In such an instance, the non-compulsory outer polymeric layer 636 (e.g., as masking armor) could also be of a thickness of about 1 mm (e.g., a 1 mm layer). In the cable 630, the conductors 632 could also be about 7.35 mm (e.g., about 1 AWG) in diameter with insulation of about 2 mm thickness, metallic lead (Pb) of about 1 mm thickness (e.g., as a gas barrier layer), a jacket layer (e.g., the layer 634) over the lead (Pb) of about 1 mm thickness at ends of the cable 630, optionally available armor of about 0.5 mm thickness and an non-compulsory polymeric layer of about 1 mm thickness (e.g., the layer 636 as an outer polymeric coat). For example, a cable can embrace a conductor with a conductor shield that has a radial thickness of roughly 0.010 inch (e.g., roughly 0.254 mm). As to the insulation shield 440, it could optionally be a semiconductive materials having a resistivity less than about 5000 ohm-m. In some embodiments, an insulation layer and insulation shield layer will be co-extruded via stress extrusion and cured utilizing suitable cure methods with substantially similar cure charges. For instance, a conductor (e.g., solid or stranded) could also be surrounded by a semiconductive material layer that acts as a conductor shield the place, for instance, the layer has a thickness better than approximately 0.005 inch (e.g., approximately 0.127 mm).

For instance, the armor layer 780 can have a wall thickness that is lower than roughly 0.5 mm. As an example, a cable can embody a conductor with a conductor shield that has a radial thickness in a variety from larger than approximately 0.005 inch to roughly 0.015 inch (e.g., approximately 0.127 mm to roughly 0.38 mm). For example, the conductor shield 420 may be provided as an extruded polymer that penetrates into areas between strands of the stranded conductor 410. As to extrusion of the conductor shield 420, it may optionally be co-extruded or tandem extruded with the insulation 430 (e.g., which may be or include EPDM). An extruded cushion layer can present improved lead (Pb) barrier crush resistance from the armoring course of when in comparison with a braided strategy that makes use of nylon or polyethylene terephthalate string. As talked about, a woven polyester braid layer (e.g., a PET fiber braided layer) may be applied on a lead (Pb) barrier as a protecting caution in opposition to damage or deformation during an armoring process. In the example of FIG. 5, the MLE 500 (or "lead extension") a conductor 510, a conductor shield 520, insulation 530, an insulation shield 540 and/or a metallic shield 550, one or more different barrier layers 560, a braid layer 570 and armor 580. While the example of FIG. 5 mentions MLE or "lead extension", it may be applied as a single conductor assembly cable for one or more of a variety of downhole makes use of.

In the geometry of the facility cable 702, three assemblies are proven the place every assembly includes a conductor 710 (e.g., a substantially pie formed conductor with an arc span of roughly a hundred and twenty degrees), insulation 730 (e.g., a considerably pie shaped layer of insulation that surrounds the conductor 710), a metallic shield 750 (e.g., a substantially pie shaped layer of lead (Pb) that surrounds the insulation 730, and a cushion layer 760 (e.g., a substantially pie formed layer of fabric that surrounds the metallic shield 750. As shown, the three assemblies will be grouped (e.g., One hundred twenty levels each to kind a circular cross-part of 360 levels) and a number of further layers may be applied that surrounds the three assemblies where a number of of such layers can embody armor. Such a shape could also be outlined by one or more parameters equivalent to, for example, an arc angle. In such an instance, extruding polyethylene can include extruding talc combined with the polyethylene and/or extruding polypropylene combined with the polyethylene.

As to continuous vulcanization (CV), polyethylene material can embody a peroxide component that generates free radicals, initiating chain-to-chain crosslinking. Such an extrudable material could also be formulated to have desired properties upon extrusion and before substantial crosslinking of the polyethylene. The totally cured XLPE/PP/Talc composites might have higher chemical compatibility and decrease swelling/fluid uptake proportion than pure XLPE. As shown within the plot 2100, the fluid uptake proportion decreased slightly for XLPE/PP/Talc 90/6/4 wt % composite as a result of low focus of PP. As proven within the plot 2200, the plateau modulus of fully cured XLPE and XLPE/PP/Talc 90/6/four wt % composite are typically substantially the same; whereas the plateau modulus of XLPE/PP/Talc 80/15/5 and 70/25/5 wt % composites are much greater than that of totally cured XLPE. As proven in FIG. 6, the cable 610 includes a circular cross-sectional form while the cable 630 consists of an oblong cross-sectional form. As to the cable jacket 470, it could also be spherical or as shown in the example 401, rectangular (e.g., "flat"). As an choice, nanoscale fillers may be included for low resistivity and suitable mechanical properties (e.g., for top temperature thermoplastics). Where a cable consists of polypropylene insulation adjacent to a copper conductor, a lead (Pb) layer may be positioned over the polypropylene insulation, which may improve its temperature score (e.g., from about 96 levels C. to about 125 degrees C.).