A cable, especially a data transfer cable, has at least one wire having an inner conductor and a wire sheath which has been applied directly thereto. The wire sheath has a dielectric layer composed of a foamed uncrosslinked thermoplastic polymer, preferably polyethylene or polypropylene, and the dielectric layer is encased by an outer skin layer composed of unfoamed, chemically crosslinked polyethylene. The specific wire sheath leads to a distinct improvement in soldering properties. Additionally specified are a corresponding wire and a production process therefor.

A method for forming magnet wire includes co-extruding multiple layers of different insulating materials. A conductor may be provided, and extruded insulation may be formed around the conductor by co-extruding both a first layer of thermoplastic insulation and a second layer of thermoplastic insulation with the second layer formed around the first layer. The first layer may include a first polymeric material having a first thermal index, and the second layer may include a second polymeric material having a second thermal index higher than the first thermal index.

A conductor of a twisted-pair data cable comprises a primary profiled insulation layer formed over a conductive wire, and a second insulation layer formed over the primary profiled insulation layer. This design prevents nesting of the profiled insulation layers of adjacent conductors without the need to back-twist or forward-twist the conductors, thereby maintaining consistent center-to-center distance between the conductors of a twisted pair. Since the second insulation layer prevents nesting between the primary layers regardless of the widths of the troughs of the cross-sectional profile, this configuration also allows for a greater range of width ratios between the peaks and troughs of the cross-sectional profile, which can allow greater freedom in tuning the electrical characteristics of the twisted pair.

This disclosure describes co-extruded multilayer articles including at least one continuous layer and one discontinuous layer, as well as systems and techniques for the manufacture of co-extruded multilayer articles. For example, a co-extruded multilayer article is described that includes a body having a plurality of layers, where a first layer of the plurality of layers is formed from a first material and is continuous along a longitudinal axis of the body, and a second layer of the plurality of layers is formed from a second material and is discontinuously co-extruded along the longitudinal axis.

A method of making a joint of a power cable, including: a) providing two cable sections to be jointed, each cable section including a conductor having a conductor end, and an insulation system including an inner semiconducting layer arranged around the conductor, an insulation layer arranged radially outside the inner semiconducting layer, and an outer semiconducting layer arranged radially outside the insulation layer, b) mechanically processing the insulation system of each cable section by gradually increasing a radius of the insulation layer in an axial direction away from the conductor end of the cable section, to obtain a tapering insulation layer section that tapers towards the conductor end, wherein the processing is performed such that an outer surface of a radially innermost portion of the tapering insulation layer section, interfacing the inner semiconducting layer, obtains a first inclination relative to a longitudinal axis of the cable section, and that an outer surface of an intermediate portion of the tapering insulation layer section obtains a second inclination which is larger than the first inclination, wherein the outer surface of the radially innermost portion transitions smoothly to the outer surface of the intermediate portion, and c) making a joint insulation system, after the conductors of the two cable sections have been electrically connected to each other by means of a conductor joint, the joint insulation system connecting to the inner semiconducting layer of each cable section, to the tapering insulation layer section of each cable section, and to the outer semiconducting layer of each cable section.

There is provided a power cable including a conductor extending along a centre axis; an insulation system including at least a first semiconducting layer surrounding the conductor, and an insulation layer surrounding the first semiconducting layer; wherein the insulation layer includes a) 40-94 wt % LDPE; and b) 6-60 wt % PS and/or styrene block copolymer, wherein the weight percentages are based on the insulation layer as a whole.

A method of manufacturing a corrosion-resistant wireline cable includes embedding a first layer of armor wires onto a core cable using a heated carbon fiber reinforced polymer. A second layer of carbon fiber reinforced polymer is then extruded to envelop the first layer of armor wires. In one method, a layer of virgin or colored polymer is extruded over the second layer, and a second layer of armor wires is embedded through the virgin or colored polymer, displacing it to envelop the outer armor wires. In another method, each wire in the second armor layer is coated with virgin polymer before being embedded into the second carbon fiber reinforced polymer layer. The assembly is then heated to cause the virgin polymer to migrate outward, forming an outermost layer. In both methods, a final jacket layer is applied over the exterior to complete the cable. The resulting cable provides corrosion resistance and mechanical reinforcement.