Differentially compressed, multi-layered, concentric cross lay stranded cable electrical conductor, and method of forming same

A compressed, multi-layered, concentric lay stranded cable comprising a central strand and at least two layers of overlying strands with each succeeding overlying layer of strands helically wound in an alternately opposite direction to adjoining layers of strands and circumferentially compressed without discernible strand deformation to an overall outside diameter reduction of not more than about three percent of its uncompressed diameter, said multi-layered, concentric lay stranded cable having each succeeding overlying, oppositely helically wound layer of strands circumferentially compressed without discernible strand deformation in sequence to a regressively reduced degree of compression, whereby the overall diameter of the cable is reduced and the strands of the layers helically wound in alternately opposite direction are substantially free of any impeding indentations at intersections with crossing strands of adjoining layers.

An electrical conductor comprising a compressed, multi-layered, concentric lay metal stranded cable comprising a central strand and at least two layers of overlying strands with each succeeding overlying layer of strands helically wound in an alternately opposite direction to adjoining layers of strands and circumferentially compressed without discernible strand deformation to an overall outside diameter reduction of not more than about three percent of its uncompressed diameter, said multi-layered, concentric lay stranded electrical conductor cable having each succeeding overlying, oppositely helically wound layer of strands circumferentially differentially compressed without discernible strand deformation to a regressively reduced degree of compression, whereby the overall diameter of the cable is reduced in diameter up to about three percent and the strands of the layers helically wound in alternately opposite direction are substantially free of any identations at intersections with crossing strands of adjoining layers.

An electrical conductor comprising a compressed, multi-layered, concentric lay metal stranded cable comprising a central strand and a plurality of overlying layers of strands with each succeeding overlying layer of strands increasing in number of strands in multiples of six and being helically wound in an alternately opposite direction to adjoining layers of strands and circumferentially compressed without discernible strand deformation to an overall outside diameter reduction of not more than about three percent of its uncompressed diameter, said multi-layered, concentric lay stranded electrical conductor cable having each succeeding overlying, oppositely helically wound layer of strands circumferentially differentially compressed without discernible strand deformation in sequence to a regressively reduced degree of compression, whereby the overall diameter of the cable is reduced in diameter up to about three percent and the strands of the layers helically wound in alternately opposite direction are substantially free of any indentations at intersections with crossing strands of adjoining layers.

A method of producing a compressed, multi-layered, concentric lay stranded cable with each succeeding overlying layer of strands helically wound in an alternately opposite direction to any adjoining layers of strands and circumferentially compressed without discernible strand deformation to an overall outside diameter reduction of not more than about three percent of its uncompressed diameter, comprising the steps of helically winding a plurality of strands to form a layer of strands and circumferentially compressing without discernibly deforming the helically wound layer of strands to a relatively high level of compression, then applying at least another succeeding overlying layer of strands helically wound in opposite direction to the underlying layer of strands and circumferentially compressing without discernibly deforming each of said succeeding overlying layers of helically wound strands to a regressively reduced degree of compression, whereby the strands of the layers helically wound are substantially free of any indentations at intersections with strands of adjoining layers.

A method of producing a compressed, multi-layered, concentric lay stranded cable comprising a central strand and at least two layers of overlying strands with each succeeding overlying layer of strands helically wound in an alternately opposite direction to any adjoining layers of strands and circumferentially compressed without discernible stand deformation to an overall outside diameter reduction of not more than about three percent of its uncompressed diameter, comprising the steps of helically winding a plurality of strands around a central strand to form a layer of strands overlying the central strand and circumferentially compressing without discernibly deforming the helically wound layer of strands overlying the central strand to reduce its diameter at least about four percent of its original diameter, then applying at least another succeeding overlying layer of strands helically wound in an opposite direction to the underlying layer of strands and circumferentially compressing without discernibly deforming each of said succeeding overlying layer of helically wound strands in sequence to a regressively reduced degree of compression of at least about 2.5 percent of its uncompressed diameter, whereby the strands of the layers helically wound are substantially free of any impeding indentations at intersections with crossing strands of adjoining layers.

A method of producing an electrical conductor comprising a compressed, multi-layered, concentric lay metal stranded cable comprising a central strand and at least two layers of overlying strands with each succeeding overlying layer of strands helically wound in an alternately opposite direction to adjoining layers of strands and circumferentially compressed without discernible strand deformation to an overall outside diameter reduction of not more than about three percent of its uncompressed diameter, comprising the steps of helically winding at least two layers of strands about the central strand with each layer of strands wound in alternately opposite directions to adjoining layers of strands, and circumferentially differentially compressing without discernibly deforming each succeeding overlying, oppositely helically wound layer of strands in sequence to a regressively reduced degree of compression, whereby the strands of the layers helically wound are substantially free of any indentations at intersections with crossing strands of adjoining layers.

An insulated electrical conductor comprising a compressed, multi-layered, concentric lay metal stranded cable comprising a central strand and at least two layers of overlying strands with each succeeding overlying layer of strands helically wound in an alternately opposite direction to adjoining layers of strands and circumferentially compressed without discernible strand deformation to an overall outside diameter reduction of not more than about three percent of its uncompressed diameter, said multi-layered, concentric lay stranded electrical conductor cable having each succeeding overlying, oppositely helically wound layer of strands circumferentially differentially compressed without discernible strand deformation to a regressively reduced degree of compression, whereby the overall diameter of the cable is reduced in diameter up to about three percent and the strands of the layers helically wound in alternately opposite direction are substantially free of any indentations at intersections with crossing strands of adjoining layers, and having a covering of dielectric polymeric insulation material extrusion molded thereover.

An electrical conductor covered with a conductor shield of semiconductive material and a dielectric insulating material comprising a compressed, multi-layered, concentric lay metal stranded cable comprising a central strand and a plurality of overlying layers of strands with each succeeding overlying layer of strands increasing in number of strands in multiples of six and being helically wound in an alternately opposite direction to adjoining layers of strands and circumferentially compressed without discernible strand deformation to an overall outside diameter reduction of not more than about three percent of its uncompressed diameter, said multi-layered, concentric lay stranded electrical conductor cable having each succeeding overlying, oppositely helically wound layer of strands circumferentially differentially compressed without discernible strand deformation in sequence to a regressively reduced degree of compression, whereby the overall diameter of the cable is reduced in diameter up to about three percent and the strands of the layers helically wound in alternately opposite direction are substantially free of any indentations at intersections with crossing strands of adjoining layers, and having a covering comprising an inner conductor shield of semiconductive polymeric material and an overlying dielectric insulating polymeric material.