A thermoplastic extrusion will be carried out at an virtually unlimited pace depending on the dimensions of the tools used and the specs of the method. In such an example, the crosslink response fee could be determined by thickness of the XLPE layer, speed of extrusion of the XLPE layer and temperatures. FIG. Thirteen reveals a plot 1300 of storage modulus obtained from DMA measurements at different temperatures for each uncured and fully cured XLPE samples. As to excessive temperature performance, the cable 700 of FIG. 12 can exhibit improved excessive temperature performance when in comparison with the cable 1200 of FIG. 12. For instance, as the extruded cushion layer 760 can be thicker than the braided layer 1260, the extruded cushion layer 760 can allow for extra room for thermal growth, which can assist to stop lead (Pb) from deforming at excessive temperatures. As proven in FIG. 12, the cable seven-hundred is flatter than the cable 1200 because the cable 1200 has bulged in the center as a result of pressure that has distorted lead (Pb) barrier layers of the cable 1200. A flatter cable can sit higher on a reel, in addition to, for example, provide a extra standard and better clearance throughout installation and once put in.

Cable nearer to a center (e.g., rotational axis) of a reel will be underneath pressure the place such drive may trigger one or more edges of armor to dig-in. In some spherical cable embodiments, a energy cable contains three conductors. In some spherical cable embodiments, a plurality of particular person coated conductors could be braided together earlier than armor is applied. As to manufacturing, the cable seven-hundred of FIG. 12 can exhibit improved manufacturing when compared to the cable 1200 of FIG. 12. For instance, the braided layer 1260 may be applied at roughly 18 to 20 toes per minute (e.g., approximately 5.5 to approximately 6.1 meters per minute) while a excessive speed tape wrapping machine can course of a cable at approximately one hundred to 200 feet per minute (e.g., approximately 30.5 to roughly 61 meters per minute). For example, for the cable 700 of FIG. 12, the cushion layer 760 may be extruded at an extrusion velocity that's in a spread from approximately 200 to roughly 800 feet per minute (e.g., approximately 61 to roughly 244 meters per minute). For example, a energy cable such because the cable 700 of FIG. 7 could be utilized with an electric submersible pumping system.

As explained, a cable can include a number of cushion layers for lowering danger of lead (Pb) deformation. Additionally, low cost fillers or additives can be compounded into a cushion layer materials to further cut back materials value. For instance, a polymeric material generally is a polyethylene materials that's able to being crosslinked to a desired extent, which may embrace a full cured extent. For instance, a formulation can embrace polymeric material akin to crosslinkable polyethylene and a carbon-primarily based materials resembling carbon black. As an 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 proven in FIG. 19, the melting peak (Tm) and the melting enthalpy (ΔHm) of pure PP are approximately 166 levels C. and 80.4 J/g, respectively; whereas the values of Tm and ΔHm for pure uncured XLPE are 113.6 degrees C. and 90.8 J/g, respectively. The DSC data confirmed that the blends are two-phases with little effect on the melting and crystallization behavior of each component. A system (e.g., a mixture) can include about 95 phr S1054A and about 5 phr S1000B (e.g., a catalyst batch part).

As to steady vulcanization (CV), polyethylene material can embody a peroxide element 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 identical storage modulus within the temperature vary from approximately −70 levels C. as much as approximately 115 levels C. The value of storage modulus of the absolutely cured sample tends to be about one order of magnitude greater than that of uncured sample in the excessive temperature vary, greater than the melting level of XLPE. The third materials 2416 can type a cushion layer in regards to the second material 2414. The third material 2416 can have a hoop stress such that it helps to retain form, which can, in flip, assist to retain form of the second material 2414. The third materials 2416 could be formulated for at the least some amount of crosslinking after extrusion by the extruder 2417. For example, crosslinking can occur at least in part in situ while the assembly formed through the extruder 2417 is waiting to be armored and/or otherwise processed. And, added prices may be related to maintaining a high temperature steam (or sizzling air) tube and/or boilers or nitrogen generators that may feed it.

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