a plurality of individual coated conductors might be braided collectively earlier than armor is applied. As to manufacturing, the cable seven hundred of FIG. 12 can exhibit improved manufacturing when in comparison with the cable 1200 of FIG. 12. For example, the braided layer 1260 may be applied at roughly 18 to 20 ft per minute (e.g., approximately 5.5 to approximately 6.1 meters per minute) whereas a high velocity tape wrapping machine can course of a cable at approximately 100 to 200 ft per minute (e.g., approximately 30.5 to roughly 61 meters per minute). For example, for the cable seven-hundred of FIG. 12, the cushion layer 760 could be extruded at an extrusion speed that is in a variety from approximately 200 to approximately 800 feet per minute (e.g., roughly sixty one to roughly 244 meters per minute). For example, a energy cable such because the cable seven-hundred of FIG. 7 might be utilized with an electric submersible pumping system.

As explained, a cable can embrace one or more cushion layers for reducing threat of lead (Pb) deformation. Additionally, low price fillers or additives could be compounded right into a cushion layer material to further cut back materials price. As an example, a polymeric materials can be a polyethylene materials that's capable of being crosslinked to a desired extent, which might embrace a full cured extent. As an example, a formulation can embody polymeric materials similar to crosslinkable polyethylene and a carbon-based mostly materials resembling carbon black. For example, adding polypropylene (PP) or PP with talc can enhance the mechanical and thermal stability of an extruded XLPE material. Trials demonstrated that PP improved the thermal and chemical compatibility of uncured XLPE. As shown in FIG. 19, the melting peak (Tm) and the melting enthalpy (ΔHm) of pure PP are roughly 166 levels C. and 80.Four J/g, respectively; whereas the values of Tm and ΔHm for pure uncured XLPE are 113.6 levels C. and 90.8 J/g, respectively. The DSC data confirmed that the blends are two-phases with little impact on the melting and crystallization conduct of every component. A system (e.g., a mixture) can embody about 95 phr S1054A and about 5 phr S1000B (e.g., a catalyst batch element).

As to continuous vulcanization (CV), polyethylene materials can embody a peroxide part that generates free radicals, initiating chain-to-chain crosslinking. The worth of the storage modulus above the melting point is a function of the crosslink density of the fabric. Both samples have substantially the same storage modulus in the temperature range from approximately −70 levels C. up to roughly a hundred and fifteen degrees C. The worth of storage modulus of the totally cured pattern tends to be about one order of magnitude higher than that of uncured pattern in the excessive temperature vary, larger than the melting point of XLPE. The third material 2416 can type a cushion layer about the second material 2414. The third materials 2416 can have a hoop stress such that it helps to retain form, which can, in turn, assist to retain form of the second material 2414. The third materials 2416 may be formulated for at least some amount of crosslinking after extrusion by the extruder 2417. For example, crosslinking can happen not less than partially in situ while the assembly formed through the extruder 2417 is waiting to be armored and/or otherwise processed. And, added costs could also be related to sustaining a high temperature steam (or sizzling air) tube and/or boilers or nitrogen generators that will feed it.

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